Service Manual: C20-30 D/L/G C20-32C L/G

C20-30 D/L/G
C20-32C L/G
SERVICE MANUAL
RATED CAPACITY: 2000 – 3200KG
Part No. 8009285

Book No. SM-661
2317 Alumni Park Plaza,

Suite 500 Lexington,
KY 40517
Truck Models Covered by this Manual
This manual consists of “base” module that pertains You may, however, purchase specific modules and
to all C20 models and other modules that pertain expand your manual to fully cover multiple models.
only to specific models. Manuals shipped with the To do so, order the desired modules as you would
truck contain the base module and the modules spe- any other Clark part.
cific to the purchased truck.
Arrangement and Use of this Manual

Clark arranges parts and service procedures by stan- You can quickly locate a specific point in the manual
dardized Groups. In this manual, Groups are similar by using the headers and footers that appear on every
to “chapters”. Groups are listed in the indexes on the Section page. The following illustration points out
next page. these areas.
Each Group begins with a table of contents that
shows the Sections contained within the Group.
Lengthy Sections also begin with a table of contents.
Each Group and Section has an identifying name and
number, or “ID”.
Each page also has a unique ID. The page ID con-
sists of three numbers separated by hyphens. The
three numbers represent the Group number, the Sec-
tion number, and the page number. For example,
“00-1-2” on the lower corner of the page indicates This manual is intended for the use of trained service
Group 00, Section 1, page 2. personnel. Please read Group SA, “Safe Mainte-
The Group number sometimes has a letter or letters nance”, and the Operator’s Manual before working
added to it in parentheses if one or more variations of on or operating the truck.
the Group exist. For example, if the truck has a stan-
dard transaxle, Group 06 is expressed as “06(S)”; if
the truck has a hydrostatic transmission, Group 06 is
expressed as “06(H)”.
CONTENTS
CONTENTS
Contents of this Manual
Group Index
Group SA. Safe Maintenance Group 22. Wheels and Tires
Group PS. Periodic Service Group 23. Brake / Inching System
Group 00. Engines Group 25. Steering Column and Gear
Group 01. Cooling System Group 26. Steer Axle
Group 02. Fuel System Group 29. Hydraulic Pump, Sump, and Filters
Group 03. Air Induction System Group 30. Hydraulic Control Valve/Lift Circuit
Group 06. Transmission Group 32. Tilt Cylinders
Group 12. Ignition System Group 34. Upright
Group 13. Instrument Pod Group 38. Counterweight, Sheet Metal & Chassis
Group 13. Electrical System Group 40. Specifications
Group 34. Upright
Group 06. Transmission
Group 32. Tilt Cylinders

Group 23. Brake/Inching System
Group 25. Steering Column and

Gear Group 30. Hydraulic Control Valve/
Lift Circuit
Group 13. Instrument Pod
Group 29. Hydraulic Pump, Sump,
and Filters
Group 03. Air Induction System

Group 02. Fuel System
Group 00. Engines Group 14. Electrical System
Group 12. Ignition System

Group 01. Cooling System
Group 22. Wheels and Tires

Group 38. Counterweight,
Sheet Metal, & Chassis
Group 26. Steer Axle
SM 661, Aug ’01 CONTENTS-1

GROUP SA
GROUP SA
SAFE MAINTENANCE
Safety ................................................................... Section 1
Lifting, Jacking, and Blocking the Truck ....... Section 2
Towing................................................................. Section 3
SM661, Aug ’01 Group SA, Safe Maintenance

Group SA, Safe Maintenance
Section 1
Safety
Safety Signs and Messages Safe Maintenance Practices

Safety signs and messages in this manual and on the lift The following instructions have been prepared from cur-
truck provide instructions and identify specific areas rent industry and government safety standards applicble to
where potential hazards exist and special precautions industrial truck operation and maintenance. These recom-
should be taken. Be sure you know and understand the mended procedures specify conditions, methods, and
meaning of these instructions, signs, and messages. Dam- accepted practices that aid in the safe maintenance of
age to the truck, death, or serious injury to you or other industrial trucks. They are listed here for the reference and
persons may result if these messages are not followed. safety of all workers during maintenance operations.
Carefully read and understand these instructions and the
NOTE
specific maintenance procedures before attempting to do
This message is used when special informa- any repair work.
tion, instructions or identification is re-
quired relating to procedures, equipment, When in doubt of any maintenance procedure, please con-
tools, pressures, capacities, and other spe-cial tact your local Clark dealer.
data. 1. Powered industrial trucks can become hazardous if
maintenance is neglected. Therefore, suitable mainte-
IMPORTANT nance facilities, trained personnel, and procedures
This message is used when special precau- must be provided.
tions should be taken to ensure a correct
action or to avoid damage to, or malfunc-tion 2. Maintenance and inspection of all powered industrial
of, the truck or a component. trucks shall be done in conformance with the manu-
facturer’s recommendations.
3. A scheduled planned maintenance, lubrication, and
! CAUTION inspection program shall be followed.
This message is used as a reminder of safety
4. Only trained and authorized personnel shall be per-
hazards that can result in personal injury if
mit-ted to maintain, repair, adjust, and inspect indus-
proper precautions are not taken.
trial trucks. Work should be performed in accordance
with the manufacturer’s specifications.
! WARNING 5. Properly ventilate work area, vent exhaust fumes,
This message is used when a hazard exists and keep shop clean and floor dry.
that can result in injury or death if proper 6. Avoid fire hazards and have fire protection equip-
precautions are not taken. ment present in the work area. Do not use an open
flame to check for level or leakage of fuel, electro-
! DANGER
lyte, oil, or coolant. Do not use open pans of fuel or
flammable cleaning fluids for cleaning parts.
This message is used when an extreme haz-
ard exists that can result in injury or death or 7. Before starting work on truck:
serious injury if proper precautions are not a. Raise drive wheels off of floor and use blocks or
taken. other positive truck positioning devices.
b. Disconnect battery before working on the electri-
The above terms have been adopted by Clark Material cal system.
Handling Company. The same terms may be used in dif- 8. Before working on engine fuel system of gasoline- or
ferent context in service literature supplied directly or diesel-powered trucks, be sure the fuel shut-off valve
indirectly by vendors of truck components. is closed.
SM 661, Aug ’01 Safety • SA-1-1

9. Operation of the truck to check performance must be 19. Modifications and additions that affect capacity and
conducted in an authorized, safe, clear area. safe truck operation must not be done without the
manufacturer’s prior written approval. Capacity,
10. Before starting to drive truck:
operation and maintenance instruction plates, tags, or
a. Be in operating position.
decals must be changed accordingly. This is an
b. Be sure parking brake is engaged.
OSHA requirement.
c. Put direction control in neutral.
d. Start engine. 20. Care must be taken to assure that all replacement
e. Check functioning of direction and speed con- parts, including tires, are interchangeable with the
trols, steering, brakes, warning devices, and any original parts and of a quality at least equal to that
load handling attachments. provided in the original equipment. Parts, including
tires, are to be installed per the manufacturer’s proce-
11. Before leaving truck
dures. Always use genuine CLARK or CLARK-
a. Stop truck.
approved parts.
b. Put directional control in neutral.
c. Apply the parking brake. 21. Use special care when removing heavy components
d. Stop the engine by turning off the ignition circuit. from the truck, such as counterweight, seat deck,
e. Put blocks at the wheels if truck is on an incline. upright, etc. Be sure that lifting and handling equip-
ment is of the correct capacity and in good condition.
12. Brakes, steering mechanisms, control mechanisms,
Also, this removal may upset the stability of the
warning devices, lights, governors, guards, safety
truck. The frame must always be safely blocked for
devices, and frame members must be carefully and
major component removal.
regularly inspected and maintained in a safe operat-
ing condition.
NOTE
13. Special trucks or devices designed and approved for
hazardous area operation must receive special atten- You should also be familiar with additional
tion to ensure that maintenance preserves the origi- operating and maintenance safety instruc-
nal, approved, safe-operating features. tions contained in the following publica-
tions:
14. Fuel systems must be checked for leaks and condi-
tion of parts. Extra special consideration must be ASME B56.1 - : Operator Control-Industrial Tow Tractors
given in the case of a leak in the fuel system. Action (Safety Standard For Powered Industrial Trucks). Pub-
must be taken to prevent the use of the truck until the lished by: American Society of Mechanical Engineers,
leak has been corrected. Three Park Avenue, New York, NY 10016.
15. The truck manufacturer’s capacity, operation, and NFPA 505: Fire Safety Standard for Powered Indus-trial
maintenance instruction plates, tags, or decals must Trucks: Type Designations, Areas of Use, Mainte-nance
be maintained in legible condition. and Operation. Available from: National Fire Protection
16. Batteries, motors, controllers, limit switches, protec- Assoc., Inc., Batterymarch Park, Quincy, MA 02269.
tive devices, electrical conductors, and connections General Industrial Standards, OSHA 2206: OSHA Safety
must be inspected and maintained in conformance and Health Standards (29 CFR 1910), Subpart N-Mater
with good practice. Special attention must be paid to als Handling and Storage, Section 1910.178 Powered
the condition of electrical insulation. Industrial Trucks. For sale by: Superintendent of Docu-
17. To avoid injury to personnel or damage to the equip- ments, U.S. Government Printing Office, Washington, DC
ment, consult the manufacturer’s procedures in 20402.
replacing contacts on any battery connection.
18. Industrial trucks must be kept in a clean condition to
minimize fire hazards and help in the detection of
loose or defective parts.
SA-1-2 • Safety SM 661, Aug ’01

Section 2
Lifting, Jacking, and Blocking the Truck
! WARNING
Lifting or jacking any large piece of equipment such as your fork truck presents obvious haz-
ards. It must be done with great care and forethought. Consult the truck weight tabulations
in Group 40, “Specifications” to ensure that your lifting equipment is of adequate capacity.
SM 661, Aug ’01 Lifting, Jacking, and Blocking the Truck • SA-2-1
Safe Parking Raising Drive Wheels Off Floor

Before working on truck: This procedure uses the upright as a lever to lift the drive
wheels off the floor and prevent accidents due to inadvert-
1. Park truck on a hard, level, and solid surface, such as
ent powering of the drive wheels.
a concrete floor with no gaps or breaks.
1. Park truck safely as described in “Safe Parking.”
2. Put upright in vertical position and fully lower the
Block steer wheels.
forks or attachment.
2. Be sure upright trunnion bolts are tight. Bolt torques
3. Put all controls in neutral. Turn key switch OFF and
must be 75-80 N⋅m (55-59 ft-lb).
remove key.
3. Start the engine. Tilt the upright fully back. Adjust
4. Apply the parking brake and block the wheels.
upright height as necessary to put blocking under-
neath the lower end of the upright.
! WARNING
4. Put a solid 100 x 100 mm (4 x 4 in) hardwood block
Defective equipment can cause accidents. All under the front section of each upright rail. Put a 3-6
tools and lifting equipment must be in good mm (.125-.250 in) steel plate on top of each block.
condition, meet the load capacity require-
ments and have OSHA labels when required.
Tools with defects can have failures causing
severe injury or death.
Lifting, Blocking, and Jacking Points

Steel
Use the following illustration to locate general lifting, Plate
blocking, and jacking points on the truck. Read the proce-
dures for raising, blocking, or jacking specific compo-
nents of the truck to make sure you understand the correct, Block
safe procedures
On Tie Bars
of Upright 5. Tilt upright fully forward. This raises the drive
wheels off the floor. Release the tilt control lever and
turn engine OFF.
Under Under Frame Under Upright

Steer
Axle Frame Mount
! WARNING
Do not attempt to lift the truck by the over-
head guard or the counterweight. Severe
injury may result and the truck can be dam-
aged.
SA-2-2 • Lifting, Jacking, and Blocking the Truck SM 661, Aug ’01
6. Insert blocking under the frame behind the drive 3. To raise the front of the truck using the upright,
wheels or slip wheel cradles under the drive wheels. spread two chains on the outer rail tiebar of the
If using blocking, check for safe clearance between upright.
drive wheels and floor and blocks.
Place
chains
here
Rag
NOTE
When forks are raised as in illustration
above, use shop rags, paper, or bright tape on
fork tips to signal the danger of tripping.
7. Check for stable condition of the truck. Be sure that ! WARNING

the blocks are located securely under the truck frame Chain and hoist used to lift truck should be
before operating the drive or working on truck. checked to make sure they are of safe lifting
8. Lower the drive wheels to the floor and remove the capacity. See the truck data plate for infor-
blocks by reversing the above procedure. mation.
4. Slowly lift truck and lower drive wheels onto the cra-
dles or place blocking under frame prop points.
Raising Truck with A Hoist
When suitable equipment is available, the front of the
truck may be raised by means of a hoist, with wheel cra-
dles placed under the wheels or blocking placed under the
frame.
! CAUTION
When lifting the front of the truck watch
truck for signs of lateral instability. It may tip
sideways. You may have to support or guide
the side of the truck or overhead guard to
prevent tipping.
1. Park truck safely as described in “Safe Parking.” 5. When maintenance work is completed, lower the
Block rear steer wheels. truck to the floor by reversing the lifting procedure.
Check to be sure no tools or equipment are under the
2. Check trunnion bolts to make sure they are tightened
truck or wheels.
to correct torque. Bolt torques must be 75-80 N⋅m
(55-59 ft-lb).
Blocking the Upright In Raised

Position
This procedure is used to safely provide clearance for Carriage
access from the front of truck to components on or near

the drive axle. Illustrations show upright with forks
removed however, fork removal is not necessary
Outer Rail
2. Put blocks in front of and behind drive wheels.
Inner Rail
3. Put wooden support blocks conveniently near upright
rails before raising the upright. Use two 100 x 100
mm (4 x 4 in) hardwood blocks or equal, of about
300 x 300 mm (12 in) and 600 x 600 mm (24 in)
length. Short Block
NOTE
For standard uprights, block may need
length cut to suit. For triple stage uprights, 7. Reverse the procedure to remove blocking.
the carriage may be blocked up, as shown.
4. Start engine and raise the upright carriage. Raising Rear of Truck
5. Hold the taller block against inner rail and lower the The truck may be raised at the rear by jacking and block-
upright until carriage rests on block. ing under the center of the frame member at either the
front or rear steer axle mounting, or under the center sec-
tion of the steer axle.
Refer to truck data plate for truck weights.
Carriage
! WARNING
An incorrectly installed counterweight can
move or fall unexpectedly. Never lift or block
a truck using the counterweight. Failure to
Outer Rail follow procedures outlined in this manual can
result in injury or death.
Inner Rail
1. Park truck safely as described in “Safe Parking.” Put
blocks at front and rear of drive wheels.
Tall Block
6. Hold the shorter block against the outer rail and

lower the upright until inner rail rests on the block.
2. Put a floor jack under the steer axle mounting frame 6. When maintenance work is completed, lower the rear
member, centered between the two wheels. of truck to the floor by reversing the above procedure
and lowering each side of the truck 50 mm (2 in) at a
! WARNING time:
• Put jack under frame and raise truck.
Never lift the truck by the counterweight. • Carefully remove blocks and lower truck.
• Remove jack and blocks from drive wheels.
Raising Entire Truck

Refer to truck data plate for truck weights.
Lower upright fully.
2. If necessary, drive truck onto boards to increase
underclearance.
NOTE
If there is insufficient clearance under frame
! WARNING
for your jack, the truck may first be driven SIDE-TO-SIDE TIPOVER. When jacking
onto shims, such as 25 x 150 x 300 mm (1 x 6 side of truck, be sure upright is lowered fully
x 12 in) pieces of board, to increase the truck and do not raise one side of the truck more
frame underclearance. than about 50 mm (2 in) higher than the
other, to avoid tipping truck over laterally.
3. Raise the truck only as high as necessary to perform
the maintenance work. END-TO-END TIPOVER. If the upright and
transaxle are removed while the truck is
4. Put blocks at both sides of the truck, fully under the blocked up, the truck will tip backwards due
frame main side structure. Put the blocks in front of to the heavy counterweight. Both upright and
but close to the counterweight and steer wheels for counterweight must be removed before
best truck stability. attempting to raise the truck for transaxle
removal. The back of the truck must be sup-
ported by blocking under the steer axle to
prevent movement.
The reverse is also true. If the counterweight

is removed while the truck is up on blocks,
the weight of the upright and transaxle will
cause the truck to tip on the front blocks and
fall forward.
Put an equal amount of blocks under each side of the truck

to provide a level working position.
5. Lower the truck onto the blocks and remove the jack.
! CAUTION
Before performing any maintenance work,
check the truck for stable condition on the
blocking.
3. Put the jack under side frame near the center of the
truck. ! CAUTION
Before performing any maintenance work,
check the truck for stable condition on the
blocking.
8. When maintenance work is completed, lower the

entire truck to the floor by reversing the lifting proce-
dure. Lower the truck one side at a time, while care-
fully removing the blocks. Check to be sure no tools
or equipment are under the truck or wheels.
NOTE
Depending on jack height, shims under the
Jack truck tires may be needed for clearance to allow
here
removal of jack.
IMPORTANT
Be sure to put the jack squarely and fully
under the main side structure of the frame. Shipping Tie-Down Instructions
Do not put the jack under the outer covers 1. Front of Truck
which enclose the fuel and hydraulic sump a. With Upright and Carriage Installed
tanks. • Lower the carriage fully.
• Put a tie down (e.g., chain) between the carriage
4. Carefully raise the truck one side at a time, only as fork bars.
high as necessary to do the maintenance work and
not more than a maximum of 150 mm (6 in) total.
5. Put blocks under the side frame, at each side of the
jack. Spread the blocks close to the steer and drive
wheels for maximum stability.
b. Without an Upright and Carriage Installed

• Put a chain across the truck floor plate. Protect
6. If using one jack, lower the truck onto the blocks and
truck from chain damage by using covered chain
move the jack to the opposite side. Repeat the lifting
or protective material under the chain at contact
procedure.
points.
7. Put the same size blocks under each side of the truck
2. Rear of Truck
so it will be level.
• Attach the tie down to pocket in bottom of coun-
terweight.
Section 3
Towing
If your truck is disabled but can be moved freely on its 4. Check that the counterweight bolts on both trucks are
own wheels without further damage, use the following in place and properly torqued to 440-490 N⋅m (325-
procedures to tow the truck safely to a repair area. 361 ft-lb). These bolts are made of special, high-ten-
sile steel and are not commercially available. When
! WARNING necessary, replace these bolts only with a genuine
Clark replacement part.
It is important for your safety and to the care
of your lift truck to use the proper equipment 5. Use an approved, solid metal tow bar with towing
and carefully follow these recommendations couplers that connect to the towing pins in the coun-
for safe towing. terweights.
Do not tow a lift truck if there is a problem
NOTE
with the brakes or tires, or if the steering
DOT-approved towing equipment is available
cannot be operated.
from your Clark dealer.
Do not tow the disabled truck up or down
ramps or steep inclines.
6. Release the parking brake on the towed vehicle.
Do not attempt to tow the disabled truck if
Place directional control lever in neutral.
traction or weather conditions are poor.
7. Tow the disabled truck backwards. An operator must
1. Be sure to apply the parking brake or block the drive be on the disabled truck.
wheels on the disabled truck while working around
it. ! CAUTION
2. When possible, raise the carriage (forks) on the dis- The power steering will not operate on the
abled truck 300 mm (12 in) from the floor or ground. disabled truck when the engine is not run-
Secure the carriage on the upright with a chain. ning. The steering handwheel will be difficult
3. Use a truck for towing that is of equal or larger to turn.
capacity than the disabled truck. Carry a partial load
on the tow truck for improved traction. 8. Tow the truck slowly. Careful towing is necessary to
prevent injury to personnel or damage to the disabled
truck. The truck should be towed at a speed of less
than 8 kph (5 mph, or a moderate walking speed)
with a driver in place and steering the disabled truck.
Direction of towing for distances of

300 meters (325 yards) or less.
Solid-metal
tow bar
Partial
load
Disabled truck with Tow truck moving at 8 kilome-

driver in place to steer. ters-per-hour (5 mph) or less.
SM661, Aug ’01 Towing • SA-3-1

IMPORTANT
Do not lift the disabled truck or any wheels
! WARNING
off the floor while the truck is being towed. Always engage the parking brake when park-
ing a lift truck. The truck can roll and cause
9. Park the disabled truck in authorized areas only. injury or death to personnel near it.
Fully lower the forks on the floor, leave the direc-
tional control in neutral, turn the ignition switch to
OFF, and engage the parking brake. Remove the igni-
tion key and, when necessary, block the wheels to
prevent the truck from rolling.
LIFT TRUCK PARKING
SA-3-2 • Towing SM661, Aug ’01

GROUP PS
GROUP PS
PERIODIC SERVICE
Maintenance Schedules ............................ Section 1
The Planned Maintenance Program ....... Section 2
SM 661, Aug ’01 Group PS, Periodic Service

Group PS, Periodic Service
Section 1
Maintenance Schedules
“Periodic Service” and “Planned Determining Maintenance Intervals

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

trucks vary widely, the above descriptions
are highly generalized and should be applied
as actual conditions dictate.
SM 661, Aug ’01 Maintenance Schedules • PS-1-1

Service Chart/Lubrication Points

A decal, similar to the illustration below, is located on the
underside of the truck’s engine cover. This decal is a basic
guide to periodic maintenance intervals and tasks. A more
detailed chart is supplied on the next page.
API,CD,CF-4
API,SD,SE/SG,SF
PS-1-2 • Maintenance Schedules SM 661, Aug ’01

Recommended Periodic Service Schedule

This chart lists maintenance tasks that should be done Apply as appropriate for diesel, gas, and LPG trucks.
periodically, the suggested time intervals, and the service Refer to Operator’s Manual for Daily Checks.
manual Group in which the task is covered.
Every 450- Every 900- Every 2000

Every
TASKS 1st 50 Hours 500 Hours 1000 Hours Hours
50-250 Hours
(or 3 months) (or 6 months) (or 1 year)
Group PS - Periodic Maintenance
Perform Planned Maintenance
inspections, lubrications, and •
adjustments
Group 00 - Engine
Exhaust smoke from gas engine -
•
inspect (blue-oil ; black-fuel)
Idle/governed rpm - check/adjust •
Mounts/brackets - inspect/tighten •
Oil change - drain/fill* • •
Oil filter cap & seal - clean/check •
Oil filter - replace • • •
Oil level/condition - check • •
Stall rpm - check on standard
•
transaxle truck
Tune up - determine if needed by stall
•
check and/or functional test
Valve tappet adjustment - diesel engine •
Group 01 - Cooling System
Coolant level/condition - check/sample •
Coolant protection level - hydrometer test •
Coolant change - drain & flush •
Coolant hoses - inspect/replace • •
Fan blades - inspect loose/damaged •
Fan belt(s) - check tension, wear • •
Radiator cap - inspect/test • •
Thermostat - test/replace •
Water pump - check leaks/wear •
Group 02 - Fuel System
Carburetor idle/air - check/adjust •
CO level - check/adjust •
Diesel injectors/lines - clean/inspect •
Filler cap/screen - clean/inspect •
Fuel filter, diesel - replace •
Fuel filter, gas - replace •
LPG lock-off valve filter - inspect/replace •
LPG tank mounting/guard - inspect •
LPG tank shut-off valve - inspect/test •
LPG vaporizer/regulator/hoses - inspect •
Throttle linkage - check/adjust •
* Oil change interval may be determined by laboratory analysis


Every
50-250 Hours
Group 02 - Air Intake & Exhaust
Air filter element - replace • (Diesel) • (Gas/LPG)
Air hoses/clamps - inspect •
Exhaust pipe/muffler - inspect •
Group 06 - Transaxle
Air vent - inspect, clean or replace on
•
standard transaxle
Axle end lube - clean/repack During brake repairs
Axle mounting bolts - inspect/tighten •
Charging pump - stall test standard
•
transaxle
Clutch pack operation - stall test standard
•
transaxle
Pressure checks •
Fluid change - drain/fill • •
Fluid filter - replace • •
Fluid level/condition - check/sample • •
Inching operation - check/test •
Oil cooler/lines - inspect •
Transmission strainer - clean on standard
•
transaxle
Group 12 - Ignition and Starting System
Diesel cold starting plug - test •
Distributor cap/rotor - inspect •
Electronic ignition - test •
Ignition timing - check/adjust •
Ignition wiring - inspect •
Neutral start - check •
Parking brake interlock - check •
Spark plugs - regap/replace •
Starter motor - inspect/test •
Starter solenoid - inspect/test •
Group 13 - Gauges, Indicators
Hourmeter - check •
Lamp check - at start-up •
Wiring harness - inspect •
Group14 - Electrical : Alternator, Regulator, Battery
Alternator - inspect/test •
Alternator dirve belts - inspect/adjust • •
Alternator output - test •
Battery electrolyte level - check/add •
Battery condition - cranking voltage test •
Battery terminals/cables - clean/tighten •
Group 22 - Wheels And Tires
Wheel mounting bolts - tighten • •
Tire pressure/condition - check • •
PS-1-4 • Maintenance Schedules SM 661, Aug ’01


Every
50-250 Hours
Group 23 - Brakes
Operation - check •
Service brake - check wear •
Brake lines - check • •
Parking brake - check/adjust • •
Group 26 - Steer Axle and Lines
Power steering relief pressure - check •
Steer axle mounting - inspect •
Steer wheel bearings - check •
Steer wheel bearings - lubricate/adjust •
Steering cylinder seals - check leakage •
Steering linkage - lubricate •
Group 29 - Hydraulic Pump, Sump, and Filter
Hydraulic fluid level/condition -
•
check/sample
Hydraulic fluid change - drain/fill •
Hydraulic suction screen - clean •
Hydraulic fluid filter - replace • •
Hydraulic tank breather - clean/replace •
Group 30 - Hydraulic Valve & Linkage
Hydraulic system relief pressure -
•
test/adjust
Group 32 - Tilt Cylinders
Tilt cylinder adjustment - check/adjust •
Tilt cylinder drift - test •
Tilt cylinder mounting - check/tighten •
Tilt cylinder rod ends -
•
check/tighten/lubricate
Tilt cylinder rod/seals - check for leaks •
Group 34 - Upright, Lift Cylinder, Carriage, Forks
Carriage and lift chain - lubircate •
Carriage chain condition - inspect/adjust •
Forks, latches, stop pin -
•
inspect/check wear
Lift chain condition - inspect/adjust •
Load backrest •
Upright lift cylinder downdrift-test •
Upright rollers - check •
Upright trunnion bolts - tighten •

Section 2
The Planned Maintenance Program
This Section defines a set of basic service procedures, known as the “Planned
Maintenance Program”, and describes systematic approach for performing
them.
SM 661, Aug ’01 The Planned Maintenance Program • PS-2-1

Introduction to Planned Maintenance The Basic PM Procedures

A program of regular, routine inspections, lubrication, and The chart on the next page lists the basic PM tasks. The
other service tasks is important for the long life and trou- actual PM program may be modified to meet the specific
ble-free operation of the lift truck. needs of the truck application.
The Clark service organization offers customers a formal- The procedures beginning on page 4 outline a systematic
ized program—called Planned Maintenance, or PM—for approach to performing the PM tasks. These procedures
performing these tasks. consist of:
• External visual checks you make as you walk
PM Intervals around the truck with it turned off.
The PM inspections, adjustments, and lubrications are • Operational checks you make while operating the
typically performed on each covered truck at 50-250 hour truck.
intervals. (See Section 1, in this Group about defining ser- • Tests, adjustments, and lubrication you perform
vice intervals.) with the covers removed.
The PM Form
! CAUTION
As an aid to service technicians performing and docu-
• Do not make repairs or adjustments unless
menting PM inspections, Clark has prepared a “Gas, LPG
authorized to do so.
or Diesel Planned Maintenance Report” form. A black-
and-white copy of this form is inserted in Section 3 of this • Disconnect the battery ground cable (-) from the
Group. engine or frame before working on electrical
components.
We recommend that you use this form as a checklist and
• Always wear safety glasses.
to make a record of your inspection and truck condition.
This record can be used to inform the owner of needed • Wear a safety (hard) hat in industrial plants
repairs and help establish the optimal PM intervals. and in special areas where protection is neces-
sary or required.
When you have finished the PM inspections, be sure to
• Remove all jewelry (watch, rings, bracelets,
give a copy of the report to the person responsible for lift
etc.) before working on the truck.
truck maintenance.
PS-2-2 • The Planned Maintenance Program SM 661, Aug ’01

The Recommended PM Task Chart
Listed by Service Manual Group
Group PS - The Basic PM Procedures Wiring harness - inspect

Visual inspection Alternator - inspect/test
Functional performance check - test dirve Alternator dirve belts - inspect/adjust
Air cleaning of truck Alternator output - test
Lubrication, filters, and fluid levels checks Battery condition - performance load test
Critical fasteners torque check Battery electrolyte level - check/add
Group 00 - Engine Battery terminals/cables - clean/tighten
Exhaust smoke (blue-oil ; black-fuel) Neutral start - check
Idle RPM - check/adjust Starter cranking voltage - test
Max no-load gov’d RPM - check/adjust Group 22 - Wheels And Tires
Mounts/brackets - inspect/tighten Tire pressure/condition - check
Oil filler cap & seal - clean/check Group 23 - Brakes
Oil level/condition - check Brake lines - check
Stall RPM - check Check operation
Group 01 - Cooling System Parking brake - check/adjust
Coolant hoses - inspect/replace Service brake - check wear
Coolant level/condition - check/sample Group 26 - Steer Axle & Lines
Coolant protection level - hydrometer test Operation - check
Fan belt(s) - check tension, wear Steer axle mounting - inspect
Fan blades - inspect loose/damaged Steer wheel bearings - check
Fan speed control - inspect Steering cylinder seals - check leakage
Group 02 - Fuel System & Exhaust Steering valve - check leakage
Air hoses/clamps - inspect Group 29 - Hydraulic Fluid
Exhaust pipe/muffler - inspect Hydraulic fluid level/condition - check/sample
LPG tank mounting/guard - inspect Lines - check for leakage
LPG tank shut-off valve - inspect/test Group 30 - Hydraulic Valve & Linkage
LPG vaporizer/regulator/hoses - inspect Hydraulic system relief pressure - test/adjust
Throttle linkage - check/adjust Linkage and control handle operation - check
Group 06 - Transmission Group 32 - Tilt Cylinders
Charging pump - stall test standard transaxle Tilt cylinder mounting - check/tighten
Clutch pack - stall test standard transaxle Tilt cylinder rod ends - check/tighten
Fluid level/condition - check/sample Tilt cylinder rod/seals - check condition
Inching operation - check/test Group 34 - Upright, Lift Cylinders,
Oil cooler/lines - inspect Carriage, Forks
Group 12 - Ignition System Carriage/lift chain - lubricate
Distributor cap/rotor - inspect Carriage chain condition - inspect/adjust
Ignition wiring - inspect Forks, latches, stop pin - inspect/check wear
Parking brake interlock - test Lift chain condition - inspect/adjust
Group 13 - Gauges, Indicators, Alternator, Load backrest - inspect
Battery, Starter Operation of lift and tilt cylinder - check
Hourmeter - check Racking - check for
Indicator lights - check Upright trunnion bolts - tighten

Visual Inspection Carriage, Load Backrest, and Upright
First, perform a visual inspection of the lift truck and its (See Group 34 for detailed inspection procedure.)
components. Walk around the truck and take note of any Inspect the welds on the carriage, load backrest, and
obvious damage and maintenance problems. upright for cracks. Be sure that the mounting fasteners are
in place and tight.
Inspect the upright assembly: rails, carriage rollers, car-
riage fork bars, lift chains, and lift and tilt cylinders. Look
for obvious wear and maintenance problems and damaged
or missing parts. Check for any loose parts or fittings.
Check for leaks, any damaged or loose rollers and rail
wear (metal flaking). Carefully check the lift chains for
wear, rust and corrosion, cracked or broken links, stretch-
ing, etc. Check that the lift and carriage chains are cor-
rectly adjusted to have equal tension. Check that the lift
chain anchor fasteners and locking means are in place and
tight.
Be sure all safety guards and chain retainers are in place
Decals, Fasteners, and Leaks and not damaged. Inspect the carriage stops and cylinder
retainer bolts. Check all welded connections.
Check for loose fasteners and fittings.
Inspect all lift line hydraulic connections for leaks. Check
Check to be sure all capacity, safety, and warning plates the lift cylinder rods for wear marks, grooves and
and decals are attached and legible. scratches. Check the cylinder seals for leaks.
NOTE
Do not operate a lift truck with damaged or
missing decals and nameplates. Replace them Overhead guard
immediately. They contain important infor- Upright
mation. See Group 40 for decal locations.
Inspect the truck before and after starting engine for any Load Backrest
signs of external leakage: fuel, engine oil or coolant,
transmission fluid, etc.
Carriage
Check for hydraulic oil leaks and loose fittings. DO NOT
Fork
USE BARE HANDS TO CHECK.
! CAUTION
Hydraulic Fluid Pressure. Do not use your
hands to check for hydraulic leakage. Oil
may be hot or under pressure. Fluid under Forks
pressure can penetrate your skin and cause
serious injury. Inspect the load forks for cracks, breaks, bending and
wear as described in Group 34.
Overhead Guard
Be sure that the overhead guard and any other safety ! WARNING
devices are in place, undamaged, and attached securely. HEEL WEAR. If the fork blade at the heel is
Inspect welds and structural members for cracks or other worn down by more than 10 percent, the load
damage. Also check for loose or missing fasteners. capacity is reduced and the fork must be
replaced. See Group 34 for inspection proce-
dures.

Inspect the fork latches to ensure that they are in good Functional Tests
condition, operate freely, and lock correctly.
Be sure that:
Wheels and Tires • Parking brake is applied
Check the condition of the drive and steer wheels and • Directional control is in "N" (neutral).
tires. Remove objects that are embedded in the tread.
Inspect the tires for excessive wear or breaks or "chunking Test the horn, lights, and all other safety equipment. Be
out. sure they are properly mounted and working correctly.
Test all controls to ensure that they operate freely and
return to neutral properly.
Now prepare to start the truck and test its operation.
Starting System
A 3-position starter switch is standard equipment.
Check the neutral start function by placing the direction
control lever in forward or reverse and turning key switch
to “start” position. The starter must not engage until the
direction control lever is moved to “neutral” position.
Check all wheel lug nuts or bolts to be sure none are loose
or missing. Have missing bolts or lug nuts replaced and As you start the engine, check the instrument display. All
tightened to correct torque as explained in Group 22. indicator lights should come on for a 2-second lamp
check. The seat belt prompt light should remain on for 4
seconds, accompanied by a buzzer sound. The parking
brake light should remain on if the brake is set. If the truck
has a diesel engine, the glow plug preheat light should
remain on for 6 seconds. If the lights do not operate as
described, refer to Group 13 to diagnose the problem.
ON
OFF
Start
Engine Shut Down Mode

If the truck’s fault protection system detects low engine oil
! WARNING pressure, excessive transmission oil temperature, or exces-
sive engine coolant temperature, the truck will go into
Check tire pressure from a position facing “shutdown mode”—a buzzer will sound for 30 seconds,
the tread of the tire, not the side. Use a long- after which the truck will shut itself off. The truck may be
handled gauge to keep your body away. If restarted, but if the fault condition still exists, the engine
tires are low, the tire may require removal will again shutdown in 30 seconds.
and repair. Incorrect (low) tire pressure can
reduce truck stability. See “Specifications” in Parking Brake Interlock
Group 22 for proper inflation pressure.
The transmission should disengage when the parking brake
Brake and Inching Pedal Freeplay is on and reengage when the parking brake is released.
There should be no inching and 4~6mm braking pedal 1. Apply the parking brake.
freeplay. Both pedals should be at same the height. Adjust 2. Start the engine, if it is not already running.
as described in Group 23.
3. Place the direction control in forward or reverse.
Make sure the path is clear in the chosen direction.

4. Accelerate briefly. The truck should not move or put c. Depress the brake pedal and depress the accelera-
any strain on the parking brake if the interlock sys- tor pedal slightly, the truck should not move.
tem is OK.
5. Be sure the travel area is clear behind the truck.
5. Release the parking brake (and service brake). Truck Repeat steps 2 through 4 in the reverse direction.
should move slowly in selected direction. (On hydro-
6. Drive the truck and check that it accelerates and
static truck, depress accelerator pedal slightly.)
decelerates smoothly and stops properly.
Accelerator, Brake/Inching System, Direction 7. Depress the inching (left) pedal and depress the
Control, and Parking Brake accelerator to see if the transmission disengages
properly.
! WARNING 8. Check the function of the parking brake. Park the
Fasten your seat belt before driving the truck on a grade and apply the parking brake. The
truck. parking brake should hold a lift truck with rated load
on a 15% grade.
Make sure that you on a level surface, the travel area is
clear in front of the truck, the parking brake is release, and ! CAUTION
the truck is running.
If the service brake, parking brake, or inter-
1. Push the brake (right) pedal down fully and hold. The lock is not operating properly, take the truck
brakes should apply before the pedal reaches the out of service until it is repaired.
floorplate. If the pedal continues to creep downward,
report the failure immediately. Do not operate the Steering System
truck until the brakes are repaired.
Check the steering system by moving the steering hand-
2. Move the direction control lever from neutral to for- wheel in a full right turn and then in a full left turn. Return
ward. the steer wheels to the straight-ahead position. The steer-
ing system components should operate smoothly when the
3. For standard transaxle trucks: Release the brake
steering handwheel is turned. Hard steering, excessive
pedal and let the truck travel slowly forward. Then
play(looseness), or unusual sounds when turning or
push down on the brake pedal to stop the truck. The
maneuvering indicates a need for inspection or servicing.
brakes should apply smoothly and equally.
4. For hydrostatic transmission trucks:
a. Release the brake pedal. The transmission should
not engage and the truck should not move.
b. Accelerate briefly, then release the accelerator
pedal. Do not depress the brake pedal. The truck
should decelerate to a stop briefly after the accel- If the truck has a steering system fault, take the truck out
erator pedal is released. of service until it is repaired.
Lift Lever
Tilt Lever
Aux Lever
Direction
Control
Parking Brake Brake Pedal
Accelerator
Inching Pedal
Operator’s Controls. Standard arrangment shown.

Lift Mechanisms and Controls Auxiliary Controls

(See Group 34 for detailed test procedure.) If the truck is equipped with an attachment, test the con-
trol lever for correct function and operate the attachment
1. Check the function of the lift system and controls
to check its function
with the engine running.
When you have completed the operational tests, park and
2. Pull back on the tilt control lever and hold until the
leave truck according to standard shutdown procedures.
upright reaches the full back tilt position. Push for-
Be sure to make a record of all maintenance and operating
ward on the lever to return the upright to the vertical
problems you find.
position. Release the lever.
If there is excessive play between rails and channels,
upright adjustment is required. If there is racking, Air Cleaning the Truck
adjustment of the cylinder rod yokes is required.
! CAUTION
! CAUTION
Wear suitable eye protection and protective
Be sure that there is adequate overhead clothing.
clearance before raising the upright.
Open the hood and remove the floorplate. Then air clean
3. Pull back on the lift control lever and raise the fork the following: upright assembly, drive axle, radiator from
carriage to full height. Watch the upright assembly as both counterweight and engine sides, engine and accesso-
it rises. All movements of the upright, fork carriage, ries, driveline and related components, and steer axle and
and lift chains must be even and smooth, without steer cylinder.
binding or jerking. Watch for chain wobble or loose-
ness; the chains should have equal tension and move Use an air hose with special adapter or extension that has
smoothly without noticeable wobble. Release the a control valve and nozzle to direct the air properly. Use
lever. clean, dry, low-pressure compressed air. Restrict air pres-
sure to 30 psi (207 kPa), maximum. (OSHA requirement).
It is important to maintain a lift truck in a clean condition.
Do not allow dirt, dust, lint or other contaminants to accu-
mulate on the truck. Keep the truck free from leaking oil
and grease. Wipe up all oil or fuel spills. Keep the controls
and floorboards clean, dry, and safe. A clean truck makes
it easier to see leakage, loose, missing, or damaged parts,
and will help prevent fires. A clean truck will run cooler.
The environment in which a lift truck operates determines
how often and to what extent cleaning is necessary. For
example, trucks operating in manufacturing plants which
have a high level of dirt, dust or lint, (e.g. cotton fibers,
paper dust, etc.) in the air or on the floor or ground,
require more frequent cleaning. The radiator, especially,
may require daily air cleaning to ensure correct cooling. If
air pressure does not remove heavy deposits of grease, oil,
etc., it may be necessary to use steam or liquid spray
cleaner.
If the maximum fork height cannot be reached, this
indicates there is low oil level in the hydraulic sump
or severe binding within the upright.
4. Push forward on the lift control lever. Watch the
upright as it lowers. If you suspect a problem with
lifting or lowering speeds, refer to Group 34 to diag-
nose the problem.

Truck Chassis Inspection and Lubrication Under-the-Hood Inspection

Lubrication requirements are given in the “Service Chart/ General Checks
Lubrication Points” chart in Section 1 of this Group. Also
Check all fluid levels and make sure that the following
see Lubricants and Shop Supplies” in Group 40 for parts
items are clean, secure, and in good condition:
information, and “General Specifications” in Group 40 for
lubricant specifications. • Hoses, lines, clamps, and fittings
Lubrication and inspection of truck chassis components • Wires, cables, and connectors
includes steer wheels, steer axle linkages, and steer wheel • Distributor, distributor cap, and rotor, coil, and
bearings, and drive wheel bearings. To check these items, plug wires (gas/LPG engine only)
the truck must be properly raised and blocked as described • Control linkages, pedals, and levers
in “Lifting, Jacking, and Blocking” in Group SA.
• Engine mounts
Check for play in wheel bearings by attempting to move • Fan and fan belts
the wheel side to side and up and down, by hand.
• Oil filler cap
Inspect the steering cylinder piston rods, seal, and fasten- • Steering gear (check for leaks).
ers for damage and leaks, and looseness.
Check linkages by observing whether the steer wheels lag ! CAUTION
when you turn the handwheel. To avoid the possibility of personal injury,
Lubricate the steer axle linkage rod ends and pivot points. never work in engine compartment with
Be sure to clean the grease fittings before lubricating. engine running except when absolutely nec-
Remove the excess grease from all points after lubricat- essary to check or make adjustments. Take
ing. Lubricate miscellaneous linkage as needed. extreme care to keep face, hands, tools, loose
clothing, etc., away from fan and drive belts.
Also, remove watches, bracelets, and rings.
Upright and Tilt Cylinder Lubrication Do not smoke.
Clean the fittings and lubricate the tilt cylinder rod end
bushings (forward end). Clean the fittings and lubricate Engine Air Cleaner
the tilt cylinder base rod end bushings (rear end). Clean Do not open the air cleaner to check the filter element.
and lubricate the upright trunnion bushings. The filter element should be replaced only at the specified
service interval or when the air filter light indicates that it
Lift Chain Lubrication is dirty.
Lubricate the lift chains as described in Group 34.

Fluid Checks
Battery
Inspect the battery for any damage, cracks, leaking condi-
tion, etc. If the terminals are corroded, clean and protect
them with CLARK Battery Saver (available from your
Clark dealer). If the battery has removable cell caps, check
to be sure the cells are all filled. If necessary, refill with
distilled water.

Engine Cooling System Fill the oil level above the LOW mark on the dipstick by
adding only the hydraulic fluid prescribed in Group 29.
Check coolant level in the coolant recovery bottle and in
DO NOT OVERFILL.
the radiator as described in Group 01.
! CAUTION
Low Full
STEAM. Do not remove the radiator cap

when the radiator is hot. Steam from the
radiator will cause severe burns.
Transaxle Fluid Level
Coolant should be checked on a daily basis in high-cycle Check the transaxle fluid level with the engine running, as
applications. explained in Group 06.
Engine Oil Fill to the FULL mark on the dipstick, using the transaxle
fluid specified in Group 06.
Oil Level: With the truck level and the engine shutdown
for at least 5 minutes, check the engine oil level.
Locate the engine oil dipstick. Pull the dipstick out, wipe
it with a clean wiper and reinsert it fully into the dipstick
tube. Remove the dipstick and check oil level.
FULL
Stall Test
ADD
On standard transaxle trucks, perform the stall test
described in Group 00 to determine engine and transaxle
condition.
Cranking Voltage Test

It is normal to add some oil between oil changes. Keep the To determine battery condition, check the cranking volt-
oil level above the ADD mark on the dipstick by adding age as described in Group 14.
oil as required. Use only the oil specified in Group 00.
Oil Change: Change oil as described in Group 00. Critical Fastener Torque Checks
Diesel Engine Oil Filter:Replace as described in Group
For safety it is important that the correct torque be main-
00.
tained on all critical fasteners of components which
directly support, handle or control the load and protect the
Hydraulic Fluid Level
operator.
Check the hydraulic sump tank fluid level as described in
Check torque of critical items, including:
Group 29. Correct fluid level is important for proper sys-
tem operation. Low fluid level can cause pump damage. • Drive axle mounting
Overfilling can cause fluid leakage. • Drive and steer wheel mounting
Hydraulic fluid expands as its temperature rises. There- • Counterweight mounting
fore, it is preferable to check the fluid level at operating • Overhead guard mounting
temperature (after approximately 30 minutes of truck
• Operator’s cell mounting
operation).
• Tilt cylinder mounting and yokes
• Upright mounting and components.
Critical fastener torque specifications are given in the gen-
eral specifications Section of Group 40.


GROUP 00(G)
GROUP 00(G)
ENGINE
(4G64 GAS/LPG)
Specifications and Description ................ Section 1
Troubleshooting .........................................Section 2
Oil and Filter ..............................................Section 3
Tune-Up ......................................................Section 4
RPM, Vacuum, and Stall Checks .............Section 5
Compression Checks .................................Section 6
Removal and Replacement .......................Section 7
Overhaul .....................................................Section 8
NOTICE
DETAILED FUEL SYSTEM INFORMATION is
given is Group 02, “Fuel System.”
DETAILED IGNITION SYSTEM INFORMA-

TION is given in Group 12, “Ignition System.”
SM 661, Aug ’01 Group 00(G), Engine

Group 00(G), Engine
Section 1
Engine Specifications
(4G64 Gas/LPG Engine)
General Specifications Tune-Up Specifications

Engine Type: Mitsubishi 4G64 in-line, overhead valve, Tune-up specifications are listed in the engine tune-up
single overhead camshaft Section of this Group.
Number Of Cylinders: 4
Overhaul Specifications
Combustion Chamber: Semi-spherical
Overhaul specifications are listed in the engine overhaul
Total Displacement: 2350 cu cm (143.4 cu in) Section of this Group.
Cylinder Bore: 86.5 mm (3.41 in)Piston Stroke: 100.0
mm (3.94 in)
Compression Ratio: 8.5
Cylinder Compression: 1880 kPa (163.5 psi) at 300 rpm
Valve timing:
Camshaft Identification(D)
Intake valve Open 12° BTDC
Close 40° ABDC
Exhaust valve Open 54° BBDC
Close 6° ATDC
Lubrication System: Pressure feed, full-flow filtration

Oil Pump Type: Involute gear type
Engine Oil: 10W30, API SD, SE / SG, SF engine oil
Sump Capacity: 4.8 L (5.1 qt)
Cooling System: Water-cooled circulation
Water Pump Type: Centrifugal impeller type
SM 661, Aug ’01 Engine Specifications • 00(G)-1-1

Group 00(G), Engine
Section 2
Engine Troublshooting
Also use the rpm, vacuum, and stall tests in Section 5 to analyze engine performance
The following troubleshooting guide lists typical complaints or troubles encountered in rou-
tine operation of the 4G64 engine, and suggests possible remedies.
Engine hard to start or won’t start Engine runs unevenly at high speed
• Fuel system fault; see fuel system troubleshooting • Fuel system fault; see fuel system troubleshooting
in Group 02. in Group 02.
• Ignition system fault; see ignition system trouble- • Ignition system fault; see ignition system trouble-
shooting in Group 12. shooting in Group 12.
• Starter motor faulty; see electrical system trouble-
shooting in Group 14. Engine fires erratically
• Battery, ground, or wiring is faulty; see electrical
system troubleshooting in Group 14. • Fuel system fault; see fuel system troubleshooting
in Group 02.
• Engine oil is too viscous (heavy weight oil);
change to lighter oil viscosity. • Ignition system fault; see ignition system trouble-
shooting in Group 12.
• Engine timing too advanced; adjust timing.
• Uneven compression or cylinder head problem:
• Valves or valve seats worn and leaking; relap or
− Carbon deposits in combustion chamber; clean.
replace valves.
− Cylinder head water passages clogged; clean.
• Intake manifold gasket leaking: replace gasket if − Cylinder head gasket leaking; replace.
necessary and retighten manifold nuts to correct − Cylinder head bolts not torqued properly;
torque. tighten per specification.
• Cylinder head gasket leaking; replace head gasket • Leaking intake gasket.
and retighten cylinder head nuts to correct torque.
• Valves sticking; repair or replace valves.
• Internal engine seizure; refer to engine overhaul
• Valve springs weak or broken; replace valve
procedures.
springs.
• Instrument pod faulty; see instrument pod trouble-
Backfiring
• Out of fuel.
• LPG tank shut off or improperly coupled. • Fuel system fault; see fuel system troubleshooting
in Group 02.
Irregular idling • Ignition system fault; see ignition system trouble-
• Fuel system fault; see fuel system troubleshooting • Sticking valves; repair.
in Group 02. • Broken or fatigued valve springs; repair or replace.
• Spark plug gap is too wide; adjust.
• Cylinder head gasket leaking; replace head gasket.
• Valves not seating tight; relap valves.
• Excessive valve-to-valve guide clearance; replace
valves and valve guides.
SM 661, Aug ’01 Engine Troublshooting • 00(G)-2-1

Group 00(G), Engine
Lack of power or poor acceleration • Fuel system malfunctioning; see fuel system trou-
bleshooting in Group 02.
• Ignition system malfunctioning; see ignition sys- • Faulty compression pressure; see “Faulty Com-
tem troubleshooting in Group 12. pression.”
• Fuel system malfunctioning; see fuel system trou- • Overloading of engine; review operation.
bleshooting in Group 02.
• Blown head gasket; replace.
• Air intake system restriction:
− Air filter element clogged; replace. • Exhaust system leak or blockage; repair or replace.
− Throttle control not opening fully; adjust.
− Carburetor choke faulty (gasoline only); adjust Faulty compression
or repair.
− Excessive exhaust back pressure; inspect and • Valve holding open; repair.
repair. • •Incorrect valve timing; retime engine assembly.
− Sharp bend or kink in hose from air filter to car- • Burned or sticking valves; repair or replace.
buretor; inspect, repair or replace.
• Broken or fatigued (weak) valve springs; replace.
− Engine valves sticking or worn; repair or
replace. • Cylinder head gasket faulty (leaking); tighten bolts
− Engine valves adjusted incorrectly; adjust. or replace.
• Cylinder head gasket leaking; replace head gasket • •Piston rings worn, broken or stuck; repair or
if necessary and retighten cylinder head bolts to replace.
specified torque.
• Piston rings sticking or worn; replace rings. Low oil pressure
• Cylinders worn; check and replace if necessary.
• Oil level is low; check and add oil.
See also “Faulty Compression.”
• Oil viscosity too light or diluted; check and replace
• Overheating; see “Overheating.”
oil.
• Valve seats leaking; relap valves.
• Pump suction screen clogged; clean.
• Valve stems sticking; repair or replace valves.
• Dirt in relief valve or broken spring; clean or
• Valve springs weak or broken; replace springs. repair/replace.
• Worn or damaged oil pump; replace.
Overheating • Worn engine bearings; replace.
• Cooling system malfunctioning; see cooling sys- • Worn cam bushings; replace.
tem troubleshooting in Group 01. • Oil pressure indicator, sensor, or wiring faulty;
• Cylinder head gasket leaks coolant; tighten bolts or repair or replace.
replace.
• Cylinder block or head cracked; repair or replace. High oil pressure
• Radiator fins plugged (dirty) or core clogged; clean
Oil pressure should not exceed recommended pressures
or replace.
except when engine is starting up cold. Abnormally high
• Fan installed backwards; remove and reinstall cor- oil pressure is not desirable because it increases oil con-
rectly. sumption. Possible causes of high oil pressures are:
• Thermostat faulty; replace.
• Engine oil too viscous (heavy weight); change to
• Rust buildup in engine block; clean cooling system correct oil grade.
or overhaul.
• Stuck relief valve; repair or replace.
• Fan belt slipping, worn or damaged; clean, adjust,
• Obstruction in distributing line.
or replace.
• Faulty oil pressure gauge; replace.
• Ignition timing incorrect; see ignition system trou-
bleshooting in Group 12. • Dirty or plugged oil filter; replace.
• Engine oil level is low; add oil, inspect for cause.
00(G)-2-2 • Engine Troublshooting SM 661, Aug ’01

Group 00(G), Engine
High oil consumption Engine knocks and other noises

• Loose oil filter; tighten oil filter with gasket.
Operating knocks
• Oil leaks in system; inspect and repair.
• Fuel, when detonation knock is caused by low
• Oil pan plug or pan attaching bolts loose; retighten
octane gasoline; check fuel specification.
plug or bolts.
• Preignition, when most common cause is due to
• Damaged oil pan gasket; replace gasket.
incorrect type plugs which are too hot; replace
• Oil level too high; check cause and maintain cor- plugs with correct heat range.
rect oil level.
• Carbon buildup, noticeable when engine is acceler-
• Oil pressure too high, stuck relief valve; repair or ated when hot; clean cylinder head and pistons.
replace.
• Incorrect timing, when early (advanced exces-
• Incorrect grade of oil used; change to heavier vis- sively) timing causes knocks similar to carbon
cosity grade. buildup, but may tend to kick back when starting;
• Clogged crankcase breather; clean. adjust timing.
• Worn, broken or stuck piston rings and clogged oil • Overloads, particularly at lower operating speeds;
control rings; replace. review operating methods.
• Worn pistons and sleeves; replace.
Mechanical knocks
• Worn bearings; replace.
• Worn valve guides and seals; replace. • Crankshaft and main bearings:
− Worn, burned-out, or melted main bearings
• Defective front or rear crankshaft oil seals; replace
indicated by a heavy, dull knock when acceler-
oil seal.
ating under load; locate by shorting out spark
• Damaged head cover gasket. plugs on both sides of the bad bearing; replace
• Excessive oil reaching combustion chambers: bearings and if melted, check lubrication sys-
− Improperly positioned ring gaps; reposition tem.
ring gaps. − Crankshaft end play is indicated by an intermit-
− Worn piston rings or ring grooves; replace rings tent knock which will come and go when the
or pistons. load is released and engaged.
− Excessive accumulation of carbon in oil return − Crankshaft thrust bearing worn; replace thrust
hole in oil ring; replace rings. bearing.
− Worn pistons and cylinders; rebore cylinders • Connecting rod and bearings
and replace pistons. − Worn or burned-out bearings indicated by a
− Too much oil in oil pan; drain oil to specified light pounding or metallic knock, is noted at
level. idling speed and to about 2/3 maximum speed;
• Excessive downward oil flow along valve stems: bad bearings can be located by shorting out
− Worn valve stems or guides; replace valves or spark plugs; replace rod or bearings.
guides. • Pistons and piston pins
− Damaged valve stem oil seals; replace oil seals. − Excessive piston clearance in cylinder; rebore
• Piston rings not run-in (seated), due to too smooth cylinders and replace pistons.
cylinder bore finish or glazed condition; repair or − Piston sticking; replace pistons.
replace rings and deglaze cylinder walls. − Loose or worn piston pins, which may be
located by shorting out spark plugs; noise
increases when the correct plug is shorted out,
most noticeable at idling speed; replace pistons
or pins.
SM 661, Aug ’01 Engine Troublshooting • 00(G)-2-3

Group 00(G), Engine
− Piston loose in cylinder or damaged piston Vibration originating at engine

rings, indicated when “piston slap” is noted by
metallic knocking at low speed under load but The most common sources of vibration originating in or
disappears at high speed; also most noticeable on the engine, as distinguished from causes created out-
when starting cold; test by shorting out spark side the engine, are as follows:
plugs and replace piston rings. • Misfiring
− Broken piston ring or pin is indicated by a
sharp clicking noise that doesn’t change when • Misalignment of engine
spark plugs are shorted out; repair engine. • Bent or off-center driveline coupling.
• Crankpin bearings worn, damaged, or melted; • Engine loose on mountings, or wrong mountings.
replace bearings and check lubrication system. • Out-of-balance condition of flywheel and clutch
• Valves assembly.
− Oil drained from lifters. Lifters should fill
within 20 minutes, as engine runs.
− Defective lifters; replace.
− Burned valves and seats indicated when engine
misses, especially at low speeds, or accelera-
tion under load; repair engine.
− Weak or broken valve springs indicated when
the engine is missing at low or high speeds
when under load; replace springs.
− Sticking valves indicated by a loss of power
and popping sound; overhaul head.
• Camshaft makes noise due to loose bearings or end
play, usually occurs at half engine speed; replace
camshaft thrust plate.
00(G)-2-4 • Engine Troublshooting SM 661, Aug ’01

Group 00(G), Engine
Section 3
Engine Oil and Filter
Engine Oil Requirements To help achieve proper engine performance and durability,
use only engine lubricating oils of the proper quality.
Engine oil does not “wear out.” However, the lubricating These oils also help promote engine efficiency, which
oil in internal combustion engines becomes contaminated results in improved fuel economy. A symbol has been
from the by-products of combustion: dirt, water, unburned developed by the API (American Petroleum Institute),
fuel entering the crankcase, and the detergents holding the SAE, and ASTM to help you select the proper engine oil.
carbon particles in suspension in the crankcase. It should be included on the oil container you purchase.
Motor oils used for internal combustion engine lubrication
ICE SD, SE
perform many useful functions including: RV /
SE
SG
, SF
API
SAE
• Dissipating heat 10W-30
EN
II
• Sealing piston rings
G
R
N
GY VI
CONSER
• Preventing metal-to-metal contact wear
• Reducing power loss through friction.
IMPORTANT
Lubricating oil recommendations are based upon engine
Use 10W30, API SD, SE/SG, SF engine oil.
design, type of service, and the ambient temperature in
which the engine is operating. High-quality oils are
required to assure maximum performance, long engine Engine Oil Level Check
life, and minimum cost of operation.
The engine oil level should be checked every 8 hours.
The schedule for changing oil is directly dependent upon
the operational environment. An extremely clean opera- 1. Check the oil level with engine stopped. Allow 5
tion could go 150-250 hours while a dirty operation minutes for the oil level to stabilize. Pull the dipstick
(foundry or cement factory) could be 50 hours or less. out, wipe it with a clean wiper, and reinsert it fully
into the dipstick tube. Remove the dipstick and check
NOTE the oil level.
Oil changes should be scheduled every 50-250
2. Oil level should be at the FULL level marking on the
hours, monthly, or more frequently if neces-
dipstick. Add recommended oil as needed. Wait 5
sary. The time interval for changing engine
minutes after adding oil and check the oil level again.
oil depends upon your application and oper-
Do not overfill.
ating conditions. To determine the correct
schedule for your truck, it is suggested that FULL
you periodically submit engine oil samples to
a commercial laboratory for analysis of the
ADD
condition of the oil.
NOTE
It is normal to add some oil between oil
changes. Keep the oil level above the ADD
mark on the dipstick . Do not overfill. Use the
correct oil as specified above.
SM 661, Aug ’01 Engine Oil and Filter • 00(G)-3-1

Group 00(G), Engine
3. Check the periodic service schedule (operating 3. Remove the engine oil filter.
hours), or the condition of the oil to determine if it
4. Make sure sealing surface on engine is clean.
needs to be changed.
5. Install new oil filter. Follow installation instructions
IMPORTANT
printed on the outside surface of the filter. Check that
Use 10W30, API, SD, SE/SG, SF engine oil. the oil seal is lubricated and correctly in place.
Sump capacity is 4.8 L (5.1 qt.).
IMPORTANT
Always use genuine CLARK parts.
Engine Oil and Filter Change
Recommended service intervals and procedures: 6. Clean and inspect the oil drain plug and seal. Replace
the drain plug and/or seal if damaged.
• Drain and replace the engine crankcase oil every
50 to 250 operating hours, or sooner as explained 7. Install drain plug. Remove oil drain pan.
on the previous page. 8. Remove and inspect the condition of the engine oil
• Replace engine oil filter at every other oil change. filler cap located on top of the engine valve cover.
• Drain and replace engine oil in a new or rebuilt Replace cap if it is damaged or the seal is broken.
engine after the first 50 hours of operation. 9. Refill the crankcase with fresh engine oil through the
• Drain oil after engine is at operating temperature. rocker cover oil filler opening. Sump capacity is 4.8
L (5.1 qt.).
To change the engine oil and oil filter: 10. Wait several minutes after adding oil to check the oil
level. Add oil if necessary.
1. Safely park the truck and place an oil drain pan under
it 11. Start the engine and allow it to run at idle for several
minutes. Check the oil filter and drain plug for leak-
2. Remove drain plug at bottom of engine oil pan and
age.
drain the oil completely.
12. Check the engine oil level with the engine stopped
NOTE
for 5 minutes. Add oil as necessary.
Raise and block up the truck under the
frame to give easier access to the engine drain IMPORTANT
plug. Refer to “Lifting, Jacking, and Block- Discard oil in an environmentally responsible
ing” in Group SA. manner.
Dipstick
Drain plug
Oil Filter
00(G)-3-2 • Engine Oil and Filter SM 661, Aug ’01

Group 00(G), Engine
Section 4
Engine Tune-Up
Tune-Up Specifications 3. Inspect engine for loose or damaged hoses, belts,

electrical connections, and choke and throttle link-
Spark Plug Type: ages.
Gas Engine: NGK BP4ES, Champion NY16 4. Start the engine, and let it warm up. While doing this,
LPG Engine: NGK BP5ES, Champion NY12 look for excessive exhaust smoke and listen for
unusual engine noise that indicates a need for engine
Spark Plug Gap: 0.7-0.8 mm (0.028-0.031 in) repair.
Spark Plug Tightening Torque: 25 N⋅m (18.4 in-lb) NOTE
Ignitor Air Gap: 0.8 mm (.031 in) Black exhaust smoke indicates excessive fuel
consumption caused by carburetor or choke
Ignition Timing: Gasoline 4° BTDC @ 680 rpm; LPG9° mis-adjustment or malfunction (gasoline
BTDC @ 680 rpm engines only). Blue exhaust smoke indicates
Centrifugal Advance: Beginning: 0° at 1000 rpm (engine). excessive oil consumption caused by faulty
End: 6.5° at 2600 rpm (engine) seating of piston rings, dirt, or worn engine
components such as rings, cylinders, pistons,
Vacuum Advance: Beginning: 0° at 80 mmHg (3.14 or valve guides.
inHg.) End: 11.5° at 280 mmHg (11.0 inHg.)
Engine Speed (rpm): 5. Make sure all instrument panel lights indicate normal
conditions. Perform service indicated by lights as
• Idle: 650-700 explained in Group 13, “Instrument Pod.”
• Maximum No-Load Governed: 2600-2700
6. Listen to the engine idle, then accelerate the truck
• Converter Stall—LPG: 1790-1890 with the tilt lever fully forward or back. If idle or
• Converter Stall—Gas: 1850-1950 acceleration is erratic, consult fuel system trouble-
Engine Vacuum kPa (psi): shooting in Group 02, “Fuel System.”
• Idle: 406-457 mmHg (16-18 inHg) 7. Perform the engine rpm, vacuum, and stall tests in
Section 5 of this Group (00 G). If these tests indicate
• Maximum No-Load Governed: 330-381 mmHg poor engine performance, perform the fuel system
(13-15 inHg) checks and adjustments given in Group 02 and the
• Converter Stall: 38-64 mmHg (1.5-2.5 inHg) ignition system checks and adjustments given in
Group 12. (Transaxle repair may also be indicated.)
Procedures 8. Verify engine performance after making adjustments
by repeating the stall tests in Section 5 of this Group
It is recommended that you perform the entire set of basic
(00 G). If adjustments cannot connect engine perfor-
planned maintenance procedures described in Section 2 of
mance, consult engine, fuel system and ignition sys-
Group PS when tuning up the engine. As a minimum, you
tem troubleshooting charts in Groups 00, 02, and 12,
should perform the following procedures.
respectively.
1. Check oil level. Fill as necessary.
2. Check coolant level using safe procedure given in
Group 01.
SM 661, Aug ’01 Engine Tune-Up • 00(G)-4-1

Group 00(G), Engine
Section 5
RPM, Vacuum, and Stall Tests
SM 661, Aug ’01 RPM, Vacuum, and Stall Tests • 00(G)-5-1

Group 00(G), Engine
Introduction Test Procedures

The tests in this Section should be part of all engine tune- Perform the tests in the order given here.
ups and planned maintenance inspections.
These tests check : Preliminary Procedures
• Engine speed settings. 1. Safely park the truck on a level surface. Apply park-
• Overall engine performance ing brake and place controls in neutral.
• Whether major components or systems other than 2. Connect a tachometer, or a combination test instru-
the engine have problems or are causing problems. ment such as the Clark Dynamic Engine Analyzer
Tests include: (part number 1802047).
• Engine idle speed and vacuum. 3. Install a vacuum gauge between the breather hose
• Engine maximum no-load governed speed and vac- (PCV line) leading from the rocker cover to the
uum. intake manifold. Use a tee, short hose, and adapter to
• Engine speed and vacuum at hydraulic tilt bypass connect the gauge.
(relief pressure).
• Engine stall speed and vacuum.
Minimum tools required are:
• Tachometer
• Vacuum gauge.
Intake manifold vacuum is determined by how far the
throttle plate is opened and how much rpm the engine can
produce at a given throttle position. The wider the throttle
plate is opened, the less vacuum (pressure drop) can
develop across the throttle bore. The extent to which the
throttle has to be opened in order to achieve a certain rpm
or power level, is affected by how well the engine is run-
ning and how much the fluid coupling (the torque con-
verter) in the transaxle resists engine rotation. Therefore, a
lower than normal vacuum reading indicates a wider throt-
tle opening and lower performance.
Similarly, when the throttle is held wide open, the vacuum
and rpm levels can vary from normal according to how
well the engine and torque converter are performing.
Other loads, such as the hydraulic pump, can also affect
performance. Engine Top View
Whenever the engine is running, its drive shaft drives the 4. Check all throttle control linkage for complete and
torque converter, which is in the transaxle. The torque free movement.
converter is a fluid coupling that slips to a varying extent,
depending on the condition of the torque converter com- 5. Start the engine and let it warm up until it runs evenly
ponents and the clutches that the torque converter drives. and accelerates smoothly when you push on the
The resistance offered by the torque converter is reflected accelerator pedal.
in the engine rpm and vacuum readings when a stall test is Allow the engine to warm up to operating temperature
performed. before putting it under any load conditions.
00(G)-5-2 • RPM, Vacuum, and Stall Tests SM 661, Aug ’01

Group 00(G), Engine
Engine RPM and Vacuum at Idle Engine RPM at Maximum No-Load Governed
1. Check the engine idle speed. If idle speed is not 650- Speed
700 rpm, adjust the carburetor idle screw setting as Check the speed to which the governor limits the engine:
explained in Group 02, “Fuel System.”
1. Push the accelerator pedal slowly to the floor. When
2. Check the engine intake manifold vacuum with the the governor begins taking control of the throttle,
engine idling at the 650-700 rpm, then increase slight variation (hunting) in engine speed may occur.
engine speed. This is normal.
The typical intake manifold vacuum reading at idle should 2. When the engine speed stabilizes, read the maximum
be 406-457 mmHg (16-18 inHg) at 650-700 rpm. Refer to no-load governed speed on the tachometer.
the chart below to analyze the reading you obtain.
If the no-load governed speed is not 2600-2700 rpm, refer
to Group 02, “Fuel System,” for governor adjustment pro-
Vacuum cedures.
Gauge Readings Engine Condition If rpm is OK and if overheating is observed at long runs at
high speed, check the vacuum at maximum no-load gov-
High and Steady: Good
erned speed.
Low and Steady: Loss of power in all cylinders caused
by: Engine Vacuum at Maximum No-Load Gov-
• Late ignition or valve timing. erned Speed
• Loss of compression due to
leakage around piston rings. Check the engine intake manifold vacuum with the engine
running at the maximum speed allowed by the governor
Very Low: Manifold, carburetor or cylinder head (only if overheating is observed at long runs at high
gasket leak. speed):
Needle Pulses Steadily as Speed Increases: 1. Run the engine to the maximum no-load governed
A partial or complete loss of power in speed, as above.
one or more cylinders caused by: 2. When the engine speed stabilizes, read the vacuum
• Leaking intake valve gauge.
• Cylinder head or intake mani- The vacuum at no-load governed speed should be 330-
fold gasket leak 381 mmHg (13-15 inHg).
• Fault in the ignition system If vacuum is low, such as 229-279 mmHg (9-11 inHg),
• Weak valve spring. this is an indication that the transaxle has a fault, such as a
locked stator, in the torque converter.
Gradual Drop at Engine Idle; Intermittent Fluctuation:
Perform stall test.
Excessive back pressure in the
exhaust system.
An occasional loss of power possibly
caused by a defect in the ignition sys-
tem or a sticking valve.
Slow Fluctuation or Drift of the Needle:

Improper idle mixture adjustment, or
carburetor, spacer or intake manifold
gasket leak.
If vacuum is OK, check the no-load governed speed.
SM 661, Aug ’01 RPM, Vacuum, and Stall Tests • 00(G)-5-3

Group 00(G), Engine
Engine RPM and Vacuum at Stall Engine vacuum at stall should be 38-64 mmHg (1.5-2.5
inHg). Engine rpm at stall should be 1790-1890 rpm for
Be sure that transaxle fluid level has been checked and is the LPG engine and 1850-1950 for the gasoline engine.
correct (see Group 06) and that braking and inching ped- See analysis chart on next page.
als are adjusted correctly (see Group 23) before you run a
stall test. To test both clutch packs in the transmission, check stall
speed and vacuum with transaxle in forward and reverse.
! CAUTION
Stall tests must be performed with the park- Analysis of Stall Test
ing brake off and with the truck placed Normal Stall Speed
against a solid barrier (such as a wall or
another lift truck) to prevent movement. LPG:1790-1890 rpm
Make sure that the truck cannot move and Gas:1850-1950 rpm
that the solid barrier is capable of withstand- − Engine performance is good.
ing the force before you begin. − Torque converter is operating correctly.
− Transmission clutch packs are operating cor-
1. Add load on forks to increase weight and prevent rectly (not slipping).
inadvertent drive wheel spin.
2. Place truck against an immovable barrier (such as a Below Normal Stall Speed
wall or another lift truck). LPG:1600-1700 rpm
3. Put the directional control lever in forward (or Gas:1650-1750 rpm
reverse, depending upon truck position to barrier). − Engine performance is poor (needs tune-up or
repair).
NOTE − Transmission and torque converter are OK.
Use of the power service brakes or steering
handwheel can affect engine rpm. Do not
Very Low Stall Speed
touch either during the test.
LPG:1100-1200 rpm
4. Release the parking brake. Gas:1150-1250 rpm
− Torque converter stator is slipping. Repair of
5. Slowly push the accelerator pedal fully down and
torque converter is required. See Group 06,
hold it there while you read the tachometer and vac-
“Transaxle,” troubleshooting.
uum gauge.
IMPORTANT
High Stall Speed
Do not run engine and converter at stall
longer than necessary to take the rpm and LPG:Above 1890 rpm
vacuum readings, or longer than 30 seconds Gas:Above 1950 rpm
at one time. Then, shift transmission into − Transaxle clutch or converter problems, See
neutral for 15 seconds and run the engine at Group 06, “Transaxle,” troubleshooting.
one-half speed for one to two minutes to cool
torque converter oil. Excessive temperature, Use the engine compression checks Section of this Group
120° C (250° F) maximum, will overheat the to further check engine condition.
converter and cause damage to converter,
seals, and fluid.
00(G)-5-4 • RPM, Vacuum, and Stall Tests SM 661, Aug ’01

Group 00(G), Engine
Section 6
Compression Checks
Test Preparation 5. Ground the ignition system. Disconnect the high ten-
sion coil wire from the distributor cap and connect it
Engine compression test procedures consist of removing to a jumper wire that is connected to ground on the
the spark plugs, installing a compression test pressure engine. This will prevent the engine from acciden-
gauge to the cylinder being tested, and cranking the tally being started and also prevent damage to electri-
engine while the pressure is being measured. cal components.
1. Be sure the oil in the crankcase is the correct viscos- NOTE
ity and filled to the proper level. Disconnect or Check to be sure battery is fully charged.
remove all auxiliary engine loads.
2. If truck has not been operating, start the engine and 6. Push the accelerator pedal fully down (to open the
warm it up to normal operating temperature. Coolant throttle and admit a full charge of air).
temperature should be 80-90° C (176-194° F). Turn 7. Turn the key switch to the Start position and crank
ignition key switch OFF. the engine until it turns through at least 5 compres-
sion strokes.
Compression Test Procedure
1. Disconnect the spark plug wires.
IMPORTANT
Do not allow dirt and contaminants to enter
spark plug openings when the plugs are
removed. Use an air nozzle or equivalent to
blow any dirt and contamination out of the
spark plug well before and after loosening
the plug.
2. Loosen the spark plug of the cylinder to be tested.

Repeat blowing the dirt out of the well. Remove the 8. Make a record of the highest pressure reading. Also
spark plug. note the approximate number of compression strokes
needed to obtain the highest pressure reading.
3. Install a screw-in adapter in the spark plug opening, Replace the spark plug.
if required by the compression pressure gauge.
4. Install a compression gauge to the spark plug opening.
SM 661, Aug ’01 Compression Checks • 00(G)-6-1

Group 00(G), Engine
9. Repeat the above procedure and compression test on a. If the compression pressure increases, this is an
each of the other cylinders, using the same number of indication that the piston rings are worn.
compression strokes needed to obtain the highest
reading for #1 cylinder.
10. Remove the pressure gauge, and adapter if used, and
install the spark plugs. Tighten the spark plugs to 25
N•m (18.4 in-lb).
IMPORTANT
Lubricate threads on spark plugs with ANTI-
SEIZE grease, Clark part #1802307.
Analysis of Pressure Readings

Cylinder compression should be about 1880 kPa (163.5
psi) at 300 rpm (cranking speed). b. If compression pressure does not improve, this is
an indication that:
1. Evaluate the cylinder compression pressure readings
• The valves are not operating correctly
that you have recorded:
• The valve seats are worn
a. If the pressure readings are all within 10% of the
• The piston may be burned, have a hole, or have a
nominal pressure, the engine is in serviceable
broken ring.
condition.
• A valve is burned or sticking open:
b. If the pressure readings are all at or below the
− A valve that is stuck open causes low cylinder
minimum specified pressure (Service Limit), the
compression and is indicated by an irregular
engine piston rings and/or valves are worn exces-
clattering noise and power loss.
sively and require service or replacement.
− A valve that is burned causes very low com-
2. Compare the pressure difference between cylinders: pression pressure in one cylinder and is indi-
a. A pressure difference between cylinders less than cated by a constant miss of one cylinder.
103 kPa (15 psi), or approximately 10%, is nor-
5. If two adjacent cylinders have low compression read-
mal.
ing and putting oil in the cylinder does not improve
b. If the pressure difference is greater than 103 kPa
compression, the cause can be the cylinder head gas-
(15 psi), this is an indication of faulty or worn
ket leaking between the cylinders. Further diagnosis
valves or piston rings, or leaking head gasket.
and repair of the engine is required.
3. Retest the cylinder with the lowest pressure. Put
6. If the compression test indicates a valve problem, a
approximately 14.8 cc (0.50 oz) of engine oil into the
lifter may be locked up or a valve seat damaged.
spark plug opening and on top of the piston in the
Refer to the overhaul Section of this Group for repair
cylinder. (Use a squirt oil can, or equal.) This will
information.
form a seal around the rings on the piston.
4. Repeat the compression test in this cylinder.
00(G)-6-2 • Compression Checks SM 661, Aug ’01

Group 00(G), Engine
Section 7
Engine Removal and Replacement
SM 661, Aug ’01 Engine Removal and Replacement • 00(G)-7-1

Group 00(G), Engine
Engine Removal 5. Disconnect the battery and remove it from the engine
compartment. Disconnect negative cable first.
! CAUTION
Negative cable
SAFE PARKING. Before working on truck: grounded to engine
• Park truck on a hard, level, and solid sur-
face, such as a concrete floor with no gaps or
breaks. Positive cable to starter solenoid
Battery clamp
• Put upright in vertical position and fully
lower the forks or attachment.
• Put all controls in neutral. Turn key switch
OFF and remove key.
• Apply the parking brake and block the
wheels.
To remove the engine:

1. 1.Tilt the steering column fully forward.
2. Raise the seat deck. 6. Disconnect and remove the air cleaner and hoses as
described in Group 3, “Air Induction System.”
3. Lift out the operator’s compartment floor plate and
remove the seat deck as explained in Group 38. 7. Disconnect and remove the exhaust pipe between the
engine exhaust manifold and the muffler pipe. See
4. Remove the overhead guard from the operator’s cell.
Group 3, Section 4.
Overhead guard
Exhaust
Pipe
Exhaust
Manifold
8. Label and disconnect all wiring from the engine to

components that will remain in the truck frame. See
Group 14 for wiring configurations.
00(G)-7-2 • Engine Removal and Replacement SM 661, Aug ’01

Group 00(G), Engine
9. On the standard transaxle truck, disconnect the accel- 14. Disconnect the engine from the transaxle (or hydro-
erator cable at the throttle lever. On the hydrostatic static transmission pump) as explained in Group 06.
transmission truck, disconnect the electrical connec-
15. Using a hoist and chains or engine stand of adequate
tion and remove the linkage actuator and linkage
capacity, hook the chains to the engine lifting eyes
with the engine.
Remove slack from the chains.
Accelerator
Cable Bracket
Throttle Lever
10. Disconnect and cap the fuel line at the fuel tank.
! CAUTION
Do not attempt to move the engine with your
hands as it is being disconnected from the
Band clamp
transmission or hoisted from the truck.
Always use a prybar to gently clear the
Fuel line engine from the transmission or the truck
frame.
11. Drain the coolant from the engine and radiator, and
disconnect the radiator hoses from the engine ther- 16. Slowly hoist the engine out of the frame.
mostat and water pump, as explained in Group 01.
IMPORTANT
12. Disconnect and remove the radiator upper shroud, Do not allow the engine and fan to swing for-
fan ring, and venturi (as explained in Group 01) to ward to bump the radiator during removal.
allow for engine front-to-back movement. Damage to the fan and/or radiator will result.
13. Unbolt the engine mounting bolts. Slip a sturdy piece of cardboard in front of
the radiator core to protect the fins.
Mounting bolt

Group 00(G), Engine
Engine Replacement 6. Set the engine onto the mounting isolators. Set
mounting bolts in place but do not tighten. The
Before beginning engine replacement, make sure the truck engine may have to be shifted to line up with the
parked with the parking brake applied and wheels transmission.
chocked. To replace the engine:
1. Make sure the hoist and chains or engine stand you
are using is of adequate capacity to safely lift the
engine.
2. Hook the hoist chains to the engine lifting eyes.
Mounting bolt
7. Connect the engine to the transaxle (or hydrostatic

transmission pump) as explained in Group 06.
8. Torque engine mounting bolts to 170-190 N⋅m (125-
140 ft-lb).
9. Align and connect the exhaust pipe to the engine
3. Slowly lift the engine and move it into place over the exhaust manifold using a new gasket for reassembly.
truck frame. Torque bolts to 40-45 N⋅m (30-33 ft-lb).
4. Make sure there are no wires, cables, hoses, or other
equipment in the way of lowering the engine into the
frame.
5. Slowly begin lowering the engine into the frame.
Exhaust
Pipe
! WARNING
Never use your hands to move the engine in
Exhaust
the frame. Always use a pry bar to gently
Manifold
shift or hold the engine in place. After the
engine is in place, keep the hoist chains
attached and keep slack out of the chains.
Remove the chains only when the engine is
securely mounted in the truck frame and
remounted with the transmission.
00(G)-7-4 • Engine Removal and Replacement SM 661, Aug ’01

Group 00(G), Engine
10. Replace the upper radiator shroud and venturi as 15. Replace the engine air cleaner and hoses. See Group
described in Group 01. 3 for complete details. Set the canister and hoses in
place and align before tightening clamps and mount-
11. Reconnect the radiator hoses between the radiator
ing nuts. Torque the base-mounting nuts to 20-25
and the water pump and the thermostat of the engine,
N⋅m (14.8-18.5 ft-lb); torque hose-to-engine clamp
as described in Group 01. Before reinstallation,
to 1.9-2.9 N⋅m (1.4-2.1 ft-lb).
check that hoses are in good condition with no dry-
ing, cracking, or splitting. 16. Replace the battery and reconnect the cables to the
battery posts and to the starter and ground.
12. Uncap and reconnect the fuel line at the fuel tank.
Make sure the hose is in good condition with no dry-
ing, cracking, or splitting evident. Torque band clamp Negative cable
grounded to engine
to 0.8-1.0 N⋅m (0.6-0.73 ft-lb).
Positive cable to starter solenoid

Battery clamp
Band clamp
Fuel line
13. 13.Reconnect the wiring. See Group 14 for drawings a. Torque the terminal nuts at the battery posts to
that show the wiring harness and component connec- 14-20 N⋅m (10.3-14.8 ft-lb).
tion points on the engine. b. Torque the nut on the starter terminal to 10-12
14. On the standard transaxle truck, reconnect the accel- N⋅m (90-110 in-lb; 7.5-9.1 ft-lb).
erator linkage and adjust length using the adjustment c. Install covers over cable ends after assembly.
nuts. See Group 02 for throttle linkage adjustments. 17. Replace the seat deck according to the procedures in
Group 38.
18. Close engine drain valve and fill radiator according
to the prodedures presented in “Engine Cooling Sys-
tem Testing and Maintenance” in Group 01. Check
inlet and outlet hoses for leaks.
Accelerator
Cable Bracket 19. Restart the engine and check all truck electrical,
hydraulic, and mechanical components for proper
operation before returning the truck to service.
Throttle Lever

Group 00(G), Engine
Section 8
Engine Overhaul
NOTE
Fuel system and ignition system overhaul informa-
tion is given in Groups 02 and 12, respectively.
SM 661, Aug ’01 Engine Overhaul • 00(G)-8-1

Group 00(G), Engine
GENERAL INFORMATION
Cylinder Head
Standard—mm (in) Limit—mm (in)
Flatness of Gasket Surface 0.05 (0.0020) 0.2 (0.008)
Grinding limit *0.2 (0.008)
* Total resurfacing depth of both cylinder head and cylinder block
Flatness of Manifold Mounting Surface
0.15 (0.0059) 0.3 (0.012)
Overall Height 89.9 - 90.1 (3.539 - 3.547)
Oversize Rework Dimensions of Valve Guide Hole (Both Intake And Exhaust):
0 .05 13.05 - 13.07 (0.51 38 - 0.51 46)
0.25 13.25- 13.27 (0.5217-0.5224)
0 .50 13.50 - 13.52 (0.531 5 - 0.5323)
Oversize Rework Dimensions of Intake Valve Seat Ring Hole:

0.30 47.30-47.33 (1.8622-1.8634)
0.60 47.60-47.63 (1.8740-1.8752)
Oversize Rework Dimensions of Exhaust Valve Seat Ring Hole:

0.30 40.30 - 40.33 (1.5866 - 1.5878)
0.60 40.60 - 40.63 (1.5984 - 1.5996)
Camshafts
Identification Mark: 1
Cam Height
Intake 41.62 (1.6602) 41.12 (1.6405)
Exhaust 42.62 (1 6626) 41.12 (1.6429)
Identification Mark: A
Cam Height
Intake 42.08 (1.6567) 41.58 (1.6370)
Exhaust 42.08 (1.6567) 41.58 (1.6370)
Identification Mark: 3
Cam Height
Intake 42.40(16693) 41.90 (1.6496)
Exhaust 42.40 (1.6693) 41.90 (1.6436)
NOTE: The camshaft identification mark is stamped on the rear end of the camshaft.
Journal Diameter 33.94 - 33.95 (1.3362 -1.3366)
Oil Clearance 0.05 - 0.09 (0.0020 - 0.0035)
00(G)-8-2 • Engine Overhaul SM 661, Aug ’01

Group 00(G), Engine
Valves
Overall Length 106.6 (4.197)
Intake 105.2 (4.142)
Exhaust
Stem Diameter
Intake 7.96 - 7.98 (0.3134-0.3142)
Exhaust 7.93 - 7.95 (0.3122-0.3130)
Face Angle 45 - 45° 30
Thickness of Valve Head (Margin)
Intake 1.2 (0.047) 0.7 (0.028)
Exhaust 2.0 (0.079) 1.5 (0.059)
Stem-To-Guide Clearance 0.02-0.06 (0.0008-0.0024) 0.10 (0.004)
Intake 0.05-0.09 (0.0020-0.0035) 0.15 (0.006)
Exhaust
Valve Springs
Standard Limit—mm (in)
Free Height—mm (in) 47.5 (1.869) 46.5 (1.829)
Load/Installed
Height—kg (lbs.) / mm (in.) 18.00 (40) / 40.4 (1.59)
Out-of-Squareness 2° or less Max. 4
Valve Guides
mm (in)
Overall Length
Intake 47 (1.85)
Exhaust 52 (2.05)
I.D. 8.00 - 8.02 (0.3150 - 0.3157)
O.D. 13.06 - 13.07 (0.5142 - 0.5146)
Service Size 0.05 (0.002), 0.25 (0.010), 0.50 (0.020) over size
Press-In-Temperature Room temperature
Valve Seats
mm (in)
Seat Angle 43°30' - 44°
Valve Contact Width 0.9 -1.3 (0.035 - 0.051 )
Sinkage 0.2 (0.008)
Service Size 0.3 (0.012), 0.6 (0.024) Over Size

Group 00(G), Engine
Silent Shafts
mm (in)
Journal Diameter
Right (front) 41.96 - 41.98 (1.6520 -1.6528)
Right (rear) 40.95 - 40.97 (1.6122 -1.6130)
Left (front) 18.47 -18.48 (0.7272 - 0.7276)
Left (rear) 40.95 - 40.97 (1.6122 -1.6130)
Oil Clearance
Right (front) 0.03 - 0.06 (0.0012 - 0.0024)
Right (rear) 0.05 - 0.09 (0.0020 - 0.0036)
Left (front) 0.02 - 0.05 (0.0008 - 0.0020)
Left (rear) 0.05 - 0.09 (0.0020 - 0.0036)
Pistons
mm (in)
O.D. 86.47 - 86.50 (3.404 - 3.4055)
Piston-To-Cylinder Clearance .0.02 - 0.04 (0.0008 - 0.0016)
Piston Rings
End Gap
No. 1 Ring 0.25 - 0.40 (0.0098 - 0.0157) 0.8 (0.031)
No. 2 Ring 0.45 - 0.60 (0.0177 - 0.0236) 0.8 (0.031 )
Oil ring 0.1 - 0.4 (0.0039 - 0.0157) 1.0 (0.039)
Ring-To-Ring Groove Clearance
No. 1 Ring 0.03-0.07 (0.0012-0.0028) 0.1 (0.004)
No. 2 ring 0.03-0.07 (0.0012-0.0028) 0.1 (0.004)
Service Size 0 25 (0.010) 0.50 (0.020) 0.75 (0.030) 1.00 (0.039) Over Size
Piston Pins
O.D. 22 00 - 22.01 (0.8661 - 0.8665)
Press-In Load N (kg, lbs.) 7.500 - 17.500 (750 -1.750, 1.653 - 3.858)
Press-In Temperature Room temperature
Connecting Rods
Big End Center-To-Small
End Center Length 149.9 -1 50.0 (5.902 - 5.906)
Bend 0.05 (0.0020)
Twist 0.1 (0.004)
Bin End Side Clearance 0.10 - 0.25 (0.0039 - 0.0098) 0.4 (0.016)

Group 00(G), Engine
Crankshafts
End Play 0.05 - 0.18 (0.0020 - 0.0071) 0.25 (0.0098)
Journal O.D. 56.98 - 57.00 (2.2433 - 2.2441)
Pin O.D. 44.98 - 45.00 (1.7709 -1.7717)
Out-of-Roundness and Taper of Journal and Pin 0.003 (0.0001)
Concentricity of Journal 0.003 (0.0001)
Oil Clearance of Journal 0.02-0.04 (0.0008 - 0.0016) 0.1 (0.004)
Oil Clearance of Pin 0.02 - 0.05 (0.0008 - 0.0020) 0.1 (0.004)
Cylinder Blocks
Cylinder I.D. 86.50 - 86.53 (3.4055 - 3.4067)
Flatness of Gasket Surface .0.05 (0.0020) 0.1 (0.004)
Grinding Limit 0.2 (0.008)*
*Total resurfacing depth of both cylinder head and cylinder block
Overall Height 289.9 - 290.1 (11.413 -11.421)
Oil Pump
Side Clearance
Drive Gear 0.08 - 0.14 (0.0031 - 0.0055)
Driven Gear 0.06 - 0.12 (0.0024 - 0.0047)
NOTE
O.D.:Outer Diameter
I.D.: Inner Diameter
U.S.: Undersize Diameter

Group 00(G), Engine
Service Precautions Sealant Specifications

Use specified brand of sealant.
Match Marks
Use of sealant other than specified sealant may cause
Mark parts with match marks before disassembly to guide water or oil leaks.
reassembly. However, be careful not to place match marks
where they could harm the function of a part.
Specified sealant
Special Tools Rocker cover 3M ATD Part No. 8660 or equivalent
Be sure to use special tools when their use is specified. Semicircular packing 3M ATD Part No. 8660 or equivalent
Using substitute tools will result in malfunction of or
Engine support bracket 3M ATD Part No. 8660 or equivalent
damage to the part.
bolt
Tightening Torque Oil pan gasket Mitsubishi Genuine Part MD970389

or equivalent
Tighten the part properly to specified torque.
Water outlet fitting Mitsubishi Genuine Part MD970389
or equivalent
Replacement Parts
Engine coolant 3M ATD Part No. 8660 or equivalent
When oil seal, O-ring, packing, or gasket have been temperature gauge unit
removed, be sure to replace them with new parts.
Engine coolant 3M Nut Locking Part No. 4171 or
However, rocker cover gasket may be reused if it is not temperature sensor equivalent
damaged.
Oil pressure switch 3M ATD Part No. 8660 or equivalent
Rubber Parts Oil pressure gauge unit3M ATD Part No. 8660 or equivalent
Do not stain timing belt and V-belt with oil or water.
Do not clean the pulley or sprocket with detergent.
Oil and Grease

Before reassembly, apply specified oil to the rotating and
sliding parts.

Group 00(G), Engine
Tightening Method for Permanently Disassembly

Yielding Bolts The parts assembled with the FIPG can be disassembled
A new type of bolt is currently used in some parts of the without use of a special method. In some cases, however,
engine. The tightening method for these bolts differs from the sealant between the joined surfaces may have to be
the conventional one. Be sure to observe the method broken by lightly striking with a mallet or similar tool. A
described in the text when tightening the bolts. flat, thin gasket scraper may be lightly hammered between
the joined surfaces. In this case, however, care must be
Service limits are provided for the bolts. Make sure that taken to prevent damage to the joined surfaces. For
the service limits described in the text are strictly removal of the oil pan, the special tool “Oil Pan Remover”
observed. (MD998727) is available. Be sure to use the special tool to
Areas where these bolts are in use: remove the oil pan.
• Cylinder head bolts

Surface Preparation
• Main bearing cap bolts
• Connecting rod cap bolts Thoroughly remove all substances deposited on the gasket
application surfaces, using a gasket scraper or wire brush.
After tightening the bolts to the specified torque, tighten Check to ensure that the surfaces to which the FIPG is to
them another 90° or 180°. The tightening method varies be applied is flat. Make sure that there are no oils, greases
on different areas. Observe the tightening method and foreign substances deposited on the application sur-
described in the text. faces. Do not forget to remove the old sealant remaining
in the bolt holes.
Form-In-Place Gasket (FIPG)
The engine has several areas where the form-in-place gas- Form-ln-Place Gasket Application
ket (FIPG) is in use. To ensure that the gasket fully serves When assembling parts with the FIPG, you must observe
its purpose, it is necessary to observe some precautions some precautions, but the procedure is very simple as in
when applying the gasket. Bead size, continuity and loca- the case of a conventional precut gasket.
tion are of paramount importance. Too thin a bead could
cause leaks. Too thick a bead, on the other hand, could be Applied FIPG bead should be of the specified size and
squeezed out of location, causing blocking or narrowing without breaks. Also be sure to encircle the bolt hole cir-
of the fluid feed line. To eliminate the possibility of leaks cumference with a completely continuous bead. The FIPG
from a joint, therefore, it is absolutely necessary to apply can be wiped away unless it is hardened. While the FIPG
the gasket evenly without a break, while observing the is still moist (in less than 15 minutes), mount the parts in
correct bead size. position. When the parts are mounted, make sure that the
gasket is applied to the required area only.
The FIPG used in the engine is a room temperature vulca-
nization (RTV) type and is supplied in a 100-gram tube The FIPG application procedure may vary on different
(Part No. MD970389 or MD997110). Since the RTV areas. Observe the procedure described in the text when
hardens as it reacts with the moisture in the atmospheric applying the FIPG.
air, it is normally used in the metallic flange areas. The
FIPG, Part No. MD970389, can be used for sealing both
engine oil and coolant, while Part No. MD997110 can be
used for only engine oil sealing.

Group 00(G), Engine
Special Tools
Tool Numer Name Use
MB990767 End yoke holder Holding camshaft sprocker when loosening or

torquing bolt. Use with MD998719.
MB990938 Handle Installation of crankshaft rear oil seal. Use

with MD998776.
MD990938 Handle Installation of crankshaft rear oil seal. Use

with MD998776.
MD998285 Crankshaft front oil seal Guide for installation of crankshaft front oil
guide seal.
MD998375 Crankshaft front oil seal Installation of crankshaft front oil seal.
installer
MD998440 Leak-down tester Leak-down test of lash adjuster
MD998441 Lash adjuster retainer Air bleeding of lash adjuster

Group 00(G), Engine
Tool Numer Name Use

MB998442 Air bleed wire Air bleeding of lash adjuster
MB998443 Lash adjuster holder Retainer for holding lash adjuster in rocker
arm at time of removal and installtion of
rocker arm and rocker shaft assembly
MD998713 Camshaft front oil seal Installation of camshaft front oil seal
installer
MD998719 Pulley holding pins(2) Holding camshaft sprocket when loosening or

torquing bolt. Use with MB990767.
MD998719 Oil pan remover Removal of the oil pan
MD998772 Valve spring compressor Compression of valve spring
MD998776 Crankshaft rear oil seal Installation of crankshaft rear oil seal. Use
installer with MB9900938.

Group 00(G), Engine
Tool Numer Name Use
MB998778 Crankshaft sprocket puller Removal of crankshaft sprocket
MB998780 Piston pin setting tool Removal and installation of piston pin
MD998781 Flywheel stopper Holding flywheel and drive plate
OVERHAUL PROCEDURES
Key to Notations In Overhaul Procedures
A Denotes removal or disassembly procedure. N Denotes non-reusable parts.

Letter on main drawing corresponds to ser-
vice point in text that follows main drawing.
X Denotes installation or assembly procedure. XX X.X XX Denotes torque value for fastener.
Letter on main drawing corresponds to ser-
vice point in text that follows main drawing. ft-lb
kg•m
N•m

Group 00(G), Engine
Timing Belt
Removal and installation steps

1. Timing belt front upper cover 11. Tensioner " B"
2. Timing belt front lower cover G H 12. Timing belt "B"
A N 3. Timing belt H G 13. Silent shaft sprocket
K 4. Tensioner spring F 14. Spacer
K 5. Tensioner pulley I 15. Crankshaft sprocket "B"
D J 6. Oil pump sprocket J A 16. Camshaft sprocket bolt

E I 7. Crankshaft bolt 17. Camshaft sprocket
F 8. Crankshaft sprocket 18. Timing belt rear cover
9. Flange
10. Spacer

Group 00(G), Engine
Removal Service Points D Oil Pump Sprocket Removal
A Timing Belt Removal
1. Mark belt running direction for reinstallation.

Notes:
a. Water or oil on the belt shorten its life drasti-
cally, so the removed timing belt, sprocket,
and tensioner must be free from oil and
water. These parts should not be washed.
Replace parts if seriously contaminated.
b. If there is oil or water on each part, check
front case oil seals, camshaft oil seal and
water pump for leaks.
E Crankshaft Bolt Loosening
2. Back off the tensioner spring mounting bolt three

turns.
3. Pinching the end of the tensioner spring on the ten-
sioner side with pliers, unhook it from the bracket
hook on the tensioner to free the tensioner spring. F Crankshaft Sprocket Removal
4. Loosen the tensioner mounting bolt and remove the

timing belt.

Group 00(G), Engine
G Timing Belt “B” Removal I Crankshaft Sprocket Removal
Make a mark on the back of the timing belt indicating the

direction of rotation so it may be reassembled in the same
direction if it is to be reused.
Notes:
a. Water or oil on the belt shorten its life drasti-
cally, so the removed timing belt, sprocket,
and tensioner must be free from oil and
water. These parts should not be washed.
Replace parts if seriously contaminated.
b. If there is oil or water on each part, check
front case oil seals, camshaft oil seal and
water pump for leaks.
J Camshaft Sprocket Bolt Loosening
H Silent Shaft Sprocket Removal

Group 00(G), Engine
Inspection A Camshaft Sprocket Tightening
Timing Belt
Replace belt if any of the following conditions exist.
• Hardening of back rubber.
Back side is glossy without resilience and leaves
no indent when pressed with fingernail.
F Spacer Installation
• Cracks on rubber back. Install the spacer with the chamfered end toward the oil
seal.
• Cracks or peeling of canvas.
• Cracks on tooth bottom.
• Cracks on belt sides.
5. Abnormal wear on belt sides. The sides are normal if G Silent Shaft Sprocket Installation
they are sharp as if cut by a knife.
6. Abnormal wear on teeth or missing tooth.

Group 00(G), Engine
H Timing Belt “B” Installation 4. Move the tensioner "B" in the direction of arrow
while lifting with a finger to give a sufficient tension
1. Align the timing marks on the crankshaft sprocket to the tension side of the timing belt. In this condi-
"B" and silent shaft sprocket with the marks on the tion, tighten the bolt to secure tensioner "B". When
front case respectively. the bolt is tightened, use care to prevent the shaft
from turning together. If the shaft is turned together,
2. Install the timing belt "B" on the crankshaft sprocket the belt will be overtensioned.
"B" and silent shaft sprocket. There should be no
slack on the tension side.
5. Check to ensure that the timing marks on the sprock-

3. Make sure that the relationship between the tensioner ets and the front case are in alignment.
pulley center and the bolt center is as shown in the
6. Press with index finger the center of span on the ten-
illustration .
sion side of timing belt "B". The belt must deflect 5 -
7 mm (0.20 - 0.28 in.).
I Crankshaft Bolt Tightening

Group 00(G), Engine
J Oil Pump Sprocket Installation
1. Insert a Phillips screwdriver [shank diameter 8 mm

(0.31 in.)] through the plug hole on the left side of
the cylinder block to block the left silent shaft.
2. Install the oil pump sprocket.
3. Apply an appropriate amount of engine oil to the
bearing surface of the nut.
4. Tighten the nuts to the specified torque.
3. Align the timing mark on the crankshaft sprocket

with that on the front case.
K Tensioner Installation
1. Hook the tensioner spring ends to the water pump

body projection and tensioner bracket.
2. Move the tensioner fully toward the water pump and
4. Align the timing mark on the oil pump with its mat-
tighten the bolt and tensioner spacer.
ing mark.
N Timing Belt Installation
1. Check that the timing belt tensioner and spring have

been installed in position. (See K )
2. 2.Align the timing mark on the camshaft sprocket
with that on the cylinder head.

Group 00(G), Engine
5. Remove the plug on the cylinder block and insert a 9. Apply force to the tensioner in the direction shown
Phillips screwdriver [shank diameter 8 mm (0.31 by arrow [B] to make the belt engage completely
in.)] through the hole. with each sprocket.
If it can be inserted as deep as 60 mm (2.4 in.) or
more, the timing marks are correctly aligned. If the
inserted depth is only 20 - 25 mm (0.8 -1.0 in.), turn
the oil pump sprocket one turn and realign the timing
marks. Then check to ensure that the screwdriver can
be inserted 60 mm (2.4 in.) or more. Keep the screw-
driver inserted until installation of the timing belt is
finished.
10. Tighten the tensioner attaching bolt then tighten the

tensioner spacer.
! CAUTION
If the tensioner spacer is tightened first, the
tensioner turns as the tensioner spacer is
tightened, resulting in an excessive belt ten-
sion.
6. Install the timing belt on the crankshaft sprocket, oil
pump sprocket and camshaft sprocket in that order.
There should be no slack on the tension side.
7. Loosen the tensioner mounting bolt and tensioner
spacer.
11. Hold the center of the tension side span of the timing
belt (between the camshaft and oil pump sprockets)
between your thumb and index finger as shown.
Then, make sure that the clearance between the belt
back surface and cover meets the standard value.
8. Turn the crankshaft clockwise by two teeth of the
Standard value: 14 mm (0.55 in.)
camshaft sprocket (or crankshaft sprocket).

Group 00(G), Engine
Intake Manifold and Thermostat
Removal steps
1. Water outlet fitting 5. Engine hanger
2. Gasket 6. Intake manifold
3. Thermostat 7. Gasket
4. Water temperature gauge unit
Installation: Use Threebond 1104 or
equivalent on threads.

Group 00(G), Engine
Exhaust Manifold and Water Pump
Removal Steps 10. O-ring. Installation: Wet the O-ring (with water) to
facilitate assembly. Keep the O-ring free of oil or
1. Oil level gauge grease.
2. Oil level gauge guide
3. O-ring
4. Heat protector A
5. Heat protector B
6. Engine hanger
7. Exhaust manifold
8. Gasket 11. Water hose
9. Water inlet pipe 12. Water pump
13. Gasket

Group 00(G), Engine
Rocker Arms and Camshaft
Removal steps
1. Breather hose (gas engine)
2. P.C.V. hose
3. Oil filler cap
4. Rocker cover
5. Gasket
J 6. Semicircular packing
G 7. Rocker arms and rocker shafts
8. Rear bearing cap
9. Rocker arm D
10. Spring
D 11. Bearing cap No. 4
12. Rocker arm C
C 15. Wave washer
B 16. Right rocker shaft
B 17. Left rocker shaft
18. Front bearing cap
F 19. Lash Adjuster
I 20. Oil seal
21. Camshaft

Group 00(G), Engine
Removal Service Point Lash Adjuster Leak Down Test
A Rocker Arm and Rocker Shaft Removal ! CAUTION

Before removing rocker arms and shafts assembly, install The lash adjuster is a precision part. Keep it
the special tool as illustrated to prevent the adjusters from free from dust and other foreign matter.
dropping. Do not disassemble lash adjusters.
When cleaning lash adjusters, use clean die-
sel fuel only.
1. Immerse the lash adjuster in clean diesel fuel.

2. While lightly pushing down the inner steel ball using
the special tool, Air Bleed Wire, move the plunger up
and down four or five times to bleed air. Use of the
retainer (special tool) helps facilitate the air bleeding
of the rocker arm mounted type lash adjuster.
3. Remove the wire and press the plunger. If the plunger
Inspection is hard to be pushed in, the lash adjuster is normal. If
the plunger can be pushed in all the way readily,
Camshaft bleed the lash adjuster again and test again. If the
plunger is still loose, replace the lash adjuster.
Measure the cam height, using the following values:
Identification Standard value Limit mm (in)

mark mm (in)
Intake 41.62 (1.64) 41.12 (1.62)
Exhaust 41.62 (1.64) 41.12 (1.62)
! CAUTION
Upon completion of air bleeding, hold the
lash adjuster upright to prevent inside diesel
Rocker Arm fuel from spilling and keep it free from dust
and other foreign matter.
4. After air bleeding, set the lash adjuster on the special

tool (Leak down tester MD998440).
5. After the plunger has gone down somewhat (0.2 - 0.5
mm), measure the time taken for it to go down 1 mm.
Replace if the measured time is not 5- 20 seconds / 1
mm (0.04 in.). [Diesel fuel at 15 - 20°C (59 - 68°F)]
Check the slipper surface. If any dents, damage, or sei-

zure is evident, replace the rocker arm.

Group 00(G), Engine
Installation Service Points G Rocker Shaft Spring, Rocker Arm and

Rocker Shaft Installation
B Rocker Shaft Installation 1. Temporarily tighten the rocker shaft on the inlet
Insert the rocker shafts into the front bearing cap so that valve side with the bolt so that all rocker arms do not
the notches on the shafts face up, and insert the installa- push the valves.
tion bolts without tightening them. 2. Fit the rocker shaft spring from the above and posi-
tion it so that it is right angles to the spark plug
guide.
NOTE
Install the rocker shaft springs before instal-
lation of the exhaust side rocker arms and
shaft.
3. Remove the special tool used to hold the lash

adjuster.
C Wave Washer Installation
4. Make sure that the notch in the rocker shaft is
Install the wave washer in correct direction as shown.
directed as shown in the illustration.
F Lash Adjuster Installation I Camshaft Oil Seal Installation
1. Immerse the lash adjuster in clean diesel fuel.

2. Using the special tool (air bleed wire), move the
plunger up and down 4 or 5 times while pushing
down lightly on the check ball in order to bleed out
the air.
J Semi-Circular Packing Installation
Specified sealant:
Threebond 1212D or equivalent
3. Insert the lash adjuster to the rocker arm, being care-
ful not to spill the diesel fuel. Then use the special
tool to prevent the adjuster from falling while install-
ing it.

Group 00(G), Engine
Cylinder Head and Valves
Removal steps
A D 1. Cylinder head bolt
2. Cylinder head assembly
3. Gasket
B C 4. Retainer lock
5. Valve spring retainer
B 6. Valve spring
7. Intake valve
B C 8. Retainer lock
9. Valve spring retainer
B 10. Valve spring
11. Exhaust valve
C A 12. Valve stem seal

13. Valve spring seat
C A 14. Valve stem seal
15. Valve spring seat
16. Intake valve guide
17. Exhaust valve guide
18. Intake valve seat
19. Exhaust valve seat
20. Cylinder head

Group 00(G), Engine
Removal Service Points Inspection
Precaution for Removed Parts Cylinder Head

Keep removed parts in order according to the cylinder 1. Check the cylinder head for water leaks, gas leaks,
number and intake/exhaust. damage or cracks before cleaning.
2. Thoroughly remove oil, water scale, sealant, carbon
A Cylinder Head Bolt Removal deposits, etc. After the oil passages have been
cleaned, blow air to make sure they are clear.
Using a 12 mm - 12 point socket wrench, loosen the cylin-
der head bolts. Loosen evenly, little by little. 3. Check the cylinder head gasket surface for flatness
by using a straightedge and thickness gauge.
Standard value: 0.03 mm (0.0020 in.)
Limit: 0.2 mm (0.008 in.)
Grinding limit: 0.2 mm (0.008 in.)
Cylinder head height (when new):
89.9 - 90.1 mm (3.539 in. - 3.547 in.)
B Retainer Lock Removal
Store removed valves, springs and other parts, tagged to

indicate their cylinder No. and location for reassembly.
4. If the service limit is exceeded, correct to meet the

specifications.
C Valve Stem Seal Removal
Do not reuse removed valve stem seal.

Group 00(G), Engine
Valve Valve Guide

Check the valve face for correct contact. If incorrect, Measure the clearance between the valve guide and valve
reface. Valve seat contact should be maintained uniform at stem. If the limit is exceeded, replace the valve guide,
the center of the valve face. valve, or both.
If the margin is less than the limit, replace the valve. Standard Value:
Intake0.02 - 0.06 mm (0.0008 - 0.0024 in.)
Standard Value:
Exhaust0.05 - 0.09 mm (0.0020 - 0.0035 in.)
Intake1.2 mm (0.047 in.)
Exhaust2.0 mm (0.079 in.) Limit:
Limit:
Exhaust0.15 mm (0.006 in.)
Exhaust1.5 mm (0.059 in.)
Valve Spring Valve Seat Reconditioning Procedure

1. Measure the free height of spring and, if it is smaller 1. Before correcting the valve seat, check for clearance
than the limit, replace it. between the valve guide and valve and, if necessary,
Standard value: 49.8 mm (1.961 in.) replace the valve guide.
Limit: 48.6 mm (1.921 in.)
2. Correct to obtain the specified seat width and angle.
2. 2.Measure the squareness of the spring and, if the
3. After correction, valve and valve seat should be
limit is exceeded, replace it.
lapped with a lapping compound.
Standard value: 2° or less
Limit: Max. 4°

Group 00(G), Engine
Valve Seat Replacement Procedure

1. Cut the valve seat to be replaced from the inside to
thin the wall thickness. Then, remove the valve seat.
NOTE
Do not install a valve guide of the same size
2. Rebore the valve seat hole in the cylinder head to a again.
selected oversize valve seat diameter.
3. Press in the valve guide to the position shown in the
3. Before fitting the valve seat, either heat the cylinder illustration.
head up to approximately 250°C (482°F) or cool the Standard value: 11.5 mm (0.45 in.)
valve seat in liquid nitrogen, to prevent the cylinder • Press-fit the valve guide, working from the cylin-
head bore from galling. der head top surface.
4. Using a valve seat cutter, correct the valve seat to the • Note that the intake and exhaust side valve
specified width and angle. See "Valve Seat Recondi- guides are different in length.
tioning Procedure". • After installing valve guides, insert new valves in
them to check for sliding condition.
Valve Guide Replacement Procedure

1. Using the special tool and a press, remove the valve
guide toward the cylinder head gasket surface.
2. Rebore the valve guide hole to the new oversize valve
guide outside diameter.
0.0513.05 - 13.07 mm (0.5138 - 0.5146 in.)
0.25 13.25 - 13.27 mm (0.5217 - 0.5224 in.)
0.5013.50 - 13.52 mm (0.5315 - 0.5323 in.)

Group 00(G), Engine
Installation Service Points D Cylinder Head Bolt Installation

1. When installing the cylinder head bolts, check that
A Valve Stem Seal Installation the shank length of each bolt meets the limit. If the
1. Install the valve spring seat. limit is exceeded, replace the bolt.
2. The special tool must be used to install the valve

stem seal. Improper installation could result in oil
leaking past the valve guide.
Limit: Max. 120.4 mm (4.74 in.)

2. Apply engine oil to the bolt threads and washers.
3. According to the tightening sequence, tighten the
bolts to 75 Nm (7.5 kgm, 54 ft. lbs.) using a 12mm -
12 point socket wrench.
4. Loosen the bolts completely.
! CAUTION
5. Torque the bolts to 20 Nm (2.0 kgm, 14.5 ft.lbs.)
Do not reuse removed valve stem seal.
6. Tighten the bolts 1/4 turns (90°) more.
B Valve Spring Installation 7. Tighten the bolts 1/4 turns (90°) additionally.
Direct the valve spring end with identification color
toward the spring retainer.
C Retainer Lock Installation
The valve spring, if excessively compressed, causes the

bottom end of the retainer to be in contact with, and dam-
age, the stem seal.

Group 00(G), Engine
Front Case, Silent Shaft and Oil Pan
Removal steps
1. Oil filter 21. Oil pump cover
2. Drain plug 22. Oil pump shaft
3. Drain plug gasket G 23. Oil pump driven gear
A N 5. Oil pan G 24. Oil pump drive gear
6. Oil screen F 25. Crankshaft front oil seal
7. Oil screen gasket E 26. Oil pump oil seal
M 9. Oil pressure switch D 27. Silent shaft oil seal
11. Relief plug I 28. Front case
12. Gasket 29. Front case gasket
13. Relief spring 30. Silent shaft, left
14. Relief plunger 31. Silent shaft, right
15. Oil filter bracket E C 32. Silent shaft, front bearing
16. Oil filter bracket gasket F B 33. Silent shaft, rear bearing, left
B K 17. Plug F A 34. Silent shaft, rear bearing, right
18. O-ring 35. Check valve
C J 19. Flange bolt 36. Oil jet
D H 20. Oil pump sprocket 37. Gasket

Group 00(G), Engine
Removal Service Points 3. Loosen the flange bolt.
A Oil Pan Removal

1. Remove the all oil pan bolts.
2. Drive in the special tool between the cylinder block
and oil pan.
NOTE
Never use a screwdriver or chisel, instead of
the special tool, as a deformed oil pan flange
will result, resulting in oil leakage.
E Silent Shaft Front Bearing Removal
1. Using the special tool, remove the right silent shaft

bearing from the cylinder block.
NOTE
Be sure to remove the front bearing first. If it
has not been removed, the Rear Bearing
Puller cannot be used.
B Plug Removal
1. If the plug is too tight, hit the plug head with a ham-
mer two to three times, and the plug will be easily
loosened.
F Rear Bearing Removal
1. Using the special tool, remove the rear bearings from

the cylinder block.
2. To remove the left rear bearing, install the special
tool, Silent Shaft Bearing Installer Stopper, to the
C Flange Bolt Removal front of the cylinder block, then remove the bearing
1. Remove the plug on the side of the cylinder block. using the special tool, Silent Shaft Bearing Puller.
2. Insert a Phillips screwdriver [shank diameter 8 mm

(0.32 in.)] into the plug hole to lock the silent shaft.

Group 00(G), Engine
Inspection 3. Check the side clearance

Standard value:
Front Case 0.08 - 0.14 mm (0.0031- 0.0055 in.) .... Drive gear
0.06 - 0.12 mm (0.0024- 0.0047 in.) .... Driven gear
1. Check the oil holes for clogging and clean if neces-
sary.
2. Check the left silent shaft front bearing section for
wear, damage and seizure. If there is anything wrong
with the section, replace the front case.
3. Check the front case for cracks and other damage.
Replace cracked or damaged front case.
Oil Seal
1. Check the oil seal lip for wear and damage. Replace
the oil seal if necessary.
Installation Service Points
2. Check the oil seal lip for deterioration. Replace the
oil seal if necessary.
A Right Silent Shaft Rear Bearing Installation
Silent Shaft 1. Install the guide pin of the special tool in the
threaded hole of the cylinder block as shown.
1. Check the oil holes for clogging.
2. Check the journal for seizure, damage and contact
with bearing. If there is anything wrong with the
journal, replace the silent shaft, bearing or front case
assembly.
3. Check the silent shaft oil clearance. If the clearance
is excessively due to wear, replace the silent shaft
bearing, silent shaft or front case assembly.
Standard value:
Front
0.03 - 0.06 mm (0.0012 - 0.0024 in.)...Right
0.02 - 0.05 mm (0.0008 - 0.0020 in.)...Left 2. Align the ratchet ball of the special tool with the oil
Rear hole in the rear bearing to install the bearing on the
0.05 - 0.09 mm (0.0020 - 0.0036 in.)...Right special tool.
0.05 - 0.09 mm (0.0020 - 0.0036 in.)..Left 3. Apply engine oil to the outside circumference of the
bearing and the bearing hole in the cylinder block.
Oil Pump
1. Assemble the oil pump gear to the front case and
rotate it to ensure smooth rotation with no looseness.
2. Ensure that there is no ridge wear on the contact sur-
face between the front case and the gear surface of
the oil pump cover.

Group 00(G), Engine
4. Insert the installer so that it is in alignment with the C Silent Shaft Bearing Installation
guide pin, and install the bearing in position.
1. Remove the rear bearing installing portion from the
special tool.
2. Install the guide pin of the special tool in the

threaded hole of the cylinder block.
B Left Silent Shaft Rear Bearing Installation
1. Install the special tool (MD998374) to the cylinder 3. Align the ratchet ball of the special tool with the oil
block. hole in the front bearing to install the bearing on the
2. Apply engine oil to the rear bearing outer circumfer- special tool.
ence and bearing hole in the cylinder block. 4. Apply engine oil to the outside circumference of the
bearing and the bearing hole in the cylinder block.
3. Using the special tool install the rear bearing.

NOTE
The left rear bearing has no oil hole.

Group 00(G), Engine
5. Insert the installer so that it is in alignment with the F Crankshaft Front Oil Seal Installation
guide pin, and install the bearing in position.
Using the special tool, install the crankshaft front oil seal
into the front case.
G Oil Pump Driven Gear / Oil Pump Drive

Gear Installation
Apply engine oil to the gears and line up the alignment
marks.
D Silent shaft Oil Seal
E Oil Pump Oil Seal Installation

Group 00(G), Engine
I Front Case Installation 2. Secure the oil pump driven gear onto the left silent
shaft by tightening the flange bolt to the specified
1. Set the special tool on the front end of the crankshaft
torque.
and apply a thin coat of engine oil to the outer cir-
cumference of the special tool to install the front
case.
K Plug Installation
1. Install a new O-ring to the groove of the front case.

2. Install the front case assembly through a new front
2. Using the special tool, install the plug and tighten to
case gasket and temporarily tighten the flange bolts
the specified torque.
(other than those for tightening the filter bracket).
3. Mount the oil filter bracket with the oil filter bracket
gasket in between, and partially tighten the 4 bolts,
each with a washer.
4. Tighten the bolts to the specified torque.
M Sealant Application To Oil Pressure

Switch
Coat the threads of the oil pressure switch with sealant
and install the switch using the special tool.
Specified sealant:
Threebond 1211 or equivalent
J Flange Bolt Installation
1. Insert a Phillips screwdriver into the hole in the left ! CAUTION

side of the cylinder block to lock the silent shaft.
• Keep the end of threaded portion clear of
sealant.
• Avoid overtightening.

Group 00(G), Engine
N Oil Pan Installation

1. Clean both mating surface of the oil pan and cylinder
block.
2. Apply a 4 mm (0.16 in.) wide bead of FIPG to the
entire circumference of the oil pan flange.
Specified FIPG:
Threebond 1207F or equivalent.
3. The oil pan should be installed within 15 minutes
after the application of FIPG.
4. Note the difference in bolt lengths at the location
shown. Oil pan viewed from lower side
NOTE
FIPG APPLICATION is explained in the
GENERAL INFORMATION subsection of
this Section.

Group 00(G), Engine
Piston and Connecting Rod
Removal steps
G 1. Nut
A F 2. Connecting rod cap
E 3. Connecting rod bearing
D 4. Piston and connecting rod assembly
E 5. Connecting rod bearing
C 6. Piston ring No. 1
C 7. Piston ring No. 2
B 8. Oil ring
B A 9. Piston pin
10. Piston
11. Connecting rod
12. Bolt

Group 00(G), Engine
Removal Service Points
A Connecting Rod Cap Removal
1. Mark the cylinder number on the side of the connect-

ing rod big end for correct reassembly.
2. Keep the removed connecting rods, caps, and bear-
ings in order according to the cylinder number.
B Piston Pin Removal
1. Insert the special tool, Push Rod, into the piston from
the side on which the front mark is stamped in the
piston head, and attach the guide C to the push rod
end. 3. Using a press, remove the piston pin.
Piston pin setting tool MD998780
NOTE
Keep the disassembled pistons, piston pins
and connecting rods in order according to the
cylinder number.
Inspection
Piston
Replace the piston if it is cracked or damaged.
Piston Pin
1. Insert the piston pin into the piston pin hole, without
the connecting rod, with your thumb. You should feel
a slight resistance. Replace the piston pin if it can be
easily inserted or there is excessive play.
2. The piston and piston pin must be replaced as an
assembly.
2. Place the piston and connecting rod assembly on the

special tool, Piston Pin Setting Base, with the front
mark facing upward.

Group 00(G), Engine
Piston Ring Crankshaft Pin Oil Clearance (Plastic Gauge

Method)
1. Check the piston ring for damage, excessive wear,
and breakage and replace if defects are evident. If the 1. Remove oil from the crankshaft pin and the connect-
piston has been replaced with a new one, the piston ing rod bearing.
rings must also be replaced with new ones. (Or,
2. Cut the plastic gauge to the same length as the width
replace piston and rings as an assembly.)
of the bearing and place it on the crankshaft pin in
2. Check for the clearance between the piston ring and parallel with its axis.
ring groove. If the limit is exceeded, replace the ring
or piston, or replace piston and rings as an assembly.
3. Install the connecting rod cap carefully and tighten

the bolts to the specified torque
Standard value:0.03 - 0.07 mm (0.0012- 0.0028 in.)
Limit: 0.1 mm (0.004 in.) 4. Carefully remove the connecting rod cap.
3. Install the piston ring into the cylinder bore. Force it 5. Measure the width of the plastic gauge at its widest
down with a piston, its crown being in contact with part by using the scale printed on the plastic gauge
the ring, to correctly position it at right angles to the package.
cylinder wall. Then, measure the end gap with a
feeler gauge. If the ring gap is excessive, replace the
piston ring.
Standard value:0.02 - 0.05 mm (0.0008 - 0.0020 in.)

Limit: 0.1 mm (0.004 in.)
Standard value:
No. 1: 0.25 - 0.40 mm (0.0098 - 0.0157 in.)
No. 2: 0.45 - 0.60 mm (0.0177 - 0.0236 in.)
Oil Ring: 0.10 - 0.40 mm (0.0039 - 0.0157 in.)
Limit:
No. 1, No. 2: 0.8 mm (0.031 in.)
Oil Ring: 1.0 mm (0.039 in.)

Group 00(G), Engine
Installation Service Points 7. Screw the guide B into the guide A until the gap
between both guides amounts to the value L obtained
A Piston Pin Installation in step 2 plus 3 mm (0.12 in).
1. Measure the following dimensions of the piston, pis-

ton pin and connecting rod.
A: Piston pin insertion hole length
B: Distance between piston bosses
C: Piston pin length
D: Connecting rod small end width
8. Place the piston and connecting rod assembly onto

the piston setting base with the front marks directed
upward.
2. Obtain dimension L (to be used later) from the above

measurements by using by following formula:
L = (A - C) - (B - D)
2
3. Insert the special tool, Push Rod, into the piston pin
and attach the guide A to the push rod end.
4. Assemble the connecting rod in the piston with their
front marks facing the same direction. 9. Press-fit the piston pin using a press. If the press-fit-
ting force required is less than the standard value,
5. Apply engine oil to the entire periphery of the piston replace the piston and piston pin set or/and the con-
pin. necting rod.
6. Insert the piston pin, push rod and guide A assembly Standard value:
having assembled in step 3 from the guide A side 7,350 -17,150 N (750 -1,750 kg, 1,653 - 3,858 Ibs.)
into the piston pin hole on the front marked side.

Group 00(G), Engine
10. Check that the piston moves smoothly.

! CAUTION
Do not use any piston ring expander when
installing side rails.
B Oil Ring Installation 3. Install the lower side rail in the same procedure as
described in step 2.
1. Fit the oil ring spacer into the piston ring groove.
4. Make sure that the side rails move smoothly in either
direction.
C Piston Ring No. 2 / Piston Ring No. 1

Installation
Using a piston ring expander, fit No. 2 and then No. 1 pis-
ton ring into position.
NOTE
The side rails and spacer may be installed in
either direction.
The new spacers and side rails are painted in the following
colors to identify their sizes:
Size Identification Color

NOTE
STD None
1. Note the difference in shape between No. 1 and No. 2
0.25 mm O.S. White
piston rings.
0.50 mm O.S. Blue
0.75 mm O.S. Black
1.00 mm O.S. Yellow
2. Install the upper side rail. To install the side rail, first
fit one end of the rail into the piston groove, then
press the remaining portion into position by finger.
See illustration.
2. Install piston rings No. 1 and No. 2 with their side

having marks facing up (on the piston crown side).

Group 00(G), Engine
D Piston and Connecting Rod Installation E Connecting Rod Bearing Installation

1. Liberally coat engine oil on the circumference of the When the bearings are replaced, select and install them
piston, piston ring, and oil ring. according to the identification colors on the crankshaft
and identification marks stamped on the connecting rod
2. Arrange the piston ring and oil ring gaps (side rail
bearing.
and spacer) as shown in the illustration.
Crankshaft Identification Color Pin OD—mm
Yellow 44.995-45.000
None 44.985-44.995
White 44.980-44.985
Connecting Rod Bearing

Identification Mark Thickness—mm
1 1.487-1.491
2 1.491-1.495
3 1.495-1.499
3. Rotate the crankshaft so that the crank pin is on the
center of the cylinder bore. Connecting rod inside diameter: 48.000-48.015 mm
4. Use suitable thread protectors on the connecting rod
bolts before inserting the piston and connecting rod
assembly into the cylinder block. Care must be taken
not to nick the crank pin.
5. Insert the piston and connecting rod assembly from
above the cylinder in such a way that the front mark
(arrow) on the top of the piston will be directed
toward the camshaft sprocket.
6. Using a suitable piston ring compressor tool, install
the piston and connecting rod assembly into the cyl-
inder block.
F Connecting Rod Cap Installation
1. Verifying the mark made during disassembly, install

the bearing cap to the connecting rod. If the connect-
ing rod is new with no index mark, make sure that the
bearing locking notches come on the same side as
shown.

Group 00(G), Engine
2. Make sure that connecting rod big end side clearance

meets the specification.
Standard value: 0.10 - 0.25 mm (0.0039 - 0.0098 in.)
Unit: 0.4 mm (0.016 in.)
G Connecting Rod Cap Nut Installation
1. Since the connecting rod bolts and nuts are torqued

using a new procedure, they should be examined
BEFORE reuse. If the bolt threads are "necked
down," the bolts should be replaced. Necking can be
checked by running a nut with fingers to the full
length of the bolt's thread. If the nut does not run
down smoothly, the bolt should be replaced.
2. Before installing the nuts, the threads should be oiled
with engine oil.
3. Install both nuts on the bolts finger tight, then alter-
nately torque each nut to assemble the cap properly.
4. Tighten the nuts to 20 Nm (2 kgm, 14.5 ft.lbs.) plus
1/4 (90°) turn.

Group 00(G), Engine
Crankshaft, Flywheel, and Drive Plate
Removal steps
1. Flywheel bolt and washer B 8. Bearing cap

2. Flywheel and ring gear A 9. Crankshaft bearing (lower)
3. Rear plate 10. Crankshaft
4. Bell housing cover A 11. Crankshaft bearing (upper)
D 5. Oil seal case 12. Cylinder block
C 6. Oil seal
B 7. Bearing cap bolt

Group 00(G), Engine
Inspection Cylinder Block

1. Visually check for scratches, rust, and corrosion.
Crankshaft Oil Clearance (Plastic Gauge Method) Use also a flaw detecting agent for the check. If
1. Remove oil from the crankshaft journal and crank- defects are evident, correct or replace.
shaft bearing . 2. Using a straightedge and feeler gauge, check the
2. Install the crankshaft. block top surface for warpage. Make sure that the
surface is free from gasket chips and other foreign
3. Cut the plastic gauge to the same length as the width matter.
of the bearing and place it on the journal in parallel Standard value: 0.05 mm (0.0020 in.)
with its axis. Limit: 0.1 mm (0.004 in.)
4. Install the crankshaft bearing cap carefully and 3. If the distortion is excessive, correct within the
tighten the bolts to specified torque. allowable limit or replace.
5. Remove the bolt and carefully remove the crankshaft Grinding limit: 0.2 mm (0.008 in.)
bearing cap. The total thickness of the stock allowed to be
removed from the cylinder block and the mating cyl-
6. Measure the width of the plastic gauge at its widest inder head is 0.2 mm (0.008 in.) at maximum.
part by using a scale printed on the plastic gauge Cylinder block height (when new):
package. 289.9-290.1 mm (11.413-11.421 in.)
Standard value: 0.02-0.04 mm (0.0008- 0.0016 in.)
Limit: 0.1 mm (0.004 in.) 4. Check the cylinder walls for scratches and seizure. If
defects are evident, correct (bore to oversize) or
replace.
5. Using a cylinder gauge, measure the cylinder bore
and cylindricity. If worn badly, rebore all cylinders to
an oversize and replace pistons and piston rings.
Measure at the points shown in the illustration.
Standard value:
Cylinder I.D.: 86.50-86.53 mm (3.4055-3.4067 in.)
Cylindricity: 0.01 mm (0.0004 in.)

Group 00(G), Engine
Cylinder Boring Installation Service Points

1. Oversize pistons to be used should be determined on
the basis of the largest bore cylinder A Crankshaft Bearing Installation
Piston size identification 1. When the bearings are replaced, select and install
Size Identification mark them according to the identification colors on the
crankshaft and the identification marks stamped on
0.25 mm (0.01 in.) O.S. 0.25
the cylinder block.
0.50 mm (0.02 in.) O.S. 0.50
0.75 mm (0.03 in.) O.S. 0.75
1.00 mm (0.04 in.) O.S. 1.00
NOTE
Size mark is stamped on the piston top.
2. Measure the outside diameter of a piston to be used.

Measure it in the thrust direction as shown.
3. Based on the measured piston O.D. calculate the bor-

ing finish dimension.
Boring finish dimension = Piston O.D. + (clearance
between piston O.D. and cylinder) - 0.02 mm
(0.0008 in.) (honing margin)
4. 4.Bore all cylinders to the calculated boring finish
dimension.
! CAUTION
To prevent distortion that may result from
temperature rise during boring, bore cylin-
ders, working from No. 2 to No. 4 to No. 1 to
No. 3.
5. Hone to the final finish dimension (piston O.D. +

clearance between piston O.D. and cylinder).
6. Check the clearance between the piston and cylinder.
Clearance between piston and cylinder: 0.02 - 0.04
mm (0.0008 - 0.0016 in.)
NOTE
When boring cylinders, finish all of four cyl-
inders to the same oversize. Do not bore only
one cylinder to an oversize.

Group 00(G), Engine
2. Install the bearings having an oil groove to the cylin- 4. After installing the bearing caps, make sure that the
der block. crankshaft end play is correct. If the end play exceeds
the limit replace the crankshaft bearings.
3. Install the bearings having no oil groove to the bear-
Standard value: 0.05 - 0.25 mm (0.0020 - 0.0098 in.)
ing caps.
Limit: 0.4 mm (0.016 in.)
B Bearing Cap/Bearing Cap Bolt Installation

C Oil Seal Installation
1. Install the bearing caps so that their arrows are posi-
tioned on the timing belt side.
D Sealant Application To Oil Seal Case

2. When installing the bearing cap bolts, check that the
shank length of each bolt meets the limit. If the limit Install the oil seal case with the bolts coated with sealant.
is exceeded, replace the bolt. Specified sealant: Threebond 1207F.
Limit: Max. 71.1 mm (2.79 in.)
3. Torque the bearing cap bolts to 25 Nm (2.5 kgm, 18
ft.lbs.) and, from that position, retighten them 1/4
(90°) turns more.

GROUP 00(D)
GROUP 00(D)
ENGINE
(4TNE94-SFW Diesel)
Engine ........................................................ Section 1
NOTICE
DETAILED FUEL SYSTEM INFORMATION is
given is Group 02, “Fuel System.”
DETAILED IGNITION SYSTEM INFORMA-

TION is given in Group 12, “Ignition System.”
SM 661, Aug ’01 Group 00(D), Engine

Group 00(D), Engine
Section 1
Engine
(4TNE94-SFW)
Fuel system
Fuel System Diagram
Fuel injection valve (Nozzle)
Fuel injection
pump
Feed pump
Fuel Filter Return
Suction
Fuel tank
SM 661, Aug ’01 Engine • 00(D)-1-1

Group 00(D), Engine
Fuel Injection Pump Exploded View
! WARNING
Fuel injection pump disassembly / assembly
and adjustment is possable at manufac-
ture’s(ZEXEL) test bench with special tools.
Therefore do not disassemble or adjust in the
field.
1. Delivery valve spring holder

2. Delivery valve spring
3. Delivery valve
4. Plunger & barrel
5. Pump housing
6. Control rack
7. Camshaft
8. Pinion
9. Control sleeve
10. Plunger spring upper retainer
11. Plunger spring
12. Plunger spring lower retainer
13. Tappet
14. Bottom screw plug
15. Lock plate
16. Pump cover
17. Bearing holder
00(D)-1-2 • Engine SM 661, Aug ’01

Group 00(D), Engine
Cooling System
System Block Diagram
From
cylinder
head
Bypass
Cooling
water
pump
Radiator
Water Pump Structure
2. Fan and pulley

3. Thermostat cover
4. Cooling water pump
5. Thermostat
SM 661, Aug ’01 Engine • 00(D)-1-3

Group 00(D), Engine
Disassembly/Assembly
Remove the alternator.
Remove the fan, V–belt and pulley.
Remove the thermostat cover.
Remove the cooling water pump.
Remove the thermostat.
For assembly, reverse the procedure.
Service points
Point 1
Disassemble–Reassembly :
• Check to see that the cooling water pump bearing
is free from abnormal noise, sticking or play and
water leakage from the bearing. If replacement is
necessary, replace the whole cooling water pump
assembly.
Point 2
Disassemble :
• Check the thermostat function, referring to the
inspection method.
00(D)-1-4 • Engine SM 661, Aug ’01

Group 00(D), Engine
Lubrication System
Lubrication System Diagram
Camshaft To cylinder head To gear case

bearing (valve rocker arm (oil pump gear
lubrication) lubrication)
Crankshaft
bearing
Lube oil pump

(with built-in pressure
regulating valve)
Fuel pump
Lube oil filter
Oil pan
Lube Oil Pump Structure
Gear case 4. Lubrication oil pump

5. Pressure regulating valve
Outer rotor
5
4 Punch mark Crankshaft
SM 661, Aug ’01 Engine • 00(D)-1-5

Group 00(D), Engine
Disassembly/Assembly Parts inspection and measurement

Loosen the belt, and remove the radiator pulley, fan and
Outer rotor
V–belt.
• Oil clearance between the outer rotor and inside
Remove the crankshaft pully.
diameter of the gear case hole.
Remove the gear case cover. • Side clearance between outer rotor and gear case
Remove the lubricating oil pump assembly from the gear hole.
case. (point 1) Unit : mm (inch)
Remove the pressure regulating valve from the lubricating Standard Limit
oil pump body. (point 2) 0.100~0.155 0.25
Oil clearance
For assembly, reverse the procedure. (0.004~0.006) (0.010)
0.05~0.10 0.15
Side clearance
Service points (0.002~0.004) (0.006)
Point 1 Outer rotor

Disassemble : Gear case
• Check if the pump rotates smoothly and see that
there is no play between the shaft and gear, and
inner rotor.
Reassemble :
• Install the outer rotor in the gear case so that the
punch mark on the end face is seen.
• When replacing the lubricating oil pump, replace
the whole assembly.
Oil clearance
Point 2
Disassemble–Reassemble :
• Only wash the pressure regulating valve. Disas-
sembly is unnecessary unless any abnormality in
operation is detected.
Side clearance
00(D)-1-6 • Engine SM 661, Aug ’01

Group 00(D), Engine
Rotor shaft Coolant

Unit : mm (inch)
• Engine : The radiator shall be completely filled.
Standard Limit • Sub–tank : The coolant level shall be between the
12.955~12.970 12.945 upper and lower limit lines.
Shaft O.D.
(0.510~0.511) (0.510)
Engine 4.2 l (1.1 gal)
12.980~13.020 13.050 Capacity
Bearing I.D.
(0.511~0.513) (0.514) Sub-tank Approx. 1.2 l (0.3 gal)
0.010~0.064 0.105
Clearance
(0.0004~0.0026) (0.0041) • The coolant must be checked when the engine is
cold.
Rotor shaft • If the level is normal in the sub–tank but low in the
radiator, check for loosened clamping of the rubber
Shaft O.D.
hose between the radiator and sub–tank or a tear in
the hose.
Leak from Cooling System and Radiator

Bearing I.D.
Coolant Leak Check in Cooling System
Lube oil pump bearing Gear case • Fill coolant to the normal level in the radiator, and
install the cap tester on the radiator.
• Operate the manual pump to set the pressure to
0.9±0.15 kgf/cm2 (12.8±2 psi).
Inspection If the cap tester pressure gauge reading drops then,
coolant is leaking from the cooling system. Check
and repair the leaking point.
Engine Oil
• The level must be between the upper and lower
limit lines on the dipstick.
Max. level 10.2 l (2.5 gal)

Min. level 4.5 l (1.2 gal)
• The oil must have appropriate viscosity and not be

contaminated : Use 15W40, API CD, CF-4 engine Cap tester
oil. Leak check in cooling water system
• No coolant or diesel fuel shall be mixed.
• Insert the dipstick fully and check the oil level.
! WARNING
The oil should not be overfilled to exceed the
upper limit line. Otherwise, oil may blow out
from the breather or impair normal engine
operation.
SM 661, Aug ’01 Engine • 00(D)-1-7

Group 00(D), Engine
Radiator Cap Inspection Valve Clearance Adjustment

• Install the radiator cap on the cap tester. Make adjustment when the engine is cold.
• Set the tester pressure to 0.9±0.15 kgf/cm2
(12.8 ± 2 psi) and check that the cap relief valve is • Align the top mark scribed on the crankshaft pulley
opened. If the relief valve does not open, or you with the gear case timing mark.
can not build test pressure, replace the cap since it • Make sure that No. 1 intake and exhaust valves
is abnormal. (from flywheel side) are free raising the rocker
arms by hand. If not, rotate the crankshaft pulley
one more turn (360°).
Radiator cap
Radiator cap inspection
Fan belt tension inspection and adjustment

• Push the center of the V–belt between the alterna-
tor and cooling water pump pulley with a finger.
The V belt tension is normal if the deflection is
between 10 to 15 mm (0.4″~0.6″). If not, adjust the • Loosen the lock nut and ajusting screw, and check
V–belt tension by the alternator adjuster. the valve cap for any inclination, entrapped dirt or
98N(10kgf)
wear.
If the valve cap head portion is worn, replace the
cap with a new one.
10~15mm
Alternator
Cooling water pump
Crankshaft pulley
V-belt tension
• Insert a 0.2mm (0.008″) feeler gauge between the
rocker arm and valve cap, and tighten the adjusting
Adjust the V-belt
tension by inserting screw to adjust the valve clearance. (marked ❍)
a bar. • Hold the adjusting screw with screwdriver and
Adjuster tighten the locknut.
• Apply oil to the contact between the adjusting
screw and push rod.
• Rotate the crankshaft pulley one turn (360°).
Alternator
Tension adjustment
00(D)-1-8 • Engine SM 661, Aug ’01

Group 00(D), Engine
• Check and adjust the valve clearance for remaining • If the measured injection pressure is lower than the
valves. (marked ×) standard level, replace the pressure adjusting shim
with a thicker one.
Nozzle tester
Injection nozzle
Cylinder No. 1 2 3 4 Injection pressure measurement

Valve IN EX IN EX IN EX IN EX with nozzle tester
No.1 cylinder at
❍ ❍ ❍ ❍
compression TDC.
Type of pressure adjust- Injection pressure
No.4 cylinder at ing shim thickness(mm): adjustment:
× × × ×
compression TDC. 0.13, 0.15, 0.18, 0.4, 0.5, The injection pressure is
0.8 increased by approx.
19 kfg/cm2 (270 psi) when
Fuel Injection Nozzle the adjusting shim thick-
ness is increased by
0.1 mm.
! WARNING
Wear protective glasses when testing the fuel
injection nozel. Never approach the injection Fuel return pipe joint
nozzle portion with a hand. The oil jetting
out from the nozzle is at a high enough pres-
sure to cause loss of sight or injury if acciden-
tally coming into contact with it.
Nozzle holder
Injection Pressure Measurement

• Remove carbon deposit at the nozzle hole thor- Pressure adjusting shim
oughly before measurement.
• Connect the fuel injection valve to the high pres- Nozzle spring
sure pipe of the nozzle tester. Nozzle spring seat
• Operate the nozzle tester lever slowly and read the Valve stop spacer
pressure at the moment when the fuel injection Nozzle
from the nozzle starts. Dowel pin valve
Nozzle
Nozzle
body
Nozzle case nut
Fuel injection nozzle exploded view
SM 661, Aug ’01 Engine • 00(D)-1-9

Group 00(D), Engine
Spray Pattern Inspection Nozzle Valve Sliding Test
After adjustment to the specified valve opening pressure, Wash the nozzle valve in clean fuel oil.
use a nozzle tester and check the spray pattern and nozzle Place the nozzle body vertically and insert the nozzle into
tip leakage. the body to about 1/3 of its length. The valve is normal if
• Nozzle tip leakage test it smoothly falls by its own weight into the body. In case
− After injecting a few times, increase the pres- of a new nozzle, remove the seal peel, and immerse it in
sure gradually. Hold the pressure for about 5 clean diesel oil or solvent to clean the inner and outer sur-
seconds at a little before the valve opening faces and to thoroughly remove rust–preventive oil before
using the nozzle. Note that a new nozzle is coated with
pressure of 20 kgf/cm2(284 psi), and check to
rust–preventive oil and is pasted with the seal peel to shut
see that oil does not drip from the tip end of the
off outer air.
nozzle.
− If extreme oil leak from the overflow joint
exists during injection by the nozzle tester,
check after retightening.
If much oil is leaking, replace the nozzle
assembly.
• Spray and injection states
− Operate the nozzle tester lever at a rate of once
or twice a second and check for abnormal
injection.
− If normal injection as shown below cannot be
obtained, replace the fuel injection valve.
Normal Nozzle valve sliding check by gravity
Nozzle Punch Mark
Y DLL A 150 P 244JO
Design code
Size : size P
: size S
Uniform spray pattern from each nozzle Injection angle
Nozzle insertion angle −Code A : angled
−No code : no angle
Abnormal
Type : DLL (semi-long type)
YANMAR
Extreme difference in angle (θ)

Extremely different injection angle (α)
Non-atomized spray
Stagnant spray
Punch mark
00(D)-1-10 • Engine SM 661, Aug ’01

Group 00(D), Engine
Fuel Injection Timing No Load Min./Max. Rpm Adjustment
• Turn the engine by using the crankshaft pulley. • After warming the engine up, gradually raise the
Inspect the injection timing of No. 1 cylinder by speed and set it at the no–load maximum revolu-
means of the delivery valve spring holder of the tion.
fuel injection pump (cylinders numbered No. 1, 2, • If the no–load maximum revolution is outside the
3 and 4 from the flywheel side.) standard range, adjust it by turning the no–load
• Rotate the crankshaft clockwise as seen from the maximum revolution adjusting bolt.
pulley side. Since the oil level at the tip end of the • Then set the no–load minimum revolution by
delivery valve spring holder rises, stop rotation as adjusting the no–load minimum revolution adjust-
soon it rises. ing bolt.
• Check the crankshaft top mark and timing scale
position. Standard
Standard : BTDC 10~12° (FID) – No load max. rpm : 2700 ± 30 rpm
• If the injection timing does not satisfy the standard, – No load min. rpm : 750 ± 30 rpm
adjust it by tilting the fuel injection pump body
toward or away from the engine after loosening the
fuel injection pump mounting nut. No-load minimum
revolution adjusting bolt No-load maximum
• If the timing is delayed, tilt the pump body away revolution adjusting bolt
from the engine.
• If the timing is too early, tilt the pump body toward
the engine.
Decrease Increase Decrease Increase
Crankshaft pulley
Top mark
Fuel injection pump

mounting nut
SM 661, Aug ’01 Engine • 00(D)-1-11

Group 00(D), Engine
Sensor Thermoswitch
Place the thermoswitch in a container filled with anti-
Thermostat and Thermal Switch Inspection freeze or oil. Heat it while measuring the fluid tempera-
ture. The switch is normal if the multimeter shows
continuity when the fluid temperature is between 107°C–
Thermostat
113°C (224.6°F~235.4°F).
Place the thermostat in a container filled with water. Heat
it while measuring the water temperature, and see that the Thermometer
thermostat is actuated between 69.5°C–72.5°C
(157.1°F~162.5°F).
Tester
probes
Engine Oil Pressure Switch

Disconnect the connector from the oil pressure switch.
Keep the multimeter probes in contact with the switch ter-
minal and cylinder block while operating the engine. It is
To radiator
abnormal if circuit is closed.
Cylinder
block
Tester probes (flywheel
Cover side)
Thermostat
Thermo switch
Continuity test
00(D)-1-12 • Engine SM 661, Aug ’01

Group 00(D), Engine
Compression Pressure Check Compression Pressure Measurement Method

Compression pressure drop is one of major causes of • After warming up the engine remove the fuel injec-
increasing blowby gas (lubricating oil contamination or tion nozzle from the cylinder to be measured.
increased lubricating oil consumption as a resultant phe- • Before installing the compression gauge, cut off
nomenon) or starting failure. The compression pressure is the fuel supply by the adjusting lever and check if
affected by the following factors : fuel comes out while rotating the flywheel manu-
1. Degree of clearance between piston and cylinder ally.
• Install the compression gage and compression gage
2. Degree of clearance at intake/exhaust valve seat
adapter at the cylinder to be measured.
3. Gas leak from nozzle gasket or cylinder head gasket
In other words, the pressure drops due to increased parts ! WARNING
wear and reduced durability resulting from long use of the Do not forget to install a gasket at the tip end
engine. of the adapter.
A pressure drop may also be caused by scratched cylinder
or piston by dust entrance from the dirty air cleaner ele-
ment or worn or broken piston ring. Measure the compres-
sion pressure to diagnose presence of any abnormality in Compression
gauge
the engine.
Measuring the compression pressure
• Install the compression gage and compression gage

adapter at the cylinder to be measured.
• Crank the engine by the starting motor until the
compression gage reading is stabilized.
Standard Compression Pressure

• Standard : 35±1 kgf/cm2 (497±14.2 psi)
• Limit : 27 kgf/cm2 (383.4 psi)
• Difference among cylinders :
2~3 kgf/cm2 (28.4~42.6 psi)
SM 661, Aug ’01 Engine • 00(D)-1-13

Group 00(D), Engine
Engine Speed and Compression Pressure

Compression pressure
(kgf/cm2 )
Engine speed (rpm)
Items to be checked
When the measured compression pressure is below the limit value, inspect each part by referring to the table below.
Item Cause Corrective action
• Air cleaner element • Clogged element • Clean the element
• Broken element • Replace the element
• Defect at element seal portion
• Valve clearance • Excessive or no clearance • Adjust the valve clearance
• Valve timing • Incorrect valve clearance • Adjust the valve clearance
• Cylinder head gasket • Gas leak from gasket • Replace the gasket
• Retighten the cylinder head bolts
to the specified torque
• Intake/exhaust valve • Gas leak due to worn valve seat or • Lap the valve seat
• Valve seat foreign matter. • Replace the intake/exhaust valve
• Piston • Sticking valve
• Piston ring • Gas leak due to scoring or wear • Perform honing or boring/horning
• Cylinder and use an oversized part
00(D)-1-14 • Engine SM 661, Aug ’01

Group 00(D), Engine
Adjusting Operation Long Storage

Perform adjusting operation as follows after the mainte- Observe the following instructions when the engine is to
nance job : be stored for a long period without operation :
• Supply the fuel oil, lubricating oil and coolant. Always drain cooling water in a cold season or before a
long storage. (This is unnecessary when antifreeze is
! WARNING used.)
Check the levels of the lubricating oil and
coolant again after test running (for about 5
! WARNING
minutes) and add as required. Negligence of water draining will cause the
water remaining inside the engine to freeze
• Start the engine, and carry out idling at a low revo- and expanded, damaging the engine cooling
lution (700 to 900 rpm) for a few minutes. system components.
• Run in the engine for about five minutes at the
rated revolution (no–load). Check for coolant, fuel Coolant draining procedure
or oil leaks and existence of abnormal vibration or • Remove the radiator cap.
noise. Also check the oil pressure, coolant temper-
• Loosen the drain cock on the side of the engine
ature and exhaust gas color.
block to drain coolant.
• Adjust the no–load minimum and maximum revo-
• After draining coolant, tighten the radiator cap and
lutions according to the specifications.
drain plug and cocks.
− Remove all mud, dust, oil deposits and thor-
oughly clean the engine and attached compo-
nents.
− Perform the nearest periodic inspection before
the storage.
− Drain or fill the fuel oil fully to prevent conden-
sation in the fuel tank.
− Disconnect the battery cable from the battery
negative (–) terminal.
− Cover the silencer, air cleaner and electric parts
with PVC cover to prevent water and dust from
depositing or entrance.
− Select a well-ventilated location without mois-
ture and dust for storage.
− Perform battery recharging once a month dur-
ing storage to compensate for self–discharge.
SM 661, Aug ’01 Engine • 00(D)-1-15

Group 00(D), Engine
Periodic Maintenance Chart

! WARNING
Make a periodic inspection plan according to the state of use. Perform periodic inspection
accurately so that inspection will not be skipped. If periodic inspection is neglected, failures
may occur or durability may be lost. Inspection and maintenance after 1000 hours require
expertise and skill, so consult our dealer or distributor.
Every month or Every 3 month Every 6 month Every year or

Part Item Daily or Every 250 or Every 1000 Every 2000
Every 50 hrs. hrs. hrs. hrs.
Fuel oil Check the fuel level and refill ❍ before operation
system Drain the fuel tank sediment ❍
Clean the fuel filter ❍
Replace the fuel filter element ❍
Drain the water separator if applicable ❍
Check for fuel oil leakage ❍ after operation
Fuel injection Check the
●
nozzle injection condition
Check the fuel injection timing ●
Check the fuel injection pump ●
Lube. oil Check the lube oil level in the oil pan
❍ before operation
system and refill
Replace the lube oil ❍ 1st time ❍
Replace lube oil filter element ❍ 1st time ❍
Check for lube oil leakage ❍ after operation
Cooling Check the coolant level and refill ❍ before operation
water system Clean the cooling system ❍
Replace the coolant ❍
Check for coolant leakage ❍ after operation
Radiator fin Check for clogging ❍ before operation
Clean the fin ❍
❍ 2nd time
Adjust the fan belt tension ❍
and thereafter
Check the fan belt ❍ before operation
Air induction Check the air cleaner element ❍
system Replace the air cleaner element ❍
Electric Check the battery electrolyte level and
❍ before operation
system refill
Check the warning lamps ❍ when the engine is started
Engine body Adjusting the intake and exhaust valve
●
clearance
! WARNING
Item marked ● should be serviced by an authorized Local dealer, unless the owner has profi-
cient mechanical ability and the proper tools.
00(D)-1-16 • Engine SM 661, Aug ’01

Starting failure Insufficient Poorex- Hunting Lubricating oil Coolant Air
engine output haustcolor intake
Engine starts During
Exhaust color
but stops soon. work
Trouble symptom
Exhaust smoke
SM 661, Aug ’01

Corrective action
Cause
Engine does not start

None
Little
Much
Ordinary
White
Black
White
Black
High knocking sound during combustion
Abnormal engine sound
Uneven combustion sound
During idling
During work
Large engine vibration
Difficulty in returning to low speed
Excessive fuel consumption
Excessive consumption
Dilution by fuel oil
Mixture with water
Low L.O. pressure
Much blow–by gas
Overheat
Low coolant temperature
Pressure drop
Pressure rise
Exhaust temperature rise
Improper clearance of intake/exhaust valve Adjust the valve clearance.
Compression leakage from valve seat Lap the valve seat.
Seizure of intake/exhaust valve Correct or replace.
Blowout from cylinder head gasket Replace the gasket.
Seized or broken piston ring Replace the piston ring.
Worn piston ring, piston or cylinder Perform honing and use oversize parts.
Seized crankpin metal or bearing Replace or replace.
toms and their causes. If any trouble symptom occurs,
The following table summarizes the general trouble symp-
Improper arrangement of piston ring joints Correct the ring joint positions.
Reverse assembly of piston rings Reassemble correctly.
Worn crankpin and journal bearing Measure and replace.
Loosened connecting rod bolt Tighten to the specified torque.
Engine system
Foreign matter trapped in combustion
Disassemble and repair.
chamber
Troubleshooting Chart
Excessive gear backlash Adjust gear meshing.

Worn intake/exhaust valve guide Measure and replace.
Defective governor Make adjustment.
Improper open/close timing of
Adjust the valve clearance.
intake/exhaust valves
Excessive cooling effect of radiator Defective thermostat (kept closed).
Defective thermostat (kept opened).
Insufficient cooling effect of radiator
or slipping fan belt
Insufficient coolant level Check leakage from cooling system.
Cracked water jacket Repair or replace.
Cooling system
Slackened fan belt Adjust the belt tension.
problem so as not to shorten the engine service life.
Defective thermostat Check or replace.

take corrective action before it develops into a serious
Group 00(D), Engine
Engine • 00(D)-1-17
Starting failure Insufficient Poorex- Hunting Lubricating oil Coolant Air
engine output haustcolor intake
Engine starts Exhaust color During
but stops soon. work
Trouble symptom
Exhaust smoke
Corrective action
Cause
00(D)-1-18 • Engine
Engine does not start
None
Little
Much
Ordinary
White
Black
White
Black
High knocking sound during combustion
Abnormal engine sound
Uneven combustion sound
During idling
During work
Large engine vibration
Difficulty in returning to low speed
Excessive fuel consumption
Excessive consumption
Dilution by fuel oil
Mixture with water
Low L.O. pressure
Excessive blowby gas
Overheat
Low coolant temperature
Pressure drop
Pressure rise
Exhaust temperature rise
Group 00(D), Engine
Improper properties of lubricating oil Use proper lubricating oil.

Leakage from lubricating oil piping system Repair
Insufficient delivery capacity of trochoid pump Check and repair.
Clogged lubricating oil filter Clean or replace.
Defective pressure regulating valve Clean, adjust or replace.
Lubricating system
Insufficient lubricating oil level Add proper lubricating oil.
Timing of fuel injection pump too early Check and adjust.
Timing of fuel injection pump too late Check and adjust.
Improper properties of fuel oil Use proper fuel oil.
Water entrance in fuel system Perform draining from the fuel filter.
Clogged fuel filter Clean or replace
Air entrance in fuel system Perform air bleeding.
Clogged or cracked fuel pipe Clean or replace.
Insufficient fuel supply to fuel injection pump Check the fuel tank cock, fuel filter, fuel pipe, and fuel feed pump
Fuel system
Uneven injection volume of fuel injection pump Check and adjust.
Excessive fuel injection volume Check and adjust.
Poor spray pattern from fuel injection nozzle Check and adjust.
Foreign matter trapped in the valve inside the priming pump.
Priming failure
(Disassemble and clean.)
Clogged strainer at feed pump inlet Clean the strainer
Clogged air filter Clean
Engine used at high temperatures or at high altitude Study output drop and load matching.
Clogged exhaust pipe Clean
Air system
Starting motor defect Repair or replace.
Alternator defect Repair or replace.
Open–circuit in wiring Repair
Elec. system
Battery voltage drop Inspect and charge the battery.
SM 661, Aug ’01

Group 00(D), Engine
Maintenance Standard
Engine Tuning
Inspection item Unit Standard Limit

Gap at intake/exhaust valve heads mm(inch) 0.15~0.25 (0.006~0.010) −
V-belt tension 98 N finger Used part mm(inch) 10~15 (0.39~0.59) −
pressure (10 kgf/cm2) New part mm(inch) 7~9 (0.28~0.35) −
Fuel injection pressure kgf/cm2(psi) 220~230 (3124~3266) −
Fuel injection timing(FID) (degrees)(bTDC) 10~12 −
No load rpm Max. rpm 2700±30 −
Min. rpm 750±30 −
Compression at 250 rpm 28±1
kgf/cm2(psi) 35±1 (497±14.2)
(398±14.2)
Top clearance mm(in) 0.737~0.869(0.029~0.034) −
Coolant capacity(engine only) l (gal) 4.2 (1.1) −
Lubricating oil capacity High l (gal) 10.2 (2.7) −
(oil pan)
Low l (gal) 4.5 (1.2) −
Lubricating oil Pressure Max. (in cold state) kgf/cm2(psi) 6.0 (85) −
At rated output kgf/cm2(psi) 3.0~4.0 (43~57) −
At idling kgf/cm2(psi) 0.6 or above (9) −
Oil pressure switch operating pressure kgf/cm2(psi) 0.5±0.1 (7±1) −
Thermostat valve opening temperature °C (°F) 69.5~72.5 (157~162) −
Thermoswitch actuating temperature °C (°F) 107~113 (225~235) −
Engine Body

Cylinder head
Combustion surface distortion mm(inch) Max. 0.05 (0.002″) 0.15 (0.006″)
Intake mm(inch) 0.5~0.7 (0.020″~0.027″) 1.0 (0.039″)
Valve sink
Exhaust mm(inch) 0.6~0.8 (0.024″~0.031″) 1.1 (0.043″)
Intake mm(inch) 1.3 (0.051″) 2.0 (0.079″)
Seat width
Valve seat Exhaust mm(inch) 2.2 (0.087″) 3.0 (0.118″)
Intake (Deg.) 120 −
Seat angle
Exhaust (Deg.) 90 −
Seat correction angle (Deg.) θ1:40, θ2:150 −
SM 661, Aug ’01 Engine • 00(D)-1-19

Group 00(D), Engine

Intake/exhaust valve guide
Valve stem outside diameter mm(inch) 7.965~7.980 (0.3136~0.3142) 7.915(0.3116)
Intake Guide inside diameter mm(inch) 8.015~8.030 (0.3156~0.3161) 8.100(0.3189)
Clearance mm(inch) 0.035~0.065 (0.0014~0.0026) 0.185(0.0073)
Valve stem outside diameter mm(inch) 7.955~7.970 (0.3132~0.3138) 7.905(0.3112)
Exhaust Guide inside diameter mm(inch) 8.015~8.030 (0.3156~0.3161) 8.100(0.3189)
Valve guide driving-in method mm(inch) Cold-fitted −
Valve guide projection from cylinder head mm(inch) 14.7~15.0 (0.5789~0.591) −
Replacement valve guide inside diameter after insert mm(inch) 8.015~8.030 (0.3156~0.3161) −
Valve spring
Free length mm(inch) 47.5 (1.87″) −
Inclination mm(inch) − 1.2(0.047)
Load for compressing uneven pitch portion by 1mm kgf(lb) 2.257 (4.97) −
Rocker arm and shaft
Arm shaft hole diameter mm(inch) 18.50~18.52 (0.7283~0.7291) 18.57(0.7311)
Shaft outside diameter mm(inch) 18.47~18.49 (0.7272~0.7279) 18.44(0.7260)
Push rod
Bend mm(inch) − 0.03(0.0012)
Cam shaft
Side gap mm(inch) 0.05~0.20 (0.002~0.008) 0.30(0.012)
Bending (1/2 the dial gauge reading) mm(inch) 0~0.02 (0~0.0008) 0.05(0.002)
Cam height mm(inch) 42.435~42.565 (1.6707~1.6758) 42.185(1.6608)
Camshaft outside diameter mm(inch) 49.925~49.950 (1.9656~1.9665) 49.890(1.9642)
Gear side Bushing inside diameter mm(inch) 49.990~50.055 (1.9681~1.9707) 50.130(1.9736)
Intermediate Block inside diameter mm(inch) 50.000~50.025 (1.9685~1.9695) 50.100(1.9724)
Flywheel side Block inside diameter mm(inch) 50.000~50.025 (1.9685~1.9695) 50.100(1.9724)
00(D)-1-20 • Engine SM 661, Aug ’01

Group 00(D), Engine

Idle gear shaft and bushing
Shaft outside diameter mm(inch) 45.950~49.975 (1.8091~1.9675) 45.900(1.8071)
Bushing inside diameter mm(inch) 46.000~46.025 (1.8110~1.8120) 46.075(1.8140)
Backlash of each gear
Crank gear, cam gear, idle gear, fuel injection pump
mm(inch) 0.08~0.14 (0.0031~0.0055) 0.16(0.0063)
gear and PTO gear
Lubricating oil pump gear mm(inch) 0.09~0.15 (0.0035~0.0059) 0.17(0.0067)
Cylinder block
Inner diameter 4TNE94 mm(inch) 94.000~94.030 (3.7008~3.7020) 94.130(3.7059)
Cylinder bore Roundness mm(inch) 0.01 (0.0004) or less 0.03(0.012)
Cylindricity mm(inch) 0.01 (0.0004) or less 0.03(0.012)
Crankshaft
Bending (1/2 the dial gauge reading) mm(inch) − 0.02(0.0008)
Pin outside diameter mm(inch) 57.952~57.962 (2.2816~2.2820) 57.902(2.2796)
Metal thickness mm(inch) 1.492~1.500 (0.0587~0.0591) −
Crank pin
US 0.25 mm(inch) 1.617~1.625 (0.0637~0.0640) −
Journal outside diameter mm(inch) 64.952~64.962 (2.5572~2.5576) 64.902(2.5552)
Metal thickness mm(inch) 1.995~2.010 (0.0785~0.0791) −
Crank journal
US 0.25 mm(inch) 2.125~2.130 (0.0872~0.0839) −
Thrust bearing
Crankshaft side gap mm(inch) 0.11~0.21 (0.0043~0.0083) −
Thrust bearing thickness mm(inch) 1.930~1.980 (0.0760~0.0780) 1.850(0.0728)
OS 0.25 mm(inch) 2.055~2.105 (0.0809~0.0829) −
Piston and ring
Piston outside Standard mm(inch) 93.945~93.955 (3.6986~3.6990) 93.900(3.6969)
diameter
OS 0.25 mm(inch) 94.195~94.205 (3.7085~3.7089) −
OS 0.50 mm(inch) 94.445~94.455 (3.7183~3.7187) −
Clearance with cylinder bore
Note) Measure at 22mm above the piston bottom mm(inch) 0.050~0.080 (0.0020~0.0031) 0.120(0.0047)
face in vertical direction to the piston pin.
SM 661, Aug ’01 Engine • 00(D)-1-21

Group 00(D), Engine

Pin outside diameter mm(inch) 29.989~30.000(1.1807~1.1811) 29.959(1.1795)
Piston pin Hole inside diameter mm(inch) 30.000~30.009(1.1811~1.1815) 30.039(1.1826)
Clearance mm(inch) 0.000~0.020(0.000~0.0008) 0.080(0.0031)
Ring groove width mm(inch) 2.040~2.060(0.0803~0.0811) −
Ring width mm(inch) 1.940~1.960(0.0764~0.0772) 1.920(0.0756)
Top ring
Side clearance mm(inch) 0.080~0.120(0.0031~0.0047) −
End clearance mm(inch) 0.250~0.450(0.0098~0.0177) 0.540(0.0213)
Ring groove width mm(inch) 2.080~2.095(0.0819~0.0825) 2.195(0.0864)
Second ring
Side clearance mm(inch) 0.090~0.125(0.0035~0.0049) 0.245(0.0096)
Ring groove width mm(inch) 3.015~3.030(0.1187~0.1193) 3.130(0.1232)
Oil ring
Side clearance mm(inch) 0.025~0.060(0.0010~0.0024) 0.180(0.0071)
Connecting rod
Thrust clearance mm(inch) 0.20~0.40(0.0079~0.0157) −
Bushing inside diameter mm(inch) 30.025~30.038(1.1821~1.1826) 30.068(1.1838)
Small end of
Pin outside diameter mm(inch) 29.987~30.000(1.1806~1.1811) 29.959(1.1795)
rod
Tappet
Tappet stem outside diameter mm(inch) 11.975~11.990(0.4715~0.4720) 11.955(0.4707)
Tappet hole(block) inside diameter mm(inch) 12.000~12.018(0.4724~0.4731) 12.038(0.4739)
Trochoid pump(Lubrication oil pump)
Clearance between outer rotor and gear case mm(inch) 0.100~0.155(0.0039~0.0061) 0.25(0.0098)
Side clearance between outer rotor and gear case mm(inch) 0.05~0.10(0.0020~0.0039) 0.15(0.0059)
Shaft outer diameter mm(inch) 12.955~12.970(0.5100~0.5106) 12.945(0.5096)
Rotor shaft and
Bearing inside diameter mm(inch) 12.980~13.020(0.5110~0.5126) 13.050(0.5138)
gear case
00(D)-1-22 • Engine SM 661, Aug ’01

Group 00(D), Engine
Tightening Torque
Unit:kgf·m(lbf·ft)
Tightening position Nominal size Tightening torque
Thermostat case M8 2.3~2.9 (16.6~20.9)
Intake manifold M8 2.3~2.9 (16.6~20.9)
Exhaust manifold M8 2.3~2.9 (16.6~20.9)
Cylinder head Rocker cover M8 2.3~2.9 (16.6~20.9)
Valve arm support M10 4.5~5.5 (32.5~39.7)
* Fuel injection nozzle M6 0.7~0.9 (5.1~6.5)
Engine hoisting hook M8 2.3~2.9 (16.6~20.9)
* L Cylinder head M11 10.5~11.5 (75.8~83.0)
Gear case M8 2.3~2.9 (16.6~20.9)
Idle gear shaft M8 2.3~2.9 (16.6~20.9)
Camshaft thrust bearing M8 2.3~2.9 (16.6~20.9)
Oil pan M8 2.3~2.9 (16.6~20.9)
M10 4.5~5.5 (32.5~39.7)
Cylinder block Mounting flange
M8 2.3~2.9 (16.6~20.9)
* L Bearing cap M11 11.0~12.0 (79.4~86.6)
Lubricating oil suction pipe M8 2.3~2.9 (16.6~20.9)
PTO lubrication pipe M8 1.3~1.7 (9.4~12.3)
Fuel injection pump inlet pipe M8 1.3~1.7 (9.4~12.3)
Fuel injection pump rear stay M8 2.3~2.9 (16.6~20.9)
Cooling water pump M8 1.8~2.3 (13.0~16.6)
Alternator M10 4.5~5.5 (32.5~39.7)
Gear case cover M8 1.8~2.3 (13.0~16.6)
Fuel injection pump M10 3.5~4.5 (25.3~32.5)
Gear case
Oil pan M8 1.8~2.3 (13.0~16.6)
Lubricating oil pump assy M8 1.8~2.3 (13.0~16.6)
Fuel injection pump drive gear cover M8 1.8~2.3 (13.0~16.6)
PTO lubrication pipe M8 1.3~1.7 (9.4~12.3)
* L Flywheel M14 19~21 (137~152)
Crankshaft
* L Crankshaft pully M14 11~13 (79.4~93.9)
Connecting rod * L Rod bolt M10 5.5~6.0 (39.7~43.3)
Mounting flange Starting motor M12 8.0~10.0 (57.8~72.2)
Main bearing cap Lubricating oil suction pipe stay M8 2.3~2.9 (16.6~20.9)
Intake manifold Fuel filter M10 3.5~4.5 (25.3~32.5)
Cooling water pump Cooling fan M8 1.8~2.3 (13.0~16.6)
! WARNING
Marked *:Reinforced type bolt, L:Lubrication oil applied tightening torque.
SM 661, Aug ’01 Engine • 00(D)-1-23

Group 00(D), Engine
Unit:kgf·m(lbf·ft)
Tightening position Nominal size Tightening torque
Fuel injection pipe M12 2.0~2.5 (14.4~18.1)
Delivery valve holder − 6.0~7.0 (43.3~50.5)
* Drive gear M14 8.5~9.5 (61.4~68.6)
Fuel pipe (inlet) M14 2.0~2.5 (14.4~18.1)
Fuel injection pump
Fuel pipe (return) M14 2.0~2.5 (14.4~18.1)
Feed pump M6 0.8~0.96 (5.8~6.9)
Inlet pipe M10 1.0~1.3 (7.2~9.4)
Rear stay M10 4.5~5.5 (32.5~39.7)
Fuel injection pipe M12 2.0~2.5 (14.4~18.1)
Fuel injection nozzle
Nozzle holder − 4.0~4.5 (28.9~32.5)
Fuel pipe (inlet) M14 2.0~2.5 (14.4~18.1)
Fuel pipe (outlet) M14 2.0~2.5 (14.4~18.1)
Fuel feed pump
Priming pump M16 4.0~4.5 (28.9~32.5)
Plug M26 8.0~9.0 (57.8~65.0)
Fuel pipe M12 2.5~3.5 (18.1~25.3)
Fuel filter
Fuel return pipe M14 4.0~4.5 (28.9~32.5)
Alternator Bracket M8 2.3~2.9 (16.6~20.9)
! WARNING
Marked *:Reinforced type bolt, L:Lubrication oil applied tightening torque.
00(D)-1-24 • Engine SM 661, Aug ’01

Group 00(D), Engine
Special Tools
Special Tools
Tool name Applicable model and tool size Illustration
Valve guide tool

(for removing valve guide) l2
(mm) d2
l
1
l1 l2 d1 d2
20 75 7.5 11
d1
Valve guide tool

l2
(for inserting valve guide)
(mm)
l1
l1 l2 d1 d2
15 65 14 20
d1
d2
Connecting rod bushing replacer

(for removal/installation of l2
(mm)
connecting rod bushing) d2
l1 l2 d1 d2 l1
10 100 30 33
d1
Valve spring compressor

(for removal/installation of
valve spring)
Part number
129100-92630
Stem seal inserter

l2
(for inserting stem seal)
(mm)
l1
l1 l2 d1 d2
19 65 16.5 23
d1
d2
SM 661, Aug ’01 Engine • 00(D)-1-25

Group 00(D), Engine
Tool name Applicable model and tool size Illustration
Filter wrench Available on the market

(for removal/installation of
lubrication oil filter)
Camshaft bushing tool

(for removing camshaft bushing) l2
(mm)
d2
l1
l1 l2 d1 d2
18 70 50 53
d1
Flex-Hone
(for re-honing of cylinder liner) (mm)
Applicable
Applicable
engine Part number
bore
model
4TNE94 129400-92430 83~95
Piston insertion tool

(for inserting piston) Part number
95550-002476
* The above piston insertion tool is appli-

cable to 60~125mm diameter piston.
Piston ring replacer Available on the market.

(for removal/installation of piston
ring)
00(D)-1-26 • Engine SM 661, Aug ’01

Group 00(D), Engine
Measuring Tools
Instrument name Application Illustration
Dial gauge Measurements of shaft bending, and strain

and gap of surfaces
Test indicator Measurements of narrow or deep portions

that cannot be measured by dial gauge
Magnetic stand For holding the dial gauge when measur-

ing using a dial gauge, standing angles
adjustable
Micrometer For measuring the outside diameters of

crankshaft, pistons, piston pins, etc.
Cylinder gauge For measuring the inside diameters of

cylinder liners, rod metal, etc.
Calipers For measuring outside diameters, depth,

thickness and width
Depth micrometer For measuring of valve sink
Square For measuring valve spring inclination

and straightness of parts
V-block For measuring shaft bend
SM 661, Aug ’01 Engine • 00(D)-1-27

Group 00(D), Engine
Torque wrench For tightening nuts and bolts to the speci-

fied torque
Feeler gauge For measuring gaps between ring and ring

groove, and shaft joints during assembly
Cap tester For checking radiator cap relief valve and

cooling system leakage
Battery/coolant tester For checking concentration of antifreeze

and specific gravity of the battery electro-
lyte.
Nozzle tester For measuring injection spray pattern of

fuel injection nozzle and injection pres-
sure
Digital thermometer For measuring temperatures
Contact type For measuring revolution by contacting

the mortise in the revolving shaft
Speedometer
Photoelectric type For measuring revolution by sensing the Revolving shaft

reflecting mark on the outer periphery of
the revolving shaft
Reflection mark
00(D)-1-28 • Engine SM 661, Aug ’01

Group 00(D), Engine
Fuel high-pressure pipe clamp Measuring the revolution regardless of the

type center or periphery of the revolving
object.
Speedometer
High-pressure pipe
Circuit tester For measuring resistance voltage and con-

tinuity of electrical circuits
Compression gauge kit For measuring compression pressure
Part number
TOL-97190080
SM 661, Aug ’01 Engine • 00(D)-1-29

Group 00(D), Engine
Precautions
Make preparation as follows before starting engine
inspection and service :
Fix the engine on a horizontal base.
! WARNING
Be sure to fix the engine securely to prevent
injury or damage to parts due to falling dur-
ing the work.
• Remove the cooling water hose, fuel oil pipe, wire

harness, control wires etc. connecting the driven
machine and engine, and drain cooling water,
lubricating oil and fuel.
• Clean soil, oil, dust, etc. from the engine by wash-
ing with solvent, air, steam, etc. Carefully operate
so as not to let any foreign matter enter the engine.
! WARNING
Always wear glasses or other protectors
when using compressed air or steam to pre-
vent any foreign matter from getting in the
eyes.
• Any part which is found defective as a result of

inspection or any part whose measured value does
not satisfy the standard or limit shall be replaced.
• Any part predicted to dissatisfy the standard or
limit before the next service as estimated from the
state of use should be replaced even when the mea-
sured value then satisfies the standard or limit.
00(D)-1-30 • Engine SM 661, Aug ’01

Group 00(D), Engine
Cylinder Head
Exploded View
Disassemble in the order of the numbers shown in the 12. Remove the cylinder head assy and head gasket. (ser-
illustration. (service point) vice point 7)
1. Remove the alternator assembly. (service point 1) 13. Remove the fuel injection valves and fuel return pipe.
(service point 8)
2. Remove the fan, pulley and V–belt.
14. Remove the intake/exhaust valves, stem seals and
3. Remove the thermostat case. (service point 2)
valve springs. (service point 9)
4. Remove the fuel filter and fuel oil piping. (service
15. Remove the rocker arms from the rocker shaft.
point 3)
For assembly, reverse the procedure.
5. Remove the oil level gauge assembly.
6. Remove the oil filter. (service point 4)
7. Remove the fuel injection pipes. (service point 5)
8. Remove the intake manifold assembly.
9. Remove the exhaust manifold assembly.
10. Remove the rocker cover.
11. Remove the rocker shaft assy, push rods and valve
caps. (service point 6)
SM 661, Aug ’01 Engine • 00(D)-1-31

Group 00(D), Engine
Service Points Point 2

Reassemble :
Point 1
• Check the thermostat function.
Disassemble :
• Loosen the mounting bolt while supporting the Point 3
alternator. Reassemble :
• Replace the fuel filter element with a new one.
! WARNING
Disassemble :
Do not tilt the alternator toward the cylinder
block in a haste since it may damage the • Cover the fuel pipe opening with tape to prevent
alternator or pinch a finger. intrusion of foreign matter.
Reassemble : Point 4
• The belt deflection shall be between 10~15mm Reassemble :
(7~9 mm for a new belt).
• Replace the oil filter with a new one.
• Replace the belt with a new one if cracked, worn or
• After fully tightening the filter manually, retighten
damaged.
it with a filter wrench by 3/4 turn.
• Carefully prevent the belt from being smeared with
oil or grease. Point 5
98N (10kgf) Disassemble :

• Cover the fuel injection pipe and pump inlets and
outlets with tape or the like to prevent intrusion of
10~15mm foreign matter.
Point 6
Alternator
Cooling water pump Disassemble :
• Keep the removed push rods by attaching tags
Crankshaft pulley V-belt tension showing corresponding cylinder numbers.
Reassemble :
Adjust the V-belt tension • Always apply oil to the contact portions of the
by innserting a bar push rods and valve clearance adjusting screws.
Adjuster
Alternator
Tension adjustment
00(D)-1-32 • Engine SM 661, Aug ’01

Group 00(D), Engine
Point 7 Point 8
Disassemble : Disassemble :
• Loosen the cylinder head bolts in two steps in the • Carefully remove the fuel injection valve so as not
illustrated order. to leave the tip end protector from being left inside
• Place the cylinder head assembly on card board to the cylinder.
prevent any damage to the combustion face. Reassemble :
Reassemble : • Replace the fuel injection valve protector with a
• Replace the head gasket with a new one. new one.
• Uniformly install the head bolts manually after
applying oil on the threads and seat portions.
Point 9
• They shall be tightened in two steps in the reverse
of the order for disassembly. Disassemble :
First step : 5~6 kgf·m (36.1~43.3 lbf·ft) • When removing each intake/exhaust valve from
Second step : 10.5~11.5 kgf·m the cylinder head, use a valve spring compressor
(75.8 ~ 83.0 lbf·ft) and compress the valve spring and remove the
valve cotter.
Disassembly • Keep each removed intake/exhaust valve after
attaching a tag showing the corresponding cylinder
number.
Fan side
• If cotter burr is seen at the shaft of each intake/

exhaust valve stem, remove it with an oil stone and
extract the valve from the cylinder head.
Head bolt disassembly order Reassemble :
• Replace the stem seal with a new one when an
intake/exhaust valve is disassembled.
Assembly • Carefully install each valve after oil application so
as not to damage the stem seal.
Fan side
• Different stem seals are provided for the intake and

exhaust valves. Do not confuse them since those
for exhaust valves are marked with yellow paint.
• After assembling the intake/exhaust valve, stem
Head bolt tightening order
seal, valve spring, seat, and cotter, tap the head of
the valve stem lightly for settling.
• Do not forget to install the valve cap.
Valve spring compressor
SM 661, Aug ’01 Engine • 00(D)-1-33

Group 00(D), Engine
Parts Inspection and Measurement • Valve sink

Measure with the valve inserted to the cylinder-
Cylinder head head.
Unit : mm (inch)
Clean the cylinder head, mainly the combustion surface,
valve seats and intake/exhaust ports, remove carbon Standard Limit
deposit and bonding agent, and check the surface state. Valve Intake 0.5~0.7(0.0197~0.0276) 1.0(0.0394)
• Appearance check sink Exhaust 0.6~0.8(0.0236~0.0315) 1.1(0.0433)
Check mainly discoloration and crack.
If crack is suspected, perform dye check.
Valve sink
• Combustion surface distortion
Depth micrometer
Apply a straight–edge in two diagonal directions
and on four sides of the cylinder head, and measure
distortion with a feeler gage.
Unit : mm (inch)
Standard Limit
Distortion 0.05 or less (0.002) 0.15 (0.0059)
Distortion at combustion surface
Straight-edge Valve sink depth

Valve sinking depth
Feeler gauge
• Seat width
Unit : mm (inch)
Standard Limit
Intake 1.3(0.0512) 2.0(0.0787)
Width
Exhaust 2.2(0.0866) 3.0(0.1181)
Valve seat width
Vernier caliper
00(D)-1-34 • Engine SM 661, Aug ’01

Group 00(D), Engine
• Seat contact • Intake/exhaust valve

Apply a thin coat of bluing on the valve seat. Insert Mainly clean and check damage and wear at the
the valve in the cylinder and push it against the seat valve stem and seat.
to check seat contact. (a) Seat contact : See above.
Standard : Continuous contact all around (b) Stem outside diameter : See above.
Valve seat contact Measuring positions
Seat Valve stem outside diameter
(c) Valve head thickness

Unit : mm (inch)
• Valve guide
Standard Limit
Mainly check damage and wear on the inside wall.
Apply supply part number 129150–11810 when Intake 1.71(0.0673) 1.00(0.0394)
replacing the part. Exhaust 1.65(0.0650) 1.00(0.0394)
Inside diameter Unit : mm (inch)
Standard Limit
Stem O.D. 7.965~7.980(0.3136~0.3142) 7.915(0.3116)
Intake
Guide I.D. 8.015~8.030(0.3156~0.3161) 8.100(0.3189)
valve
Clearance 0.035~0.065(0.0014~0.0026) 0.185(0.0073)
Thickness
Stem O.D. 7.955~7.970(0.3132~0.3138) 7.905(0.3112)
Exhaust
Guide I.D. 8.015~8.030(0.3156~0.3161) 8.100(0.3189)
valve
Clearance 0.045~0.075(0.0018~0.0030) 0.195(0.0077) Valve head thickness
(d) Valve stem bend

Measuring positions
Limit 0.01 mm (0.0004 in)
Valve guide inside diameter
SM 661, Aug ’01 Engine • 00(D)-1-35

Group 00(D), Engine
(e) Overall length • Valve rocker arm

Unit : mm (inch)
Mainly inspect valve head cap contact surface,
inside surface defects and wear.
Standard Limit Slight surface defects shall be corrected with an
Intake 115(4.53) 114.5(4.50) oilstone.
Unit : mm (inch)
Exhaust 115(4.53) 114.5(4.50)
Standard Limit
Arm hole diameter 18.50~18.52(0.7283~0.7291) 18.57(0.7311)
Length
Shaft O.D. 18.47~18.49(0.7272~0.7280) 18.44(0.7260)
Clearance 0.01~0.05(0.0004~0.0020) 0.13(0.005)
Valve bend and length

• Valve spring
Mainly inspect damage and corrosion.
Unit : mm (inch)
Standard Limit
Rocker arm hole diameter
Free length 47.5(1.87) −
Inclination − 1.2(0.047) • Valve rocker arm shaft
Mainly inspect seizure and wear at the surface in
sliding contact with the arm.
Valve spring The rocker shaft diameter shall be as specified in
above.
Free length
Rocker shaft outside diameter

Valve spring
Inclination
00(D)-1-36 • Engine SM 661, Aug ’01

Group 00(D), Engine
• Push rod • If the seat is heavily roughened and the width is

Mainly inspect the surface in contact with the tap- much enlarged, grind the seat inner surface with a
pet and adjusting screw. seat grinder whose center angle is 40°, then grind
Slight defects shall be corrected with an oilstone. the seat outer surface with a grinder whose center
Bend limit : 0.03 mm (0.0012 in) or less angle is 150° to make the seat width match the
standard. Then perform seat correction as
described above, and then carry out lapping (A)
and (B) below.
Grinding wheel θ1 θ2
Thickness gauge angle 40° 150°
(A) : Lap the valve and seat with a mixture of valve

Push rod bend
compound and engine oil.
• Valve clearance adjusting screw (B) : Lap with engine oil only.
Mainly inspect the surface in contact with the push
rod.
Slight defects shall be corrected with an oilstone. Grinder
• Rocker arm spring

Mainly inspect surface defects and corrosion.
Valve Seat Correction
! WARNING
Always check the oil clearance between the Grindstone
valve and valve guide before correcting the Seat grinder
valve seat. If it exceeds the limit, replace the
valve or valve guide first to make the clear-
ance satisfy the standard. After correction,
wash the valve and the cylinder head suffi-
ciently with diesel oil to remove all grinding
powder or compound.
• If the seat surface is slightly roughened : perform
(A) and (B) following.
• If the seat is heavily roughened but the width is
almost normal, correct with a seat grinder or seat
cutter first. Then perform lapping (A) and (B) fol- Valve lapping
lowing.
Seat cutter Intake Exhaust

angle 120° 90°
Cylinder head correction angle
SM 661, Aug ’01 Engine • 00(D)-1-37

Group 00(D), Engine
Valve Guide Replacement Valve Stem Seal Replacement

• Use a valve guide extraction tool and extract the Always use a new seal after the intake/exhaust valve dis-
valve guide from the cylinder head. assembly. Since the exhaust valve is marked with yellow
• Put liquid nitrogen or ether, (or alcohol) with dry paint, do not confuse the intake and exhaust valves.
ice added in a container and put the valve guide for • Apply engine oil to the lip.
replacement (Part No. 129150–11810) in it for
• Push with the inserting tool for installation.
cooling. Then insert it in with a valve guide insert-
ing tool.
Valve stem seal inserting tool
Valve guide replacement

Valve guide extracting
& inserting tool
Projection
Stem seal
Cylinder head
Valve gauide
Cylinder head
Valve gauide
Stem seal insertion
! WARNING
Do not touch the cooled valve guide with bare
hands to avoid skin damage.
• Check the inside diameter and finish to the stan-

dard inside diameter as required with a reamer.
Check the projection from the cylinder head.
Projection : 14.7~15.0 mm (0.5787~0.5906 in)
00(D)-1-38 • Engine SM 661, Aug ’01

Group 00(D), Engine
Gear Train And Camshaft
Exploded View
Disassemble in the order of the numbers in the 10. Remove the flywheel. (service point 6)
illustration.
11. Remove the camshaft assembly. (service point 7)
1. Perform steps 1 to 12 of the cylinder head
12. Remove the gear case. (service point 8)
disassembly procedure.
13. Remove the oil seal from the gear case cover.
2. Remove th cooling water pump.
(service point 9)
3. Remove the crankshaft pulley. (service point 1) For assembly, reverse the procedure.
4. Remove the gear case cover. (service point 2)
5. Remove the fuel injection pump. (service point 3)
6. Remove the idle gear assembly. (service point 4)
7. Remove the PTO drive gear. (service point 5)
8. Remove the PTO lubrication pipe.
9. Remove the starting motor.
SM 661, Aug ’01 Engine • 00(D)-1-39

Group 00(D), Engine
Service Points Point 3

Disassemble :
Point 1
• Remove the fuel injection pump drive gear mount-
Disassemble : ing nut, remove the gear using the gear puller, and
• Remove the crankshaft pulley using a gear puller remove the fuel injection pump. Do not forget to
after removing the mounting bolt. When removing remove the stay on the rear side. When extracting
the pulley with the gear puller, use a pad and care- the gear using the gear puller, use a pad at the shaft
fully operate so as not to damage the thread. Set and carefully operate so as not to damage the
the gear puller securely to prevent the pulley from thread.
being damaged. Reassemble :
Reassemble : • Drive gear nut tightening torque
• When installing the crankshaft pulley, apply lube 8.5~9.5 kgf·m (61.4~68.6 lbf·ft)
oil to the bolt and carefully assemble so as not to
damage the oil seal. Point 4
11~13 kgf·m (79.4~93.9 lbf·ft) Reassemble :
Point 2 • Assemble crankshaft gear A, fuel injection pump

drive gear B and camshaft gear C at the same time
Reassemble : by aligning with idle gear A, B and C marks.
• When installing the gear case cover, do not forget • Install the idle gear shaft with the oil hole facing
to install the two reinforcing bolts at the center. upward.
• Measure the backlash of each gear.
Point 5
Unit : mm (inch)
Reassemble :
Standard Limit
• Install the PTO drive gear with its inner spline side
Crankshaft gaer,
facing the flywheel.
Camshaft gear, Fuel 0.08~0.14 0.16
injection pump gear, (0.0031~0.0055) (0.0063)
Point 6
Idle gear, PTO gear,
Disassemble :
Lubricating oil pump 0.09~0.15 0.17
gear (0.0035~0.0059) (0.0067) • Install a bolt as a handle in the hole at the end face
of the flywheel and remove carefully so as not to
damage the ring gear.
Fuel injection pump
drive gear Reassemble :
Camshaft gear
• Flywheel mounting bolt tightening torque
19~21 kgf·m (137.2~151.6 lbf·ft)
(lubrication oil applied)
Idle gear
PTO gear
Lubrication oil Crankshaft gear

pump gear Direction of rotation
Gear train
• Apply sealant and install the gear case cover by

correctly positioning the two dowel pins.
00(D)-1-40 • Engine SM 661, Aug ’01

Group 00(D), Engine
Point 7 Point 8
Disassemble : Reassemble :
• Measure the camshaft side gap. • Do not forget to install the oil pan mounting bolts
Unit : mm (inch) on the bottom side when installing the gear case.
Standard Limit • Apply sealant (Part No. 977770–01212) and install
the gear case by matching the two dowel pins.
Side gap 0.05~0.20(0.0020~0.0079) 0.30(0.1181)
Point 9
Camshaft gear
Reassemble :
Thrust bearing
• Replace the oil seal whenever disassembled.
• Apply lithium grease at the time of assembly.
Parts Inspection and Measurement

Mainly check the contact between the tappet and cam con-
tact surface, bearing seizure and wear, and gear damage.
• Shaft bend measurement
Camshaft side gap Side gap
Support the camshaft with V blocks.
Rotate the camshaft and measure the runout at the
• If the measured side gap exceeds the limit, replace center of the camshaft and at each journal with a
the thrust bearing. dial gauge.
Disassemble : Half of the runout is the bend.
Unit : mm (inch)
• Since the camshaft gear is shrink–fit, heat it to
180°C~200°C (356°F~392°C) for extraction. Standard Limit
Bend 0~0.02(0~0.0008) 0.05(0.0020)
! WARNING
Do not heat directly with flame to prevent
damage.
• For camshaft removal, raise the engine with its

mounting flange at the bottom. After removing the
thrust bearing mounting bolt from the camshaft
gear hole, extract the camshaft carefully so as not
to damage the bearing bushing.
• Rotate the camshaft a few turns before extracting it
to prevent the tappet from being caught by the cam.
• After removing the camshaft, set the engine hori-
zontal and fix it on the base.
! WARNING
Unforeseen injury may arise due to falling or
slipping when raising the engine vertically or
returning it to the horizontal position. Pro-
ceed carefully so as not to lose balance.
SM 661, Aug ’01 Engine • 00(D)-1-41

Group 00(D), Engine
• Intake/exhaust cam height measurement. • Idle gear

Unit : mm (inch) Mainly check the bushing seizure and wear, and
Standard Limit gear damage.
42.435~42.565
Cam height 42.185(1.6608) Idle gear
(1.6707~1.6758) Shaft
Inside diameter
Shaft diameter
Idle gear
Shaft outside diameter and bushing inside diameter

• Camshaft outside diameter and bearing hole diam- measurement.
eter measurement. Unit : mm (inch)
Measure the camshaft outside diameter with a
Standard Limit
micrometer. The oil clearance shall be calculated
by subtracting the measured camshaft outside Shaft outside 45.950~49.975
45.900(1.8071)
diameter from the camshaft bushing inside diame- diameter (1.8091~1.9675)
ter after insertion to the cylinder measured with a
Bushing inside 46.000~46.025 46.075
cylinder gage.
diameter (1.8110~1.8120) (1.8140)
0.025~0.075 0.175
Clearance
(0.0010~0.0030) (0.0070)
• PTO drive gear

Mainly check sticking of bearings on both sides,
gear damage and looseness, and gear shaft damage
and wear.
• Oil seal replacement
Replace the oil seal with a new one when the gear
Unit : mm (inch)
case is disassembled. Extract the used oil seal.
Insert a new oil seal using the oil seal inserting
Standard Limit
tool.
Camshaft 49.925~49.950 49.890
O.D (1.9656~1.9665) (1.9652) Apply lithium grease.
Gear 49.990~50.055 50.130 • Camshaft bushing replacement
Bushing I.D.
side (1.9681~1.9707) (1.9736) Replace the bushing using the special service tool.
Oil clearance 0.040~0.130 0.240
(0.0016~0.0051) (0.0094)
Camshaft 49.910~49.935 49.875
O.D. (1.9650~1.9659) (1.9636)
Inter− 50.000~50.025 50.100
mediate Block I.D.
(1.9685~1.9695) (1.9724)
position
Oil clearance 0.065~0.115 0.225
(0.0026~0.0045) (0.0089)
Camshaft 49.925~49.950 49.890
O.D. (1.9656~1.9665) (1.9642)
Wheel Block I.D. 50.000~50.025 50.100
side (1.9685~1.9695) (1.9724)
Oil clearance 0.050~0.100 0.210
(0.0020~0.0039) (0.0083)
00(D)-1-42 • Engine SM 661, Aug ’01

Group 00(D), Engine
Cylinder Block
Exploded view
Disassemble in the order of the numbers in the 9. Remove the tappets.
illustration.
10. Remove the pistons and rings. (service point 6)
1. Perform steps 1 to 12 in the cylinder head
11. Remove the oil seal from the mounting flange.
disassembly procedure.
(service point 7)
2. Perform steps 1 to 12 in the gear train disassembly For assembly, reverse the procedure.
procedure.
3. Remove the oil pan. (service point 1)
4. Remove the lubricating oil suction pipe.
5. Remove the piston w/rod. (service point 2)
6. Remove the mounting flange. (service point 3)
7. Remove the bearing metal caps. (service point 4)
8. Remove the crankshaft. (service point 5)
SM 661, Aug ’01 Engine • 00(D)-1-43

Group 00(D), Engine
Service Points Point 3 Mounting flange

Disassemble :
Point 1 Oil pan
• Place the engine on a stable base with the cylinder
Disassemble : block upper surface facing down, and remove the
• Sealant is applied to the oil pan mounting surface mounting flange carefully so as not to damage the
on the block. Carefully operate so as not to damage combustion surface.
or distort the bonding surface. Reassemble :
Reassemble : • Apply sealant (Part No. 977770–01212) and install
• Apply sealant (Part No. 977770–01212) before the mounting flange by matching the two dowel
reassembly. pins. After assembly, rotate the engine with its
mounting flange on the bottom side.
! WARNING
Unforeseen injury may arise due to falling or
slipping when raising or reversing the engine.
Carefully operate so as not to lose balance.
Point 4 Journal bearing cap
Crankshaft Disassemble :
Feeler gage • Before removing the journal bearing, measure the
crankshaft side gap.
Standard : 0.11~0.21 mm (0.0043~0.0083 in)
Connecting rod side gap
Point 2 Piston with rod

Disassemble :
• Measure the connecting rod side gap.
Standard : 0.20~0.40 mm (0.0079~0.0157 in)
• Carefully remove the carbon deposit on top of the
cylinder so as not to damage the inner side of the
cylinder.
• Set the piston at the BDC position and remove the
connecting rod cap. Then set the piston at the TDC Crankshaft side gap
position, and push the connecting rod big end with
the wooden shaft of a hammer. Proceed carefully Reasssemble :
so as not to cause the cylinder block catch the rod
big end. Set the rod caps and crankpin metals in • If the side gap exceeds the standard, replace the
their correct combinations. thrust bearing with an oversize one.
Reassemble : 129900-02370 (Upper)

0.25 OS
• Apply oil especially carefully to the sliding contact 129900-02360 (Lower)
surfaces of the pistons, rods and rings. 2.055~2.105 mm
Standard thickness
• Use the piston insertion tool to insert each piston (0.0809~0.0829 in)
with rod in the cylinder block and install the bear-
ing metal cap.
Rod bolt : 5.5~6 kgf·m (39.7~152.4
lbf·ft) (lubrication oil applied)
00(D)-1-44 • Engine SM 661, Aug ’01

Group 00(D), Engine
Disassemble : Point 6 Piston pin and rings

• Remove the bearing caps, cap side bearings, and Disassemble :
thrust bearings. Place each thrust bearing with
• Use the piston ring replacer, remove the piston
identification of the position and direction.
rings.
Reassemble : • Remove the circlip and remove the piston pin by
• Carefully install each thrust bearing so that the pushing it out.
grooved one is positioned away from the cap.
• Do not confuse the upper and lower main bearing
metals. The upper main bearing metal (block side)
has an oil hole, and the lower one does not. The
“wheel and arrow” marks on the cap shall face the
flywheel.
Bearing cap mounting bolt
11~12 kgf·m (79.4~86.6 lbf·ft)
(lubrication oil applied)
Thrust Block side main

bearings bearing metals Reassemble :
Wheel side
Cap side main

bearing metals • Install each piston ring on the piston, with the
punched manufacturer’s mark facing upward.
• The piston ring joints shall be staggered at by 120°
intervals. Do not position the top ring joint vertical
Gear side
to the piston pin. The coil expander joint shall be

opposite to the oil ring joint.
Oil ring joint

Main bearing
Point 5 Crankshaft Second

ring joint
Disassemble : Top ring joint
• Remove the crankshaft. Remove each main bearing
metal upper (block side) and pair it with the metal
cap side lower metal.
Expander joint
! WARNING
Carefully prevent damage to the bearing or
Ring joints
finger injury when removing the crankshaft
because it is heavy.
SM 661, Aug ’01 Engine • 00(D)-1-45

Group 00(D), Engine
• When installing the piston pin to the rod and pis- • Cylinder bore and distortion
ton, the punched match mark on the big end of the Measure at 10mm below the crest of the liner, at
connecting rod shall be opposite to the size mark 20mm from the bottom end and at the center.
on the piston top.
Cylinder bore
Measure in two directions A

and B at points a, b and c.
• Install the piston in the cylinder block with the
punched mark on the big end of the rod on the noz-
zle side. (The embossed mark at the connecting rod Cylinder bore measurement positions
I–beam section shall be on the flywheel side.)
• Roundness : Maximum value of the difference
Point 7 Oil seal between the measured values in the same cross
Reassemble : section.
• Cylindricity : Maximum value of the difference
• Replace the oil seal with a new one whenever dis-
between the measured values in the same direction.
assembled. Apply lithium grease at the time of
assembly. Unit : mm (inch)
Standard Limit
Parts Inspection and Measurement
94.000~94.030
Bore 94.130(3.7059)
(3.7008~3.7020)
Cylinder block
0.01 or less
Especially clean head surface, cylinder bores and oil Roundness 0.03(0.0012)
(0.0004)
holes, and check after removing any carbon deposit and
bonding agent. 0.01 or less
Cylindricity 0.03(0.0012)
(0.0004)
• Appearance inspection
Check if there is any discoloration or crack. If
crack is suspected, perform dye check. Sufficiently
clean the oil holes and check they are not clogged.
00(D)-1-46 • Engine SM 661, Aug ’01

Group 00(D), Engine
• If the limit is exceeded or any surface defect is • Crankpin and journal measurement
found, repair by boring and honing. Use an over- Measure the outside diameter, roundness and taper
sized piston (and new piston rings) as required. at each crankpin and journal.
Correct by grinding if unevenly wear, roundness
0.25OS 0.50OS
exceeding the limit or insufficient outside diameter
Piston assembly part No. is found. Replace if the defect is excessive.
129900-22900 129900-22920
(including/Piston ring assembly)
Piston ring assembly Crankpin Unit : mm (inch)
129901-22950 129901-22970
Part No.
Standard Limit
Boring dimension φ94.250-φ94.280 φ94.500-φ94.530
mm(inch) (φ3.7106-φ3.7118) (φ3.7205-φ3.7217) Pin outside 57.952~57.962
57.902(2.2796)
diameter (2.2816~2.2820)
Head gasket 129900-01331 129900-01340
Part No. (STD) (OS) Metal 1.492~1.500
−
thickness (0.0587~0.0591)
Crankshaft 0.038~0.074
Oil clearance 0.150(0.0059)
• Mainly check seizure and wear of the crankpins (0.0015~0.0029)
and journals. Since the crankshaft gear is shrink–
fitted, heat to 180 to 200°C when extraction is nec-
essary.
• Shaft portion dye check
After washing the crankshaft, inspect it by means
of dye check or a magnaflux test. Replace it if
cracked or heavily damaged. Slight defects shall be
corrected by grinding.
Crankshaft
Inspection by dye check jouranl Crankpin
• Crankshaft bend Measuring position of the crankpin

and crank journal
Support the crankshaft journals at both ends with
V–blocks. Use a dial gauge and measure the runout If the oil clearance exceeds the limit, use an undersized
at the center journal while rotating the shaft to bearing.
inspect the bend.
Standard : 0.02 mm (0.0008ð) or less. 0.25 US bearing
Unit : mm (inch)
Bend Part No. 129900~23350
1.617~1.625
Standard thickness
(0.0637~0.0640)
Deflection φ57.702~57.712
Pin machining dimension
(φ2.2717~2.2721)
V-block V-block
Crankshaft bend measurement
SM 661, Aug ’01 Engine • 00(D)-1-47

Group 00(D), Engine
Crank journal Thrust Metal Inspection

Unit : mm (inch) Inspect any damage or wear.
Standard Limit • Thickness
64.952~64.962 Unit : mm (inch)
Journal O.D. 64.902(2.5552)
(2.5572~2.5576)
Standard Limit
Metal 1.995~2.010
− Thickness 1.930~1.980(0.0760~0.0780) 1.850(0.0728)
thickness (0.0785~0.0791)
0.038~0.068 If the side gap is exceeded, use an oversized thrust metal.
Oil clearance 0.150(0.0059)
(0.0015~0.0027)
If the clearance limit is exceeded, use an undersized 129900~02370(Upper)

0.25 OS
bearing. 129900~02360(Lower)
0.25 US crank journal bearing 2.055~2.105 mm
Standard thickness
Unit : mm (inch) (0.0809~0.0829 in)
129900~02320(Upper)
Part No.
129900~02330(Lower)
2.215~2.130
Standard thickness
(0.0872~0.0839)
Journal bearing machining φ64.702-64.712

dimension (φ2.5473~2.5477)
! WARNING
If the oil clearance is excessive though the
thicknesses of the journal and crankpin met-
als are normal or if partial uneven wear is
observed, re–grind the crankshaft and use an
oversized metals.
! WARNING
If rust or surface roughening exists on the
rear side of the metals, coat it with thin film
of ink. Then assemble the crankpin metal to
the connecting rod, and tighten the rod bolt
to the secified torque to check the metal for
contact. If the contact surface occupies 75%
or more, the metal is normal. If the contact
surface is insufficient, the metal interference
is insufficient. Replace the metal with a new
one.
00(D)-1-48 • Engine SM 661, Aug ’01

Group 00(D), Engine
Piston
0.25OS 0.50OS
• Especially clean the combustion surface, circum-
Piston assembly part No.
ference, ring grooves and piston pin bosses, and 129900-22900 129900-22920
(including/Piston ring assembly)
check after removing any carbon deposit. Any burr
at a ring groove or snap ring groove shall be Piston ring assembly
129901-22950 129901-22970
removed. If crack is suspected, inspect using color Part No.
check. Boring dimension φ94.250-φ94.280 φ94.500-φ94.530
• Piston outside diameter measurement mm(inch) (φ3.7106-φ3.7118) (φ3.7205-φ3.7217)
Measure the long diameter at 22mm from the bot-
tom end of the piston of the oval hole in the vertical Head gasket 129900-01331 129900-01340
direction to the piston pin hole. Prat No. (STD) (OS)
Unit : mm (inch)
• Piston pin hole measurement.
Standard Limit
Unit : mm (inch)
93.945~93.955 93.900
Long diameter Standard Limit
(3.6986~3.6990) (3.6969)
0.050 30.000~30.009 30.039
Min. − Pin hole diameter
(0.0020) (1.1811~1.1815) (1.1826)
Clearance between
piston and cylinder 0.080 29.989~30.000 29.959
Max. − Pin outside diameter
(0.0031) (1.1807~1.1811) (1.1795)
0.000~0.020 0.080
If the clearance between piston and cylinder Oil clearance
(0.0000~070008) (0.0031)
exceeds the limit, use an oversized piston.
Measure at positions a and b

Piston outside diameter in directions A and B.
Measurement
piston
Piston pin hole
Measure at positions a, b and

c in directions A and B.
Piston pin outside diameter
SM 661, Aug ’01 Engine • 00(D)-1-49

Group 00(D), Engine
• Piston ring, ring groove and end clearance mea-

Unit : mm (inch)
surement.
Except for the top ring, to measure the piston ring Standard Limit
groove width, first measure the width of the piston Ring groove 2.040~2.060
ring. Then insert the piston ring into the ring −
width (0.0803~0.0811)
groove. Insert a feeler gauge in between the piston
ring and groove to measure the gap between them. 1.940~1.960 1.920
Ring width
Obtain the ring groove width by adding ring width (0.0764~0.0772) (0.0756)
Top ring
to the measured side clearance. 0.080~0.120
Side clearance −
(0.0031~0.0047)
0.250~0.450 0.540
End clearance
(0.0098~0.0177) (0.0213)
Ring groove 2.080~2.095 2.195
width (0.0819~0.0825) (0.0864)
1.970~1.990 1.950
Ring width
Second (0.0776~0.0783) (0.0768)
ring 0.090~0.125 0.245
Side clearance
(0.0035~0.0049) (0.0096)
0.450~0.650 0.730
End clearance
(0.0177~0.0256) (0.0287)
To measure the end clearance, push the piston ring Ring groove 3.015~3.030 3.130
into the sleeve using the piston head, insert a feeler width (0.1187~0.1193) (0.1232)
gauge in end clearance to measure. The ring shall
be pushed in to approx. 30mm above the bottom 2.970~2.990 2.950
Ring width
end of the cylinder. (0.1169~0.1177) (0.1161)
Oil ring
For the top ring, measure only the piston ring joint 0.025~0.060 0.180
Side clearance
end clearance in normal state. (0.0010~0.0024) (0.0071)
0.250~0.450 0.550
End clearance
(0.0098~0.0177) (0.0217)
Measuring side clearance
Ring joint clearance measurement
00(D)-1-50 • Engine SM 661, Aug ’01

Group 00(D), Engine
Connecting rod • Rod small end measurement

Measure the pin outside diameter according to pro-
• Appearance inspection
cedure described above.
Inspect the portion near the boundary of the cham-
Unit : mm (inch)
fered portion and I–beam section of the big and
small ends of the connecting rod as well as the por- Standard Limit
tion near the oil hole of the bushing at the small 30.025~30.038 30.068
end for cracks, deformation, and discoloration. Piston pin I.D. bushing
(1.1821~1.1826) (1.1838)
• Twist and parallelism measurement 29.987~30.000 29.959
Use a connecting rod aligner and measure the twist Piston pin O.D.
(1.806~1.1811) (1.1795)
and bend.
0.025~0.051 0.109
Unit : mm (inch) Oil clearance
(0.0010~0.0020) (0.0043)
Standard dimension Limit dimension
Twist and 0.03(0.0012) or less
0.08(0.0031)
parallelism per 100 (3.94)
m
0m
10
m
0m
10 Parallelism
Cylinder gage
Twist
Mandrel
Connecting rod small end
If the bushing is to be replaced because the oil

Twist and parallelism measurement
clearance exceeds the limit, use spare part No.
129900–23910.
• Rod big end measurement
Measure the crankpin and bushing according to
procedure described above.
Connecting rod
alingner
Twist measurement using

a connecting rod aligner
SM 661, Aug ’01 Engine • 00(D)-1-51

Group 00(D), Engine
Tappet Cylinder Bore Correction

• Mainly check the tappet contact surface with the • Slight uneven worn, flawed, etc. shall be corrected
cam and push rod. Slight surface defects shall be by honing only. If the cylinder is unevenly worn
corrected with an oilstone. partially, flawed or otherwise damaged and cannot
be repaired simply by honing, rebore the cylinder
• Tappet stem outside diameter measurement
first and then hone.
Unit : mm (inch)
Standard Limit
11.975~11.990 11.955
Stem O.D.
(0.4715~0.4720) (0.4707)
12.000~12.018 12.038
Tappet hole I.D.
(0.4724~0.4731) (0.4739)
0.010~0.043 0.083
Oil clearance
(0.0004~0.0017) (0.0033)
Tappet
Honing cross hatch
• Items to be prepared for honing

− Flex–Hone
− Exectric drill
− Honing fluid (50 : 50 mixture of lube oil and
diesel oil)
Abnormal contact Normal contact • Apply the honing fluid to the Flex–Hone and run
surface surface the electric dril at 300 to 1200 rpm.
Then insert the Flex–Hone into the cylinder bore
while running it, and move it up and down for
about 30sec, to obtain honing mark with a cross
hatch angle of 30 to 40°.
! WARNING
Avoid faster revolution than 1200 rpm since it
may cause breakdown.
! WARNING
Do not insert or extract the Flex–Hone in
stopped state because the cylinder will be
damaged.
00(D)-1-52 • Engine SM 661, Aug ’01

Group 00(D), Engine
Piston Pin Bushing Replacement

• Replace bushing by using the special service tool.
Oil Seal Replacement

• Replace oil seal, when mounting flange is
removed. Extract the used oil seal.
• Insert a new oil seal with the oil seal insertion tool.
• Apply lithium grease.
SM 661, Aug ’01 Engine • 00(D)-1-53

GROUP 01
GROUP 01
ENGINE COOLING SYSTEM
Engine Cooling System

Specifications and Description .......................... Section 1
Engine Cooling System Troubleshooting ......... Section 2
Engine Cooling System Testing

and Maintenance..................................................Section 3
Cooling System and Alternator Belt Service ... Section 4
Radiator Removal and Replacement ............... Section 5
NOTE
Removal and replacement procedures for the water pump and
thermostat are covered in the Overhaul section of Group 00,
“Engines”.
SM 661, Aug ’01 Group 01, Engine Cooling System

Group 01, Engine Cooling System
Section 1
Specifications and Description
Specifications Coolant Protection Check (hydrometer test): Every six

months or 1000 hours of operation.
Radiator Type: Crossflow radiator with coolant recovery
system. Radiator Core Air Cleaning: Every 50-250 hours or
monthly.
System Pressure (Radiator cap): 83-109 kPa (12-16 psi).
Radiator Cap Inspection and Test: Every year or 2000
Thermostat: hours of operation.
Gas/LPG/Diesel Thermostat Test/Replacement: Every 2000 hours or each
• Open (cracking) at 82°C±1.5°(180°F±2.7°). PM.
• Fully open at 95°C(203°F). Fan Belt Tension Wear Inspection: After the first 50 hours
of operation, then every 50-250 hours or each PM.
Coolant Mixture: 50% water and 50% low-silicate, ethyl-
ene glycol, permanent-type antifreeze with rust and corro- Fan Inspection for Loose or Damaged Blades: Every 50-
sion inhibitors. 250 hours or each PM.
Cooling System Coolant Capacity:

Fastener Torques
• Cushion-tire truck with 4-row radiator capacity is
10.5 L (11.0 qt ) Cooling System Brace: 20-25 N⋅m (14.8-18.5 ft-lb)
• Pneumatic-tire truck with 4-row radiator capacity Shroud Mounting Bolts: 8-10 N⋅m (5.9-7.4 ft-lb)
is 8.5 L (9.0 qt)
Oil Cooler to Radiator Brackets: 20-25 N⋅m (14.8-18.5 ft-
• Diesel truck with 4-row radiator capacity is 9.6 L lb)
(10.1 qt).
Fan to Pulley Assembly Bolts: 20-25 N⋅m (14.8-18.5 ft-
Fan Type: Pusher type lb)
Fan Drive Belt: V-type belt Pulley to Flywheel Bolts (LPG): 20-25 N⋅m (14.8-18.5 ft-
Water Pump Type: Centrifugal lb)
Hose Clamp Sizes: Venturi to Engine Bolts: 20-25 N⋅m (14.8-18.5 ft-lb)
• Gas/LPG: 47 mm (1.8 in) @ radiator end; 44 mm Venturi to Fan Ring: 8-10 N⋅m (5.9-7.4 ft-lb)
(1.7 in) @ engine (water pump or thermostat) end Oil Cooler Hose Clips: 5-6 N⋅m (3.7-4.4 ft-lb)
• Diesel: 51mm (2 in).
Water Bottle Mounting Bracket: 3.5-4.3 N⋅m (2.6-3.2 ft-
lb)
Service Intervals Overflow Line Clips: 8-10 N⋅m (5.9-7.4 ft-lb)
Coolant Level Check: Every 8-10 hours or daily.

Coolant Change (drain and refill): Every year or 2000
hours of operation.
Coolant Hoses Inspection/Replacement: As needed and
every 50-250 hours or each PM and every year or 2000
hours of operation.
SM 661, Aug ’01 Engine Cooling System Specifications and Description • 01-1-1
Description The radiators of the different models of the truck are not
the same, but the procedures for general service are the
The engine cooling system is a conventional setup and same. Radiator repair is not covered in this manual. Radi-
consists of the radiator, the fan and drive belt, the thermo- ator service shops should be consulted if the radiator is
stat, the water pump, and associated hoses. The radiator is clogged, cracked, or otherwise unserviceable. The compo-
filled through the overflow bottle, a reservoir for extra nents that can be serviced include the belts (gas and LPG
coolant that allows for fluid expansion as the fluid gets engines have two belts), the thermostat, the water pump,
warmed in the engine. The transmission oil cooler is sepa- and hoses.
rate from the engine cooling system, but is mounted
directly below the radiator.
Cooling system brace

Oil cooler
Radiator
To thermostat
Venturi
Fan seal
Upper fan
shroud To water pump
Fan ring
Cooling System-Pneumatic-Tire Truck
01-1-2 • Engine Cooling System Specifications and Description SM 661, Aug ’01
Section 2
Engine Cooling System Troubleshooting
Temperature gauge in red zone Engine shuts down (automatic engine shut-
• Radiator fins plugged; blow debris from radiator. down sensor)
• Blockage in system; drain, flush, and refill system. • High transmission temperature; check transmission
oil cooler components.
Engine overheating • Low engine oil pressure; check oil level and fill
and check for leaks.
• Loose fan belt; tighten to correct tension (see Sec- • High coolant temperature; check “Engine over-
tion 4 for belt tensioning procedure). heating” for symptoms and remedies.
• Low coolant level; refill and check for leaks.
• Radiator pressure cap is defective. Water pump leaks
• Inadequate air flow to the radiator; check that fan • Pump has a worn shaft and/or seal.
blades have the coined imprinting facing the
engine and are not installed backwards. • Bad gasket.
• Missing or damaged fan shroud or shields on radia- • Broken pump impeller.
tor. Replace the seals and gaskets or replace the pump.
• Radiator fins plugged; blow debris from radiator.
• Radiator clogged; drain and flush radiator. Water pump making noise
• Scale or deposits in cooling system; drain and flush • Worn pump shaft or bearings loose or worn.
entire cooling system. • Pump impeller broken.
• Radiator defective; repair or replace the radiator. • Loose fan belt.
• Thermostat incorrect or defective. • Bent or broken fan blade.
• Collapsed radiator hose(s) on suction side of cool- • Fan hitting engine or shroud.
ing system.
• Water pump defective.
Engine runs cold, emits excessive blue/white
• Water passages in engine are clogged.
exhaust smoke or idles roughly
• Air in cooling system; drain and flush.
• Contaminated fuel.
• LP gas leak into cooling system.
• Autochoke malfunctioning - gas model only.
• Ignition timing misadjusted.
• Fouled spark plugs.
• Excessive exhaust system back pressure.
• Coolant temperature below normal due to incorrect
• Engine oil level is low or needs changing.
or defective thermostat; replace the thermostat.
• Engine overloaded.
• Defective temperature sender or indicator light;
• Engine internal parts worn. check and replace if necessary.
• Leaking head gasket.
• Defective temperature gauge. Oil in coolant or coolant in crankcase
• Leaking head gasket.
• Cylinder head bolts not tight.
• Cylinder head cracked.
• Engine cylinder block water jackets cracked.
SM 661, Aug ’01 Engine Cooling System Troubleshooting • 01-2-1

Section 3
Testing and Maintenance
! WARNING
2376150
The engine coolant fan, on all internal combustion engines, can cause
extensive injury and bodily harm. Keep hands, arms and clothing away
from a spinning fan. Also, don’t stand in line with a spinning fan.
SM 661, Aug ’01 Engine Cooling System • 01-3-1

1. Park the truck as described in “Safe Parking.”

! CAUTION
2. Open the engine cover and check the coolant level in
SAFE PARKING. Before working on truck: the reservoir:
• Park truck on a hard, level, and solid sur- • When at operating temperature, the coolant level
face, such as a concrete floor with no gaps must be within the hot range mark.
or breaks. • When cold, the coolant level must be within the
• Put upright in vertical position and fully cold range mark.
• Put all controls in neutral. Turn key switch Hot range mark
OFF and remove key.
• Apply the parking brake and block the Cold range mark
wheels.
Engine Coolant Level Check

! CAUTION
Use extreme care when removing the cap
from the radiator. Never remove the radiator
cap from a hot engine. It is a good safety 3. Remove the radiator cover. See Group 38 for instruc-
practice to use a shop cloth over the cap as tions.
shown if there is any possibility of pressure 4. Use a rag to cover the radiator cap and turn to the
being present. Turn cap to the first stop and first stop to release any steam. Let all pressure and
note if any steam is released. When you are steam run out of the radiator before removing the
sure all pressure has been released, press cap.
down on the cap with the cloth in place, turn
and remove the cap. Stand clear of the radia- 5. Check the coolant level in the radiator; coolant level
tor opening; hot coolant can splash out. should be to the bottom of the filler neck opening.
Steam or hot coolant can cause severe burns. 6. Fill the reservoir and radiator to the correct level of
Failure to follow these instructions could coolant and close tightly.
result in serious personal injury and/or dam-
age to the cooling system or engine. IMPORTANT
Do not overfill the system. If necessary, wait 4
hours or until the engine is completely cool
before adding coolant to the correct levels in
the reservoir and radiator.
The cooling system should be filled at all times with a

50% water and 50% ethylene glycol, permanent-type anti-
freeze solution containing rust and corrosion inhibitors.
Plain water may be used in an emergency, but should be
replaced with specified coolant as soon as possible to
avoid damage to the system or engine. When only water is
used in the system, do not let the engine run hot.
NOTE
Heated coolant expands and is driven from the radiator Do not use alcohol or methanol antifreeze.
into the reservoir. The engine must be cooled for at least 4
hours before the coolant will flow back to the radiator. To Add coolant as required. If frequent refilling or as much as
check the coolant levels in the engine: a quart is required at one time, inspect cooling system for
leaks.
01-3-2 • Testing and Maintenance SM 661, Aug ’01

Adding Coolant 4. Check the planned maintenance time interval (oper-

ating hours), or the condition of the coolant to deter-
1. The coolant level should be at the cold mark on the mine if it needs to be changed (drained and replaced).
coolant reservoir when the engine is cold.
5. Inspect the radiator cap. Check condition of the
NOTE upper and lower seals. Check the seal holder and
Fork lift truck applications require also spring for correct movement and operation. The rub-
checking the coolant level directly in the radi- ber seal face should be clean and undamaged. Look
ator. Lift truck radiators will plug up and for nicks or cracks in the seals. Replace the cap if the
overheat which forces coolant into the over- seal is defective. Cap should have a pressure rating of
flow bottle and on out at the vent. This results 90 kPa (13 psi) nominal and 83-109 kPa (12-16 psi)
in a low coolant level which may cause over- limits. See “Cooling System Tests” in this Section for
heating. procedures to test the radiator cap.
6. Inspect the radiator cap sealing surfaces located in
2. Coolant level in the radiator should be checked daily
the radiator filler neck. Look for nicks, deep
(or before each shift of operation) to make sure the
scratches, or damage which may cause radiator cap
radiator is full at all times. Radiator is full when
leakage.
coolant level is at the bottom edge of the filler neck
opening. 7. Inspect the overflow pipe and tubing for clogging,
damage, or wear. Clean the overflow pipe. Remove
! CAUTION any contaminants that can cause restriction. Replace
the tubing if it is faulty.
from the radiator. When checking coolant 8. Inspect and clean the overflow bottle (reservoir) as
level in the radiator, use a rag over the cap. needed.
Turn cap to the first stop and allow all pres- 9. Inspect the inlet and outlet hoses for damage, cracks,
sure and steam to be released. wear, or evidence of collapsing. Inspect hose clamps
to determine if they need to be replaced.
3. If the cooling system requires the addition of a large
quantity of coolant and the engine has been overheat- 10. Use a coolant tester to test the low temperature pro-
ing, perform the following cooling system inspec- tection level (the proportion of ethylene glycol to
tion. water) of the coolant solution. Add coolant solution
(antifreeze or water) to provide maximum protection
(50/50 mixture).
Cooling System Inspection

1. Check water pump, thermostat, radiator, and all
plumbing for leaks.
! CAUTION
from the radiator. When checking coolant
level in the radiator, use a rag over the cap.
Turn cap to the first stop and allow all pres-
sure and steam to be released before remov-
ing cap.
NOTE
2. Remove the radiator cap. See CAUTION above. A coolant solution containing 50% ethylene
3. Inspect the condition of the coolant. Look for exces- glycol provides freezing protection to -37° C
sive contamination, rust, oiliness, or gummy deposits (-34° F). Refer to Service Information Bulle-
in the coolant solution. The coolant should have a tin, SI-01-207-78 for more information on the
clean appearance. use of antifreeze.
SM 661, Aug ’01 Testing and Maintenance • 01-3-3

11. If the engine has been requiring the addition of large 2. The gauge pressure reading should hold within the
amounts of coolant: specified limits of the cap relief pressure. Cap should
• Inspect the radiator for blockage of air flow have a pressure rating of 96 kPa (14 psi) nominal and
through the fins. Air clean the radiator. 83-109 kPa (12-16 psi) limits. If the test relief pres-
• Check the tailpipe. Be sure exhaust flow is not sure either exceeds or is below the specified limits,
blowing into the radiator. Make sure all baffles replace the cap with a new Clark part.
and shrouds are in place.
• Check fan belt and cooling fan.
• Check and make sure the fan is not installed
Testing Radiator and Cooling System
backward. The coined imprinting on the fan
blades should be facing the engine for correct 1. Pressure test the radiator and cooling system to deter-
operation. mine if it will hold the correct pressure without leaks
• Check engine oil to see if it contains coolant. or failure. Wet the rubber sealing surfaces and install
• Check the radiator cap to see that it has the cor- the tester cap tightly on the radiator fill neck. Apply
rect rating. pressure to the cooling system equal to the radiator
• Pressure test the radiator and cooling system. cap specified relief pressure of 90 kPa (13 psi) nomi-
See “Cooling System Tests” in this Section for nal and 83-109 kPa (12-16 psi) limits.
procedures to test the radiator and cooling sys-
tem. Repair any leaks or blockage.
• Test the engine thermostat. See “Cooling System
Tests” in this Section for procedures to test the
thermostat. Replace the thermostat if faulty.
Cooling System Tests

If the need is indicated for further maintenance and testing
of the cooling system, check for both external and internal
leaks in the cooling system with an accurate pressure
pump and gauge tester. 2. Observe the gauge reading for approximately two
minutes. The pressure should not drop during this
Testing the Radiator Cap time. If pressure drops, check for leaks in the radia-
tor, hoses, connections, and the engine components.
1. Pressure test the radiator cap to determine if it is
holding the correct pressure. Wash the cap in clean
water to remove any dirt or scale from the valve seal-
ing surfaces. Wet the rubber sealing surface and Testing the Thermostat
install the cap tightly on the tester. Pressurize the 1. Remove and test the engine thermostat to determine
tester and radiator cap. if it closes correctly and opens at the correct tempera-
ture:
Gas/LPG8Diesel
• Open (cracking) at 82°C ± 1.5° (180°F ± 2.7°)
• Fully open at 95°C (203°F).

2. Fully immerse the thermostat in a pan of water. Heat 3. Place a hose on the drain valve nipple and run to the
the pan slowly while stirring the water to produce an drain pan. Open the coolant drain valve on the engine
even temperature. Use a thermometer to measure the block.
temperature at which the thermostat valve cracks
(starts to open) and when it is fully open. If the test
results are not to specification, replace the thermo-
stat.
Gas/LPG Engine Coolant Drain Valve
Drain
3. Replace the thermostat even if a slight opening of the valve
valve at normal temperature is found or if its appear-
ance shows any breakage. If the sensing part is dam-
aged, the thermostat valve will remain closed.
Hose
Engine Coolant Change

NOTE
Diesel Engine Coolant Drain Valve
Drain and replace the engine coolant after
2000 hours of operation or once a year. Sys- IMPORTANT
tem coolant capacities are listed in Section 1.
Dispose of the fluid in accordance with the
manufacturer’s and state and local regula-
Draining Radiator and Cooling System tions.
To drain the radiator and cooling system: 4. Inspect coolant hoses and clamps to determine if they
1. Remove the radiator cap. need to be replaced.
! CAUTION
Allow engine to cool first, then use extreme
care when removing the cap from the radia-
tor. Use a rag over the cap, turn cap to the
first stop, and allow all pressure and steam to
be released.
2. Place a large, 20-liter (5-gallon) drain pan under the

engine.
SM 661, Aug ’01 Testing and Maintenance • 01-3-5

Cleaning and Flushing Cooling System 4. Fill the coolant recovery bottle (overflow reservoir)
to the cold range mark line with new coolant.
NOTE
If the condition of the used coolant indicates
severe contamination, rust deposits, scale, or Hot range mark
oil in the system, determine the cause of the
contamination and make sure to clean and
flush the cooling system with a commercial Cold range mark
cleaner. Choose a product from a reliable
manufacturer and follow all instructions for
its use.
1. Close coolant drain valve in the engine block.

2. Fill cooling system and perform the cleaning and
flushing operation according to the manufacturer’s
instructions.
3. Drain the system completely again using the steps
from “Draining Radiator and Cooling System.”
5. Start and run the engine until the radiator upper hose
4. Remove the drain pan. is warm, indicating the thermostat is open and cool-
ant is circulating through the system. Check for leaks
IMPORTANT at hose connections and engine drain valve.
Dispose of the fluid in accordance with the
6. Turn engine off and check coolant level in radiator
manufacturer’s and state and local regula-
again. Add coolant as required to fill to bottom of
tions.
filler neck.
Filling Cooling System ! CAUTION

With the cooling system drained, the following procedure Use extreme care when removing the cap
should be used to insure complete fill: from the radiator. When checking coolant
level in the radiator, use a rag over the cap.
1. Close coolant drain valve in engine block.
Turn cap to the first stop and allow all pres-
2. Fill the radiator to the bottom of the filler neck with sure and steam to be released.
new coolant (50% water and 50% ethylene glycol,
permanent-type antifreeze solution containing rust 7. Check coolant level in reservoir again. Add coolant
and corrosion inhibitors). as required to fill to the Cold Mark on the bottle.
3. Install radiator cap securely.
NOTE
To cycle coolant from the recovery bottle into
the radiator, run the engine until it reaches
operating temperature, then stop the engine.
Check coolant level in the coolant recovery
bottle once the engine is again cold.
Again inspect cooling system hoses, connections and

components for any leaks that may have developed when
system was fully pressurized.

Section 4
Engine Cooling System and
Alternator Belt Service
Fan ring
Venturi
Fan bearing
support
assembly
Fan belt
Alternator/
water pump belt
Gas/LPG Engine Cooling System Belts
SM 661, Aug ’01 Engine Cooling System and Alternator Belt Service • 01-4-1
3. When you create enough slack in the fan bearing

! CAUTION support, slip the belt off the fan and engine pulleys.
SAFE PARKING. Before working on truck: 4. Move a blade of the fan into place below the indenta-
• Park truck on a hard, level, and solid sur- tion molded in the fan ring. Slip the belt over the fan
face, such as a concrete floor with no gaps blade.
or breaks.
• Put upright in vertical position and fully Slip belt over fan blade
at indentation in ring
OFF and remove key.
wheels.
Belt Checks 5. Rotate the fan so the next blade is under the indenta-
tion and slip the fan over the blade. Continue around
To check the belts:
all the fan blades. Pull belt out of venturi.
• Check belt tension by pushing and pulling on the
span; belt should move only about 4 mm (0.16 in). IMPORTANT
• Inspect belt and pulleys for damage. Use the fan pulley to turn the blades into
• Belt must not have any cracks or ride in the bottom position. Too much force can bend or break
of the pulley grooves. the fan blades.
• Be sure there is no oil on the belt.
• A belt which has been slipping will be glazed and Alternator/Water Pump Belt Removal
cracked, and should be replaced. 1. Remove fan drive belt.
Belt tensioning procedures follow belt removal and
replacement steps. 2. Loosen the lock nut and back off the adjustment bolt
on the alternator mounting bracket to create slack in
the belt.
Gas/LPG Truck Belt Removal
Lock Nut
Fan Drive Belt Removal
1. Tilt steer column forward, open the operator’s seat
deck, and remove the battery cables. Adjustment Bolt
2. Back off the jam nut and the set screw from the top of
the fan bearing support. Loosen the mounting bolts
holding the fan bearing support and bracket in posi-
tion on the engine-mounted brackets.
Set Screw
Support Bracket
Jam Nut
3. Slip the belt off the alternator and engine pulleys.

4. Remove the belt over the fan as described above and
Fan Bearing
Support remove from venturi.
01-4-2 • Engine Cooling System and Alternator Belt Service SM 661, Aug ’01
Gas/LPG Truck Belt Replacement Fan Drive Belt Replacement

To replace the fan drive belt, the alternator/water pump
Alternator/Water Pump Belt Replacement belt must be installed first as shown above. Then:
1. Slip the belt into the venturi. 1. Slip the fan drive belt into the venturi.
2. With a fan blade positioned at the fan ring indenta- 2. With a fan blade positioned at the fan ring indenta-
tion, slip the belt over the blade. tion, slip the belt over the blade.
3. Continue to position the fan blades at the indentation
Use fan ring indentation to and work the belt over blades one at a time.
slip belt over fan blades.
4. Seat the belt onto the fan and engine pulley and
tighten the fan bearing support mounting bolts to
hold the belt and bearing support in position.
Set Screw
Support Bracket
3. Continue to position the fan blades at the indentation

Jam Nut
and work the belt over blades one at a time.
IMPORTANT
Use the fan pulley to turn the blades into Fan Bearing
position. Too much force can bend or break Support
the fan blades.
4. Remount the belt over engine and alternator/water

pump pulleys. 5. Use the set screw to adjust the tension on the fan belt
and tighten the jam nut. Belt should deflect 4 mm
5. Tighten belt using adjustment bolt. Belt should
(0.16 in) when adjusted correctly.
deflect only 4 mm (0.16 in) when resetting with the
adjustment bolt. Tighten lock nut when correct belt 6. Torque the fan bearing support mounting bolts to 40-
deflection is measured. 45 N•m (29.5-33.3 ft-lb).
Jam Nut
Adjustment Bolt
SM 661, Aug ’01 Engine Cooling System and Alternator Belt Service • 01-4-3
Alternator/Water Pump Belt Tension Fan Drive Belt Tension

(Gas/LPG Engines) (Gas/LPG Engines)
With the engine off: With the engine off:
1. Adjust the belt deflection to 4 mm (0.16 in). Turn the 1. Loosen set screw and jam nut on fan bearing support.
adjusting bolt clockwise the increase the belt tension
2. Loosen fan bearing support mounting bolts. Leave
and the adjusting bolt counterclockwise to decrease
enough torque on the bolts to hold the bearing sup-
the belt tension.
port in position.
Water Pump 3. Use the set screw to set the static belt tension by
Ruler Pully deflecting span 4 mm (0.16 in).
4. Tighten the bearing support mounting bolts to 40-45
N•m (29.5-33.3 ft-lb).
5. Set the jam nut on the set screw to prevent the screw
from moving.
Alternator
Pulley Crankshaft
Pulley
Measuring belt deflection with a ruler.
Water Pump
Pulley
Alternator
Pulley
Measuring belt deflection with a gage.

2. Tighten the lock nut.
3. Tighten the pivot bolt at the base of the alternator.
01-4-4 • Engine Cooling System and Alternator Belt Service SM 661, Aug ’01
Section 5
Radiator Removal and Replacemant
Cooling system brace

Oil cooler
Radiator
To thermostat
Venturi
Fan seal
Upper fan
shroud To water pump
Fan ring
SM 661, Aug ’01 Radiator Removal and Replacemant • 01-5-1

5. Disconnect the overflow bottle hose from the filler

! CAUTION neck of the radiator. Remove the lock nuts holding
SAFE PARKING. Before working on truck: the clamps and hose to the cooling system brace.
• Park truck on a hard, level, and solid sur- Secure overflow hose out of the way.
face, such as a concrete floor with no gaps Brace
or breaks.
• Put upright in vertical position and fully Lock nuts Remove Here.
OFF and remove key.
wheels.
Radiator Removal
The radiators on the cushion, pneumatic, diesel, and gas/ 6. Remove the two flange capscrews and washers secur-
LPG trucks are different from each other. However, proce- ing the upper fan shroud to the radiator.
dures for removing the radiator for service are basically
the same. Any differences in the service procedures will Upper Fan
be noted in the instructions. The radiator and oil cooler are Shroud
separate. See Group 6 for transaxle oil-cooler removal.
Flange
NOTE Capscrews
Servicing radiators is not covered in this
manual and radiator repair shops should be
consulted for service and repair of defective
radiators.
1. Do not attempt to remove the radiator when the

engine is hot. Wait until the system has entirely Flange
cooled down. Capscrews
! CAUTION
from the radiator. When removing the radia-
tor cap, use a rag over the cap. Turn cap to
7. Remove the two flange capscrews at the base of the
the first stop and allow all pressure and
upper fan shroud securing it to the lower fan shroud.
steam to be released.
Lift out the upper shroud and attached fan seal.
2. Park the truck and block the wheels. Tilt the steering
column forward and raise the operator’s seat deck.
3. Remove the radiator cover and operator’s seat deck.
See Group 38 for procedures.
4. Drain the radiator/engine coolant as described in
Section 3.
01-5-2 • Radiator Removal and Replacemant SM 661, Aug ’01

8. Remove the fan ring and venturi. 10. Remove the two carriage bolts and nuts securing the
• For Gas/LPG engines, remove the fan bearing sup- cooling system brace to the frame-mounted pylons.
port assembly and lift out entire assembly. Retain the rubber grommet used between the brace
and the radiator.
Carrige
Bolt and Nut
Cooling System Brace
Pylon
Pylon
Grommet
Fan Bearing
Support
Assembly
11. Lift the radiator and radiator cushion brackets out

Gas/LPG engine fan, venturi, and fan ring
from the pylons.
assembly.
• For diesel engines, unbolt the venturi from its
mounts and lift out venturi and attached fan ring.
Venturi
Fan Ring
Diesel engine venturi and fan ring assembly.
9. Loosen and remove water pump and thermostat
clamps and hoses from the ports of the radiator. Hose
connection locations differ in cushion and pneu-
matic, gas and diesel trucks.

Radiator Replacement 4. Reposition the upper radiator shroud and fan seal.
Make sure the fan seal is clipped securely to the fan
The radiators for the various truck models have their hose shroud and does not interfere with the shroud, fan, or
ports located at different positions. However, replacement fan ring.
procedures are the same for each of the radiators.
Shroud
1. Fit the radiator cushion brackets onto the lower cor-
ners of the radiator.
2. Slip the radiator between the mounting pylons. Make Fan Seal
sure the radiator is completely seated.
Seat radiator
between pylons.
5. Replace the fan ring and venturi:

• For gas/LPG engines, set the assembly into place
and tighten the fan bearing support bracket bolts to
40-45 N⋅m (29.5-33.3 ft-lb). See Section 4 to set
tension on belt.
3. Set the cooling system brace into place with the rub- Fan Ring
ber grommet positioned between the post of the radi-
ator and the hole in the brace. Insert carriage bolts
between braces and pylons. Tighten the two carriage
bolt nuts to 20-25 N⋅m (14.8-18.5 ft-lb).
Venturi
Fan Bearing
Support
Assembly
Place grommet between brace
and top of radiator. Gas/LPG Fan, Venturi, and Fan Ring Assembly
01-5-4 • Radiator Removal and Replacemant SM 661, Aug ’01

• For diesel engines, set the venturi and attached fan 8. Reset the hose from the overflow bottle across the
ring into place on the engine and tighten the bolts cooling system brace. Refit the hose to the overflow
to 15-20 N⋅m (11.1-14.8 ft-lb). outlet on the radiator. Tighten the lock nuts for the
clamps to 8-10 N⋅m (6-7.5 ft-lb).
Venturi
Overflow
Hose
Coolant
Reservoir
Fan Ring
Diesel Venturi and Fan Ring Assembly.

6. Replace the flange capscrews mounting the shroud to 9. Close engine drain cock and refill the radiator with a
the radiator. Tighten the capscrews to 5-6 N⋅m (3.7- mixture of 50% ethylene glycol (antifreeze) and 50%
4.4 ft-lb). water as described in Section 3.
IMPORTANT 10. Remount the radiator cover and operator’s seat deck.
Fan ring-to-shroud clearance should be 14 See Group 38 for instructions.
mm (0.56 in). If belt is wrong size, clearance 11. Check the operator’s seat deck for correct operation
will not be correct because fan drive assem- once you have completed reassembly. Make sure the
bly will be too high or low when belt is engine cover latch works correctly and securely.
adjusted tight.
12. Once you have completed all the tests recommended
7. Remount the water pump and thermostat hoses for radiator refill (see Section 3), check to make sure
between the engine and radiator. Tighten the hose no leaks are evident in the radiator hoses before
clamps sufficiently to prevent leaks. returning the truck to service.
IMPORTANT
Use new hoses if cracking or drying is evident
around the positions of the clamps or if the
hoses are deteriorated in any way.

GROUP 02(LP)
GROUP 02(LP)
LPG FUEL SYSTEM
(CARBURETED)
LPG Fuel System Specifications

and Description ........................................................... Section 1
LPG Fuel System Troubleshooting ............................ Section 2
LPG Fuel System Adjustments and Maintenance .... Section 3
LPG Carburetor and Throttle Body Romoval

and Overhaul ............................................................... Section 4
LPG Vaporizer Removal and Overhaul ................... Section 5
LPG Fuel Lock Removal and Overhaul ................... Section 6
SM 661, Aug ’01 Group 02(LP), LPG Fuel System

Group 02(LP), LPG Fuel System
Section 1
Fuel System Specifications and Description
(Carbureted LPG Fuel System)
Specifications
LPG Tank Idle Speed: 650-700 rpm.
Capacity: 9.1, 15.2, 19.7 kg (20, 33.5, or 43.5 lb). Maximum No-Load Governed Speed: 2600-2700rpm
Working Pressure: 138-1654 kPa (20-240 psi).

Vaporizer-Regulator
Safety Relief Valve: Opens when pressure exceeds 2756
kPa (400 psi). Primary Chamber Pressure: tank pressure to 10.3 kPa (1.5
psi).
Shut-off Valve: Manual with maximum withdrawal valve.
Secondary Chamber Pressure: 10.3 kPa (1.5 psi) to a neg-
Maximum Withdrawal Valve: Closes when flow rate ative pressure to vapor outlet pressure.
exceeds 5.7 Lpm (1.5 gpm).
Vapor Outlet Pressure: -38.1 mm (-1.5 in) water column.
Fuel Gauge: Float level type.
Low Fuel Light: Instrument pod light comes on at 275 kPa Lock-Off Valve
(40 psi).
Filter element: Replace every 2000 hours.
Carburetor
Fuel
Type: Diaphragm-operated air-gas valve design with self-
contained air-fuel metering device HD-5 Propane
Idle air-fuel mixture: 0.30-0.70% CO (carbon monoxide)
@ 680 rpm.
Power Mixture: 0.6 to 1.5 % CO at converter stall.
SM 661, Aug ’01 Fuel System Specifications and Description • 02(LP)-1-1

Description LPG Tank

The complete LPG (liquefied petroleum gas) system is One end of the LPG fuel tank is equipped with a shut-off
illustrated on the next page. valve, fuel gauge, safety relief valve, and vent valve.
The LPG systems consist of a tank to hold the fuel under
pressure in a liquefied form, a lock-off valve to block flow
of fuel from the tank when the engine is not running, a
vacuum switch to operate the lock-off valve, a vapor-
izer-regulator to lower the fuel pressure and allow the
fuel to become vapor, and a carburetor to mix the vapor
with air and feed the mixture to the engine.
The flow of air through the carburetor is controlled byþthe
throttle body, which is located between the carburetor
and the governor. The governor limits maximum engine
rpm.
A water line from the engine cooling system circulates The vent valve should be opened manually only when fill-
warm engine coolant through the vaporizer-regulator to ing or cleaning the inside of the tank.
counteract the frosting effect of the vaporizing fuel.
The safety relief valve opens automatically when pressure
A hydrostatic relief valve relieves pressure in the fuel in the tank rises above 2756 kPa (400 psi). It closes when
lines should it build to a dangerous level. Another safety the excess pressure is reduced.
valve on the tank relieves excessive tank pressure.
The tank should always be mounted or stored so that the
A balance line communicates pressure from the carbure- relief valve is up or at top. The LPG tank mounting
tor air inlet to the vent port on the vaporizer-regulator. bracket has a positioning pin that engages a mating hole in
A pressure switch on the fuel lock off valve sends a fuel- the tank flange at the 6-o’clock position to ensure that the
low signal to the LPG level light on the instrument pod tank is held in the proper position with relief valve up.
when the tank pressure falls below 138 kPa (20 psi). The fuel gauge is a float level type that indicates percent-
Further details about the major fuel system components age of fuel remaining in the tank.
are given on the following pages of this Section. The shut-off valve is operated manually to control the
flow of fuel from the tank. The valve opens counterclock-
wise and closes clockwise. Threaded into its base is a
maximum withdrawal valve that closes automatically
when a large surge of fuel occurs, such as caused by a
hose bursting. At the end of each day’s operation, close
the shut-off valve no tighter than hand snug to avoid
crushing the valve seat.
A screw-type coupling is attached to the shut-off valve. It
requires no tools to operate. When disconnected, it auto-
matically seals off any flow through the valve and the
hose. For maximum safety, however, always close the
shut-off valve, run the engine until it stops, and turn off
the ignition switch before disconnecting the coupling.
Maximum
Wotjdrawal valve
Shut-Off Valve
02(LP)-1-2 • Fuel System Specifications and Description SM 661, Aug ’01

Shut-off valve
Tank
Hydrostatic relief Carburetor

valve
Vapor line
Balance line
Vaporizer regulator
Lock-0ff valve
Fuel line
LPG Fuel System

Carburetor and Throttle Body gas metering valve and leaning the idle air-fuel
mixture.
The LPG carburetor mounts on the throttle body, which • Power Mixture Adjustment. Full-power mixtures
mounts on the velocity governor, which mounts on the are controlled by this adjustment. This adjustment
intake manifold. The carburetor requires no linkage or idle must be made with the engine under full or work-
vacuum line to the intake manifold. ing load.
Vacuum supplied from the throttle body operates the dis-
tributor timing advance and a vacuum switch that controls
the lock-off valve.
The proportions of air and gas allowed into the carburetor
are controlled by the air-gas valve that is fastened to the
diaphragm. The up and down positioning of the dia-
phragm opens or closes the air-gas valve to a varying
extent. The positioning of the diaphragm is controlled by
engine vacuum and spring force acting on the top of the
diaphragm and atmospheric pressure acting on the bot-
tom. As engine vacuum increases or decreases in response
to throttle valve position, the air-gas valve changes the
quantity and relative proportions (mixture) of air and gas
entering the mixer. From the mixer, the mixture is drawn
into the engine through the governor and intake manifold.
The air/gas valve assembly consists of an air valve and a
gas metering valve. The air valve meters air into the mixer.
The gas metering valve moves with the air valve to admit
the correct amount of fuel into the mixer. Mixtures
between idle and full-load are controlled by the gas meter-
ing valve shape: lean mixtures at light loads and increas-
ingly rich mixtures at heavier loads and higher speeds.
Speed and load can increase to a point at which the gas
metering valve fully withdraws from the jet. Then, the
major restriction to gas flow becomes the power mixture
adjustment, which is most effective at full load and
decreasingly effective down to approximately one-half
load where it no longer has much effect.
When the engine is initially cranked, a pressure drop
under the air valve opens it. This vacuum also actuates the
fuel lock-off valve and the vaporizer-regulator to draw out
fuel from the LPG tank. With the engine running, the flow
of air through the carburetor is controlled by the throttle
body, as with any other carburetor. With the engine
stopped, fuel flow is sealed off within the carburetor as Throttle body
well as in the vaporizer-regulator and fuel lock-off valve,
giving a triple seal for safety. Throttle
Vacuum
connections return spring
The carburetor provides two ranges of mixture adjust-
ments:
• Idle Mixture Adjustment. The idle adjustment
bypasses a portion of incoming air around the air
valve opening. As the idle adjustment is opened, LPG Carburetor and Throttle Body
the air valve partially closes, thereby closing the

Vaporizer-Regulator
Balance Line
The vaporizer-regulator is a combined two-stage regulator (Vent) Port Primer Button
and vaporizer. It receives liquid fuel at tank pressure from
the fuel lock-off valve and reduces that pressure to slightly
less than atmospheric in two stages: the first stage is at the
primary regulator and the second is at the secondary regu-
lator. When the engine is cranking or running, a partial
vacuum is created in the fuel line to the carburetor, which
opens the regulator and permits fuel to flow to the carbu- SECONDARY
retor. REGULATOR
Pressure in the primary chamber is from tank pressure to

10.3 kPa (1.5 psi). Secondary chamber pressure is from Valve Seat
10.3 kPa (1.5 psi) to vapor outlet pressure, which is -38.1
mm (-1.5 in) water column. Diaphragm
In the process of reducing the pressure from approxi-

Water Port
mately 150-180 psi in the tank to atmospheric pressure or
slightly below, the liquid propane expands to become a
Fuel Inlet
vapor, causing refrigeration of the fuel. To compensate for Vapor
this and to assist in vaporization, engine coolant circulates Outlet
through a heat exchanger in the vaporizer-regulator body
and raises the temperature of the fuel as it enters the Water
vaporizer. The vaporizer-regulator seals off fuel flow port
when the engine is stopped.
The vaporizer-regulator uses a mechanical primer for cold PRIMARY
REGULATOR
weather starts. The primer mechanically opens the sec-
ondary regulator valve to dispense gas when operated.
The vent port allows an external balancing pressure into
the secondary regulator. Rather than use atmospheric pres-
Valve
sure for the balancing pressure, a balance line communi- Seat
cates pressure from the carburetor air inlet to the vent port.
This pressure, which varies according to the condition of
the air filter and the routing of the air induction system,
enables the vaporizer-regulator to adjust the fuel supply to Diaphragm
the actual air supply.
NOTE
MODEL K vs MODEL J. Do not use Model J Vaporizer-Regulator
parts in this vaporizer-regulator.

Governor
Throttle Plate Stabilizer Piston
The velocity governor, or “governor,” limits maximum
engine rpm and is located between the carburetor throttle
body and intake manifold. (On hydrostatic transaxle
trucks the governor’s function is normally overridden by
the electronic control system.)
The governor has a throttle plate whose shaft is offset
from the center of the governor bore. The full-open posi-
tion of the throttle plate does not coincide with the true
full-open position, but leans to the closing side. This
arrangement enables the velocity pressure of the flowing
mixture to rotate the throttle plate in the direction of clos-
Adjustment
ing. The resulting torque on the throttle plate stretches the Screw
return spring linked to it until the torque balances the ten- Return Spring Bush Nut
sion of the spring, which maintains the throttle plate at
that opening angle. The spring tension can be adjusted Velocity Governor
with the adjustment screw.
This balance between the air velocity pressure applied to
the throttle plate and the spring tension keeps the throttle
plate at a position between full-open and full-closed to
control the amount of mixture flowing into the engine.
The throttle plate opening angle of this governor is set
under the full-open condition of the carburetor. Therefore,
as the carburetor throttle valve closes, pressure applied to
the governor throttle plate lessens and the governor throt-
tle plate rotates in the direction of opening, which causes
engine speed to increase. To prevent this, the governor has
a stabilizer piston that tends to close the throttle plate
when a large vacuum acts on the upper side of it.
The bush nut is for adjusting the preload on the return
spring in order to obtain the correct idle speed at maxi-
mum no-load governed rpm. The adjustment screw is for
adjusting the number of active return spring coils (which
changes spring rigidity) in order to minimize hunting.
“Hunting” is a momentary surge in engine speed that
occurs when engine speed is increased from idle by
quickly depressing the accelerator pedal.
A small amount of hunting is a normal condition and does
not require governor adjustment. If the surge is prolonged,
however, it may be necessary to adjust the governor.

Section 2
Fuel System Troubleshooting
(Carnureted LPG Fuel System)
! LPG System Check

WARNING
BEFORE WORKING ON TRUCK : If the engine does not start:
• Park truck in well-ventilated area. Park well 1. Check that LPG tank gauge and instrument panel
away from or eliminate all open flames, light indicate tank has sufficient fuel in it. Open shut-
sparks, or other sources of ignition. Position off valve on LPG tank.
truck so LPG tank is out of path of forced
air heaters and direct heat radiation. Do not 2. Turn ignition switch to On.
smoke. 3. Remove vacuum line at throttle body and apply suc-
• Have a MULTI-PURPOSE ABC type fire tion on the vacuum hose to actuate lock off filter,
extinguisher (preferably dry powder) avail- which should operate the vacuum.
able and in good working condition.
• Use gloves on high-pressure frosted lines or
components.
Carburetor
Preliminary Checks
Since the carburetor has the least complicated function to
perform and has the fewest moving parts, examine every
other possibility of mechanical or electrical failure before
removing the carburetor or tampering with carburetor
adjustments.
A large percentage of all engine problems will be found in Vapor line
the ignition system, air cleaner system, or the cooling sys-
tem. If you are servicing a hydrostatic transmission truck,
the problem may be with the electronic control system.To
eliminate these possibilities, check the following:
1. Battery voltage (starter requires 9.6 volts, leaving not Balance line
enough for ignition system). Lock-0ff valve
2. Ignition coil, plugs, wires, ignition timing. Vaporizer regulator
3. Radiator coolant level, hoses, and thermostat.
4. Indicator lights on instrument panel.
5. Governed rpm.
6. Throttle travel. On standard transaxle trucks, there
must be a 1.1 mm (0.031 in) clearance between throt-
tle stop pin and stop screw.
7. Hoses. All LPG system hoses must be free of kinks
and breaks, and fittings are not leaking.
SM 661, Aug ’01 Fuel System Troubleshooting • 02(LP)-2-1

In following steps, keep the ignition switch on and apply • Lock-off valve filter plugged.
suction to the vacuum switch: • Low vacuum in system.
4. Push primer button. Listen for a hiss: gas should flow • Carburetor mounting loose on manifold.
into the vapor line. • Improper power jet adjustment.
5. If gas does not flow into the vapor line, loosen fitting • Maximum withdrawal valve closed due to sudden
between lock-off & valve filter and vaporizer-regula- filling of fuel line after tank change. Close and
tor. If gas leaks from fitting , the vaporizer-regulator reopen tank shut-off valve.
valve is defective (not allowing gas to flow through).
See overhaul procedure.
Engine “Hunts” at Governed RPM
6. If gas does not leak from loosened fitting, loosen fuel
fitting at fuel line supplying fuel to lock-off valve & • Secondary diaphragm in vaporizer-regulator stiff
filter. If gas leaks from fitting, the lock-off valve & or leaking.
filter is defective (not allowing gas to flow through). • Secondary valve in vaporizer-regulator dirty and
See overhaul procedure. sticking.
7. If gas does not leak from fitting the tank is empty or • Governor surge adjustment. (See governor adjust-
shut-off. ment in fuel system adjustments Section).
Symptoms and Causes Frost, Ice or Moisture on Lock-Off Valve

• Lock-off valve filter plugged.
Engine Won’t Start • Maximum withdrawal valve closed.
• Tank shut-off valve closed.

Frost, Ice or Moisture on Vaporizer-Regulator
• Low or no fuel in tank.
• Tank not positioned properly with pin at 6-o’clock. • Vaporizer coolant hoses improperly connected, bad
• Low battery voltage. hoses or air lock.
• Quick-disconnect fitting failure at tank, plunger • Primary valve seat in vaporizer-regulator not seat-
missing, double gasket, or coupling missing. ing.
• Vacuum line loose, pinched or plugged. • Engine coolant level low.
• Withdrawal valve closed.
NOTE
Hard Starting Recommended LPG fuel is HD-5 Propane.
• Loss of vacuum in system.

• Secondary valve in vaporizer sticking.
Erratic Idle
• Loss of vacuum in system.
• Primary valve in vaporizer-regulator defective.
• Air-gas valve diaphragm in carburetor stiff (inflex-
ible).
Lack of Power
• Tank shut-off valve not fully open.
• Tank low on fuel—pulling vapor only.
02(LP)-2-2 • Fuel System Troubleshooting SM 661, Aug ’01

Section 3
Fuel System Adjustments and Maintenance
SM 661, Aug ’01 Fuel System Adjustments and Maintenance • 02(LP)-3-1

General LPG Maintenance 4. Disconnect the outlet (withdrawal) hose coupling.

Pull down on each of the two latches to release the
tank from guard
LPG Tank Maintenance
5. To install, place tank in mounting bracket and
guard. Make sure hole in tank valve guard flange
! WARNING lines up with and engages positioning pin on tank
LPG TANK STORAGE, REFILL, AND mounting bracket.
REPAIR. Do not store LPG fuel tanks near To get maximum usage of fuel in tank, mounting
heat or open flame. Do not store LPG tanks hole must be down at 6-o’clock position. Tank
upside down, whether full or empty. Relief bracket should be repaired to replace pin, if pin is
valve should be up (at top). missing.
Fuel tanks should be filled only by qualified 6. Install and tighten withdrawal hose coupling by
personnel in accordance with local ordi- hand. Do not overtighten. Keep shut-off valve closed
nances. until coupling is tight.
LPG tanks are explosive even when empty.
Federal and State regulations prohibit weld- 7. Before tightening the clamps holding the tank in
ing or soldering to repair a damaged LPG place, check the fuel gauge by moving the tank
tank. Replace it instead. Do not remove any slightly and observe the gauge. The gauge pointer
components from tank. should oscillate with the movement of fuel in the
tank. A defective gauge can be suspected if the
Clean outside surface of tank with a clean cloth and kero- pointer fails to move.
sene or equivalent petroleum solvent. Carefully check for 8. Close and latch the clamps holding tank in bracket
frosted areas and gas odor that would indicate leakage.
Open shut-off valve and again check for leakage at shut- 9. Carefully check for system leaks when the tank
off and quick-disconnect valves. shut-off valve is first opened. A leak-detecting
solution may be applied to the connections to
locate a leak. (See next page.)
Changing Tanks
! WARNING
LPG FUEL IS HIGHLY FLAMMABLE
Park truck in a well-ventilated area. Never
change tanks when the engine is running.
Never smoke when changing tanks. Do not
smoke or perform maintenance near open
flame or other sources of ignition. Do not dis-
connect any lines when exhaust manifold is
excessively hot. LP gas is highly flammable.
1. Park truck safely.

2. Close shut-off valve on LPG tank, snug tight.
3. Run engine until it stops. Turn ignition switch OFF.
NOTE
Running engine until it stops after closing the
shut-off valve burns the fuel from lines, pre-
venting fuel bleed-off to air.
02(LP)-3-2 • Fuel System Adjustments and Maintenance SM 661, Aug ’01

LPG Fuel Lines When necessary to remove and replace fittings and hoses,
or to reseal connections:
Only UL-approved high-pressure type LPG hose is used
between the tank and the vaporizer-regulator. The hose is 1. Close shut-off valve on LPG tank, snug tight.
pressure and temperature stabilized, and specially formu- 2. Run engine until it stops and turn ignition switch
lated to carry liquid petroleum gas. All other hoses in the OFF. Then open connection. This burns the fuel
system are to Clark specification for vacuum or coolant from lines, preventing bleed-off to air.
usage.
Apply a UL-approved thread sealant to all fittings with
pipe threads (male threads only).
! WARNING
Use UL-approved hoses only. Never use a IMPORTANT
substitute for UL approved LPG hose. It is recommended to use only a pipe com-
pound in stick form (solid). Do not use a liq-
All lines in the LP Gas system should be inspected period- uid or plastic thread sealer; it may enter the
ically, generally every 30 days or every PM. LPG lines during assembly.
! WARNING Standard torque specifications do not apply to pipe

LPG FUEL IS HIGHLY FLAMMABLE threads. When installing fittings:
Park truck in a well-ventilated area. Do not 1. Hand tighten first.
smoke or perform this maintenance near
open flame or other sources of ignition. Do 2. Then tighten with a wrench 1-1/2 turns to a maxi-
not disconnect any lines when exhaust mani- mum of 3 turns.
fold is excessively hot. 3. Pressurize the complete system and recheck for
leaks.
NOTE
An odorant is added to LP gas to help detect Fuel Line Support
leaking. If at any time this odor is detected,
shut the engine OFF and have the leak fixed. Fuel lines must be supported by clamps, straps, or tape to
minimize chafing or wear.
Wipe hoses and fittings with a clean cloth moistened with
kerosene or equivalent petroleum solvent.
Coolant Lines
Use soap and water or leak detector solution and check
hoses, connections, and assemblies with tank at least half Coolant hoses between engine and vaporizer-regulator
full. When hose assemblies with reusable fittings are used, may be either clamp type or push-on type with reusable
also test between the fitting ferrule and the hose. fittings. Cut off bad portions of hose and strip from fit-
tings (or replace hoses). Push hoses firmly back into posi-
tion.
Vacuum Connections
The proper operation of the LPG system is based on vac-
uum originating at the carburetor. To assure full availabil-
ity of vacuum at all components, at scheduled PM
intervals:
1. Check vacuum hoses. Tighten clamps, clip off bad
ends, or replace hoses as required.
2. Tighten carburetor mounting flange bolts.
3. Tighten throttle body and cover screws to the carbu-
retor housing.
4. Check for loose intake manifold or leaking gasket.

Carburetor Adjustment 2. Set the idle air-fuel adjustment at 0.30 to 0.70 per
cent CO (carbon monoxide) @ 680 rpm with warm
Before you make any carburetor or fuel adjustments: engine and HD-5 propane fuel.
• A clean air cleaner element and end cap should be Alternate Method: With warm engine running @
installed. 680 rpm, turn idle air-fuel mixture screw OUT until
engine runs rough, then turn the idle air-fuel mixture
• Ignition timing must be checked and set per speci- screw IN approximately 1/4 to 1/2 turn. Continue
fication for LPG fuel operation. turning until engine begins to run smooth.
• Governor and idle speed must be set to specified
rpm.
Power Mixture Adjustment
• Engine and transmission should be at operating
temperatures. Full-power mixtures are controlled by the mixture adjust-
• The tank should contain HD-5 propane. ment at the fuel inlet of the carburetor (mixer). The fuel
mixer casting is marked with an “R&L” indicating the full
! rich and lean positions of the valve. This adjustment con-
WARNING
trols air-fuel mixture when gas metering valve during
LPG FUEL IS HIGHLY FLAMMABLE operation is fully withdrawn from its jet. It is effective
Park truck in a well-ventilated area. Do not only when the engine approaches full-load condition and
smoke or perform maintenance near open can be set only with the engine loaded and at or close to its
flame or other sources of ignition. Do not dis- rated rpm limit—converter stall rpm.
connect any lines when exhaust manifold is
excessively hot.
L Valve position
Idle Speed Adjustment

With engine and tachometer connected, turn idle speed
screw until tachometer reads 680 rpm.
R
Power fuel mixture
Idle Mixture Adjustment adjusting valve
1. Turning the screw IN makes the fuel mixture richer; If adjustment is necessary:
turning it OUT makes it leaner. 1. For standard transaxle trucks, operate engine at full
power stall condition, as described in Group 00.
! CAUTION
This procedure must be performed with the
parking brake off and the truck placed
against a solid barrier (such as a wall) to pre-
vent movement. Be careful that the truck
does not move unexpectedly when operating
the engine and converter at stall.
To avoid excessive heat buildup, do not oper-
IMPORTANT ate engine at stall longer than necessary to
The idle air-fuel ratio screw is sensitive and make carburetor adjustment,.
should be changed (adjusted) only with the
use of a CO (carbon monoxide) exhaust ana-
lyzer.

2. For best performance, adjust power valve to 0.6- Governor Inspection

1.0% CO at converter stall, using a CO analyzer. Less
than 0.6% CO improves emissions but reduces 1. Clean the entire governor before disassembly.
power. (On cushion-tire trucks insert analyzer probe 2. Remove side cover.
in port near the flexible exhaust pipe coupling.)
An alternate method is to back off adjustment to lean 3. Do not use gasoline or similar solvent when cleaning
side of best power at stall until rpm drops about 20- the throttle plate shaft (to prevent deterioration of
25 rpm for low CO. grease enclosed in the needle bearings at the ends of
the shaft).
3. Readjust idle air-fuel mixture after power adjustment
is made. 4. Check carefully for smooth action of the coupling
between the stabilizer rod and throttle plate. If any
stiffness is found, replace the governor assembly.
Governor Inspection and Adjustment
Stabilizer Rod
A velocity (air) governor is used on the truck. The func-
tion of the governor is to limit the maximum speed of the
engine to:
• Protect the main hydraulic pump.
• Limit the maximum travel speed of the truck.
• Prevent runaway or excessive engine rpm.
On hydrostatic transmission trucks, the governor's func- Throttle Plate
tion is normally overridden by the electronic control sys-
tem. 5. Count the active spring coils . The typical number of
IMPORTANT active coils is 14 and should be no less than 11
GOVERNOR ADJUSTMENT AND OVER- 6. Look for broken or misaligned parts and realign the
HAUL RESTRICTIONS. parts or replace the governor if necessary.
Normally, adjustment of the governor is not
7. Reinstall cover with a new gasket.
required. The correct no-load governed speed
setting adjustment is made at the factory and
the governor sealed before shipment. All Governor Adjustment
operators should be instructed not to break
the seal to tamper with the governor. NOTE
If troubleshooting proves the governor to be Governor adjustment should be made with a
defective, replace the governor. Do not warm engine running at normal operating
attempt to overhaul the governor. temperature. Be sure there is no load placed
on the engine (transmission and hydraulic
When engine speed is increased from idling speed by controls in neutral).
pushing on the accelerator pedal quickly, slight variation
(“hunting”) in engine speed may occur.
A small amount of hunting is a normal condition and does
not require governor adjustment. However, if the surge is
prolonged, it may be necessary to adjust the governor.

High-Idle Speed (No-Load Governed Speed) NOTE

Adjustment Turning the adjusting screw clockwise
increases return spring rigidity (number of
1. The governor adjusting screw and bush nut are spring active coils decreases).
enclosed with a rubber protective cover. Loosen the Turning counterclockwise decreases spring
retaining screw and remove the protective cover. rigidity (number of active coils increases).
Although, increasing the spring rigidity
2. With engine running and all hydraulic and direction
reduces hunting, excessive increase of spring
controls in neutral, push accelerator pedal fully down
rigidity changes governor characteristics,
and hold. The carburetor throttle valve must be in the
affecting engine output. Therefore, you
wide-open throttle position.
should limit movement of the adjusting screw
3. Hold the adjusting screw to prevent it from turning. to less than two turns in either direction from
Turn the bush nut to adjust the engine speed to: the standard position.
2650 rpm (range: 2600-2700 rpm). When the adjustment is correct, the number
of active return spring coils typically should
be about 14, and no less than 11. If the hunt-
ing adjustment is not providing the expected
response, inspect the spring as described pre-
Bush Nut viously.
Adjustment
Screw
(Cover Off)
Turn bush nut clockwise to increase speed (spring preload

is increased). Turn bush nut counterclockwise to decrease
speed (spring preload decreased).
Hunting Adjustment
This adjustment should be performed only if indicated by
troubleshooting. Set the high idle speed (see page 5), then:
1. With engine running and all hydraulic and direction
controls in neutral, fully depress the accelerator pedal
and hold. The carburetor throttle valve must be in the
wide-open throttle position.
2. Turn the adjusting screw gradually clockwise until
hunting ceases (engine runs at a steady, constant
speed).
3. As a result of step 2, the engine speed may have
increased to an excessively high level. Check and
adjust high idle speed as explained on page 5.
4. Operate the accelerator to check for hunting.
5. Repeat steps 2 through 4 until hunting and high idle
speed are satisfactory.

Linkage Check 3. Retighten the jam nut.
Refer to illustrations on next page. 4. Perform the check procedure.
1. Turn off the engine and safely park the truck. NOTE
2. Depress the accelerator pedal roller and check for Make sure no hoses or other items bind
free movement of the entire throttle linkage. against the throttle linkage.
Lubricate and repair as needed.
3. Check accelerator pedal travel: Move the accelerator
pedal to the fully-down position. If the pedal stops
before it hits the floorplate, the accelerator cable is
adjusted too short.
4. Check throttle stop gap at carburetor : Hold the pedal
full down and check the gap between the throttle stop
pin and stop screw. If the cable has a spring on the
pedal end, there should be no gap and no deflection
of the spring. If the cable does not have a spring on
the pedal end, gap should be 1.6 mm (1/16 in).
Accelerator Pedal Mounting. No adjustment.
Accelerator Cable Adjustment Accelerator
With the floorboard installed : Cable
1. Loosen the jam nut at the accelerator cable bracket.

Set Nut
Jam Nut
2. Press the accelerator pedal to the floor. Adjust the set
nut to obtain the proper throttle stop gap :
Bracket
• If the cable has a spring on the pedal end, there
should be no gap and no deflection of the spring.
• If the cable does not have a spring on the pedal Throttle Lever
(at carburetor)
end, gap should be 1.6 mm (1/16 in).
Linkage at Carburetor. Adjust with set nut.
Roller
Accelerator cable
Pedal lever
Linkage at Accelerator Pedal. Pedal rests on roller. No adjustment.

Section 4
LPG Carburetor and Throttle
Body Removal and Overhaul
! WARNING
LPG FUEL IS HIGHLY FLAMMABLE.
Park truck in a well-ventilated area. Never change
tanks when the engine is running. Never smoke when
changing tanks. Do not smoke or perform mainte-
nance near open flame or other sources of ignition. Do
not disconnect any lines when exhaust manifold is
excessively hot.
! WARNING
Do not store LPG fuel tanks near heat or open flame.
Fuel tanks should be filled only by qualified personnel
in accordance with local ordinances. Do not remove
any components from tank.
SM 661, Aug ’01 LPG Carburetor and Throttle Body Removal and Overhaul • 02(LP)-4-1
Carburetor and Throttle Body Removal Carburetor and Throttle Body Installation
1. Park truck safely in a well-ventilated area. 1. Mount carburetor to throttle body using a new gasket.
Install mounting washer and nuts and torque to 20-25
N•m (15-18 ft-lb).
2. Mount throttle body to governor using a new gasket.
3. Connect air, balancer, timing advance, and fuel lines
to carburetor and throttle body (observe notice
below.)
IMPORTANT
Overtightening hose fittings may crack the
castings.
3. Start and run engine until it stops. Turn ignition 4. Connect governor and throttle linkage. (Refer to the
switch OFF. This burns the fuel from lines, prevent- adjustments Section of this Group for procedure.)
ing fuel bleed-off to air.
5. Reconnect battery ground cable at engine ground
4. Disconnect battery ground cable from the engine connection.
ground connection to prevent accidental sparking.
6. Open shut-off valve at LPG tank, and start engine.
5. Disconnect accelerator linkage, return springs, etc., Push primer button on vaporizer-regulator if neces-
from carburetor. sary.
6. Disconnect air, balancer, timing advance, and fuel 7. Test all connections for leaks with soap and water, or
lines from carburetor and throttle body. leak detector solution, with the LPG tank at least half
7. Remove carburetor and throttle body from engine full.
mounting. Separate throttle body and carburetor and 8. When engine is at operating temperature, adjust car-
discard gaskets. buretor according to instructions in the adjustments
Section of this Group.
Carburetor NOTE
HOSE CONNECTIONS : At installa-
Throttle body tion, besure to apply UL-approved
thread sealant to all fittings with pipe
threads(male threads only). To avoid
getting sealant in line, do not place seal-
Torque 20~25 N.m ant on final thread of fitting. Lightly
(15~18ft.lb) snug fittings.
02(LP)-4-2 • LPG Carburetor and Throttle Body Removal and Overhaul SM 661, Aug ’01
Carburetor Overhaul Disassembly and Assembly

Remove carburetor parts as follows. Assembly is the
Cover reverse of disassembly. Perform adjustments on next page
after assembly.
1. Cover.
2. Air valve spring.
Air Valve 3. Air valve diaphragm assembly. Diaphragm must be
Spring oriented with position mark pointing toward LPG
inlet.
Diaphragm
Position
Mark
LPG Fuel
Inlet
Air Valve
Diaphragm
Assembly
4. Idle adjustment screw.

5. Idle adjustment screw spring.
Mixer NOTE
Always use a Clark repair kit and new gas-
kets when rebuilding the carburetor. Discard
old parts that will be replaced. Repair kit
includes complete air valve diaphragm
assembly. Use only the parts specified for this
truck model.
Cleaning and Inspection

1. Wash all parts in kerosene or equivalent petroleum
Idle Mixture solvent. Dry with compressed air.
Adjustment Screw
! CAUTION
Do not use carburetor cleaner or lacquer
thinner. These products will continue to
attack special coatings or synthetic rubber
seals after reassembly. Do not soak throttle
body in cleaning solution. The oilite bushings
may be damaged.
2. Inspect all surfaces for cracks, nicks, and burrs.
Check springs for damage.
3. Remove any nicks and burrs from sealing surfaces
with a sharpening stone.
4. Replace damaged parts. However, if threads are dam-
aged, you may retap holes and/or replace screws. Be
sure blind hole threads are clean full depth.
SM 661, Aug ’01 LPG Carburetor and Throttle Body Removal and Overhaul • 02(LP)-4-3
Section 5
Vaporizer-Regulator Removal and Overhaul
(LPG Carbureted Fuel System)
! WARNING
LPG FUEL IS HIGHLY FLAMMABLE. Park truck
in a well-ventilated area. Never change tanks when
the engine is running. Never smoke when changing
tanks. Do not smoke or perform maintenance near
open flame or other sources of ignition. Do not discon-
nect any lines when exhaust manifold is excessively
hot.
! WARNING
LPG STORAGE: Do not store LPG fuel tanks near
heat or open flame. Fuel tanks should be filled only by
qualified personnel in accordance with local ordi-
nances. Do not remove any components from tank.
SM 661, Aug ’01 Vaporizer-Regulator Removal and Overhaul • 02(LP)-5-1

Removing the Vaporizer-Regulator Installing the Vaporizer-Regulator

1. Place the vaporizer-regulator in its mounting posi-
tion. Install and securely tighten mounting bolts.
1. Park truck safely, as noted on page 1.
2. Connect fuel and water lines.
NOTE
3. Start and run engine until it stops. Turn ignition
switch OFF. This burns the fuel from lines, prevent- At installation, be sure to apply UL-approved
ing bleed-off to air. thread sealant to all fittings with pipe threads
(male threads only). Lightly snug fittings/
4. Disconnect battery ground cable from the engine
ground connection to prevent accidental sparking. IMPORTANT
5. Drain the radiator as described in Group 01. Overtightening hose connections may crack
the castings.
6. Disconnect the fuel, water, and balance lines from
the vaporizer-regulator. Put caps on or plugs in the 3. Refill the radiator with specified coolant as described
ends of the lines to prevent entrance of dirt. in Group 01.
7. Remove mounting bolts and vaporizer-regulator from 4. Reconnect battery ground cable at engine ground
truck mounting. connection.
5. Open fuel shut-off valve at LPG tank, and start
engine. Push primer button on vaporizer-regulator if
necessary.
6. Test all connections for leaks with soap suds, or leak
detector solution, with tank at least half full.
Torque 9~11N.m Water port

(7~8in.lb)
Lock-Off valve
Vaporizer-regulator
Torque 9~11N.m
(7~8in.lb)
02(LP)-5-2 • Vaporizer-Regulator Removal and Overhaul SM 661, Aug ’01

Overhauling the Vaporizer-Regulator

Overhaul includes disassembly, cleaning and inspection,
and reassembly using the Clark Repair Kit. Procedures are
given below.
Secondary Fulcrum Pin
NOTE Requlator Cover
Perform all disassembly and assembly work Secondary
Requlator Lever
in a clean area. Be sure the work bench and
the work area are kept clean. Thoroughly
clean the outside of the vaporizer-regulator Valve
Seat
before disassembling. Use kerosene or equiv-
alent petroleum-base solvent, as these will
Secondary
not damage the synthetic rubber seals used in Regulator
these assemblies. Diaphragm Secondary
Requlator
Spring
Remove in order listed; install in reverse order:
1. Secondary cover assembly.
Converter Body
2. Secondary regulator diaphragm: Link on underside
of diaphragm slides over lever. To remove dia-
phragm, slide it toward the LPG inlet port. LPG Inlet
3. Secondary lever assembly: Hold lever down while

removing or replacing screw. Gasket
NOTE
Color of secondary regulator spring deter-
mines vapor outlet pressure and must be Body
replaced with one of same color. Cover Plate
4. Fulcrum pin. Spring
5. Valve seat on secondary regulator lever. Tear out and Primary Regulator
Diaphragm
discard. Push in new one. O-ring
6. Primary regulator cover. Primary Regulator

Cover
7. Primary diaphragm assembly.
Primary
8. Primary valve pin, spring, and O-ring. Replace O- Regulator
Valve Pin
ring with new one.
9. Converter body cover plate.
10. Gasket. Replace with new gasket.
NOTE
Always use a Clark Repair Kit and new gas-
kets when rebuilding the vaporizer-regulator.
Discard old parts that will be replaced.
SM 661, Aug ’01 Vaporizer-Regulator Removal and Overhaul • 02(LP)-5-3

Cleaning and Inspection Tests after Reassembly

1. Wash all parts thoroughly, especially the vaporizing After reassembly is completed, pressure test vaporizer-
chamber and passages, using kerosene or equivalent regulator to detect possible leaks using soap suds or leak
petroleum-base solvent. Dry with compressed air. detector solution.
Do not use carburetor cleaner or lacquer thinner.
1. Temporarily install proper fittings and pressurize the
These products will continue to attack special coat-
“LPG In” port with air. Check for leakage at primary
ings or synthetic rubber seals after reassembly.
diaphragm, body cover plate gasket and in outlet port
2. Inspect primary and secondary valve seats for proper past secondary regulator seat.
sealing surface. If damaged, replace valve body.
2. Plug outlet port. While pressurizing the “LPG In”
3. Be sure gas inlet and the 4 vaporizing ports in heat port with air, push down on hand primer button.
exchange labyrinth are clean and open. Check with Check for leakage at secondary diaphragm.
penlight-size flashlight or small diameter screw-
driver.
4. Check the body for evenness by drawing a straight-
edge across body and cover sealing surfaces. Dress
burrs or nicks with a sharpening stone where
required. Carefully inspect for cracks at body ports
and cover flanges.
5. Check coolant passage to ensure good heat transfer.
If heavily scaled, this indicates need to clean and
flush the engine cooling system.
02(LP)-5-4 • Vaporizer-Regulator Removal and Overhaul SM 661, Aug ’01

Section 6
Fuel Lock-off & Filter Removal and Overhaul
Removal and Installation
Coolant hose
Lock-Off valve Vacuum hose
Vacuum switch
Vaporizer-regulator
Fuel hose
To tank
Coolant hose
SM 661, Aug ’01 Fuel Lock-off & Filter Removal and Overhaul • 02(LP)-6-1
GROUP 03
GROUP 03
AIR INDUCTION AND EXHAUST SYSTEM
Air Induction and Exhaust Systems

Specification and Description .................. Section 1

Troubleshooting ........................................ Section 2
Air Induction System Service .................. Section 3
Exhaust Systems ....................................... Section 4
SM 661, Aug ’01 Group 03, Air Induction And Exhaust System
Group 03, Air Induction and Exhaust System
Section 1
Specifications Description
Air Cleaner Type: Canister style with replaceable paper The reason for providing an air cleaner for the engine is to
element and air-restriction indicator. protect the engine from abrasive dust and dirt entering the
cylinders and causing excessive wear. Industrial truck
operating environments can contain a high concentration
Fastener Torques
of dust, fibers, or other contaminants. Dirty filter elements
Canister Hose Clamp Torques: 1.5-2.5 N⋅m (1.09-1.8 ft-lb) or loose, leaking, or broken hoses or clamps can dramati-
cally shorten engine life. Clogged air filters cause engine
Gas/LPG Air Horn Intake Hose Clamp Torques: 1.9-2.9 power loss and poor fuel economy.
N⋅m (1.3-2.1 ft-lb)
The air cleaner used on the truck is a canister style filter
Diesel Air Horn Intake Hose Clamp Torques: 1.5-2.5 N⋅m with a large centrifugal air pre-filter and a larger filter ele-
(1.1-1.8 ft-lb) ment to increase service intervals. A dirt ejector port of
Canister Bracket Mounting Nut Torques: 20-25 N⋅m the bottom of the canister allows particles to be expelled
(14.5-18.5 ft-lb) from, rather than trapped in, the filter. All trucks are
equipped with an “air restriction indicator” that warns the
driver of dirty and restricted air intake. The air cleaner
Service Intervals should only be serviced when the air restriction indicator
Air Cleaner (Filter) Replacement: shows service is required or every 2000 hours. However,
the system components should be visually checked regu-
• Gas/LPG trucks, replace every 2000 hours larly for leaks, holes, or other damage that could affect the
• Diesel trucks, replace every 1000 hours. readings of the air restriction indicator. The air restriction
indicator light is in the driver’s instrument pod.
IMPORTANT The air filter assembly includes intake and outflow hoses,
Filter replacement intervals also depend on the filter cannister, the filter element, the air restriction
operating conditions. The filter canister and indicator, the dirt ejector, and a mounting clamp. The air
element should be check visually at regular intake opening is located in a leg of the operator’s cell,
intervals to check for leaks, holes, or other high enough above the ground to prevent excessive dust
conditions that will affect the air restriction and dirt from entering the system. The outflow hose is
indicator. Air cleaner should be serviced connected to the gas or LPG carburetor or the diesel
when the air restriction indicator shows ser- intake manifold. The mounting bracket for the canister is
vice is required. under the seat deck to the driver’s left and is easy to reach
An optional safety element is also available for service.
which fits inside the standard element. If the
optional element becomes dirty, the standard
element is also bad and both inner (optional
element) and outer (standard element)
should be changed.
Air Hoses and Clamps Inspection: Every 50-250 hours or

each PM.
Exhaust Pipe and Muffler Inspection: Every 50-250 hours
or each PM.
SM 661, Aug ’01 Air Induction and Exhaust Systems Specifications and Description • 03-1-1
Section 2
Air Induction System Troubleshooting
Dirty or restricted air induction components can cause If any of these problems occur with the truck, the air filter
several problems with your truck’s operation. Regular may be clogged or the air intake system is restricted. Ser-
maintenance and service of the filter element and related vice the entire system to make sure that air flow is clean
components can prevent problems with your truck. The air and unrestricted. Change the filter element and check all
restriction indicator also automatically gauges the air hoses, tubing, and the filter canister for tight fittings. Look
induction system performance and can warn you when at all connections for fan-shaped dust deposits that indi-
problems arise. The air restriction indicator switch is an cate possible air leaks. Check all hoses for proper seating
mechanical control mounted on the air filter canister. The and look for cracks or damage. Make sure all hose clamps
switch monitors the vacuum present in the system and are properly torqued.
determines when the air flow is not adequate; either a
clogged air intake or dirty filter element prevents the full,
required amount of air from reaching the engine.
Clogged air filters may cause the following symptoms :
• Engine starts but does not remain running.
• Engine lacks power.
• Excessive black exhaust smoke.
• Fuel or oil leaking from exhaust manifold.
• Excessive fuel consumption.
• Low compression.
SM 661, Aug ’01 Air Induction System Troubleshooting • 03-2-1

Section 3
Air Induction System Service
Use the illustrations on the following pages to service the NOTE

air induction system, including changing the air filter ele- Do not try to air clean and blow out the filter.
ment. Illustrations for the gas-, diesel-, and LPG-engine Filter is further clogged by air cleaning.
trucks are included. Always replace with a new filter element.
NOTE
6. Reseat the canister cover, making sure that it fits
The air restriction indicator gauges vacuum
tightly around the canister.
present in the system. For gas/LPG engines,
the filter should be replaced every 2000 7. Close and latch the canister cover clamps.
hours. For diesel engines, the filter should be
8. Close and latch the seat deck.
replaced every 900-1000 hours. Regularly
check the system components, however, to
check for leaks, holes, or other damage that Air Cleaner Removal
could affect the air restriction indicator.
1. Remove the two bolts that mount the canister to the
frame.
! CAUTION 2. Loosen the clamp and remove the hose from the
SAFE PARKING. Before working on truck: engine air horn. On LPG engines, hose is connected
directly to the carburetor.
1. Park truck on a hard, level, and solid
surface, such as a concrete floor with no 3. Remove the hose from the leg of the overhead guard
gaps or breaks. cell.
2. Put upright in vertical position and fully 4. Remove the air cleaner canister and hosing from the
lower the forks or attachment. truck.
3. Put all controls in neutral. Turn key
switch OFF and remove key. Air Cleaner Replacement
4. Apply the parking brake and block the Installation is the reverse order of removal.
wheels.
• Torque the hose clamp bolts to 1.9-2.9 N•m (1.3-
2.1 ft-lb).
Air Filter Replacement • Torque canister bracket mounting bolts to 20-25
1. Tilt the steering column forward and raise the seat N•m (14.8-18.5 ft-lb).
deck. The air filter canister is located to the left of the
driver’s seat.
2. Inspect the components and look for fan-shaped dust
accumulation at all hose connections. Clean compo-
nents of dust, dirt, and other contaminants that might
enter the system on disassembly.
3. Remove the canister cover clamps and remove the
filter element.
4. Clean the inside of the air filter canister.
5. Install the new filter element. Be sure that the filter
element is fully seated in the canister.
SM 661, Aug ’01 Air Induction System Service • 03-3-1

Air Filter - Gas Engine
Torque 2.9~3.9 N.m

(2.1~2.9 lb.ft)
Air filter element canister
Outflow hose
Air horn
Torque 20~25 N.m

(14.8~18.5 lb.ft)
Intake hose
Operator's cell leg Torque 20~25 N.m

(14.8~18.5 lb.ft)
03-3-2 • Air Induction System Service SM 661, Aug ’01

Air Filter - Diesel Engine
Operator's cell leg
Torque 2.9~3.9 N.m

(2.1~2.9 lb.ft)
Outflow hose
Torque 20~25 N.m

(14.8~18.5 lb.ft)
Intake hose
Torque 20~25 N.m
(14.8~18.5 lb.ft)
SM 661, Aug ’01 Air Induction System Service • 03-3-3

Air Filter - LPG Engine
Torque 2.9~3.9 N.m

(2.1~2.9 lb.ft)
Outflow hose
Connector to vent hose

from velocity governor
Torque 20~25 N.m

(14.8~18.5 lb.ft)
Torque 2.9~3.9 N.m
(2.1~2.9 lb.ft) Intake hose
Operator's cell leg Torque 20~25 N.m

(14.8~18.5 lb.ft)
03-3-4 • Air Induction System Service SM 661, Aug ’01

Section 4
Exhaust Systems
! CAUTION
SAFE PARKING. Before working on
truck:
surface, such as a concrete floor with
no gaps or breaks.
2. Put upright in vertical position and
fully lower the forks or attachment.
switch OFF and remove key.
4. Apply the parking brake and block the
wheels.
SM 661, Aug ’01 Exhaust Systems • 03-4-1

Exhaust System - Cushion-Tire Truck
Torque 20~25 N.m

(14.8~18.5 lb.ft)
Torque 20~25 N.m
(14.8~18.5 lb.ft)
03-4-2 • Exhaust Systems SM 661, Aug ’01

Exhaust System - Pneumatic-Tire Truck
Torque 20~25 N.m Torque 20~25 N.m

(14.8~18.5 lb.ft) (14.8~18.5 lb.ft)
SM 661, Aug ’01 Exhaust Systems • 03-4-3

Exhaust System - Vertical System
Torque 20~25 N.m Torque 20~25 N.m

(14.8~18.5 lb.ft) (14.8~18.5 lb.ft)
Torque 70~80 N.m
(51.8~59.2 lb.ft)
03-4-4 • Exhaust Systems SM 661, Aug ’01

GROUP 06(S)
GROUP 06(S)
TRANSAXLE
(TA-30 STANDARD TRANSAXLE)
Transaxle Specifications and Description ... Section 1
Transaxle Troubleshooting ...........................Section 2
Transaxle Oil and Filter ................................Section 3
Transaxle Oil Cooler ..................................... Section 4
Transaxle Removal and Replacement ......... Section 5
Transaxle Overhaul ...................................... Section 6
Drive Axle Ends Overhaul ............................ Section 7
Transaxle Control Valve Overhaul ............. Section 8
SM 661, Aug ’01 Group 06(S), Transaxle

Group 06(S), Transaxle
Section 1
Transaxle Specifications and Description
SM 661, Aug ’01 Transaxle Specifications and Description • 06(S)-1-1

Specifications Fastener Torques

• Axle Shaft-to-Axle Assembly Mounting Bolts:
General Specifications 90-110 N⋅m (66-81 lbf-ft)
• Model: Clark TA-30 Transaxle • Axle-to-Frame Mounting Bolts:

450-500 N⋅m (332-369 lbf-ft)
• No. Ratios: 1-speed, forward and reverse
• Breather: 34-40 N⋅m (25-30 lbf-ft)
• Transaxle Ratio Forward: 15.78
• Clutch Lube Tube Fittings: 73-90 N⋅m
• Transaxle Ratio Reverse: 16.06 (54-66 lbf-ft).
• Ring & Pinion Gear Type: Spiral Bevel • Clutch Pressure Tube Fittings: Tube end:
• Ring Gear Backlash: 0.20-0.28 mm 33-42 N⋅m (24-31 lbf-ft) ;
(0.008-0.011 in). Boss end: 42-53 N⋅m (31-39 lbf-ft)
• Differential Type: 2-pinion • Control Valve Mounting Bolts: 22-27 N⋅m
• Differential bearing preload: 0.075 mm (16-20 lbf-ft)
(0.003 in) deflection of each carrier ear • Differential Pinion Shaft Nut: 270-340 N⋅m
• Service Brake Size: 310 x 60 mm (12.2 x 2.36 in) (200-250 lbf-ft)
• Torque Converter Size: 310 mm (12.20 in)/ • Drain Plug: 171-209 N⋅m (126-154 lbf-ft)
280 mm(11 in) • Drive Plate Mounting Bolts: 37-45 N⋅m
• Torque Converter Stall Ratio: 3.9/3.3 (27-33 lbf-ft)
• Hydraulic Pump Drive Ratio: 1.029 x engine rpm • Engine-to-Transaxle Housing Mounting Bolts:
• Dry Weight: 390 kg (858 lb) 40-45 N⋅m (30-33 lbf-ft)
• Fluid Capacity 18.5 L (19.5 quarts) • Solenoid Valves: Valve body: 30.5-37 N⋅m
(22.5-27.5 lbf-ft) ; Coil nut: 5.5-7 N⋅m (4-5 lbf-ft)
• Transaxle Fluid (Oil): Clark # 2776236
• Stator Support Capscrews: 54-64 N⋅m
(40-48 lbf-ft).
Pressure Specifications* • Transaxle Oil Cooling Lines: Tighten fittings hand-
• Charge Pump Flow: 10 gpm (37.8 L/min) @ tight and turn with a wrench 1.5 to 3 full turns
1800 rpm • Transaxle Temperature Sensor: 45-55 N⋅m
• Regulator Valve Pressure: 190-245 psi @ (33-40 lbf-ft)
1800 rpm • Transmission Case-to-Axle & -Convertor Hous-
• Clutch Pressure (Forward/Reverse): 180 psi ings Mounting Bolts: 68-79 N⋅m (50-58 lbf-ft)
(1240 kPa) @idle rpm
• Cooler Return Pressure: 50-125 psi (345-862 kPa) Service Intervals
@ 1800 rpm
• Replace transaxle oil every 1000 operating hours.
NOTE • Remove and clean the transaxle sump oil strainer
1. All rpm’s noted are engine speed. screen each time the transaxle fluid is changed.
• Replace the transaxle oil filter every 6 months or
2. All clutch pressures are at engine idle 1000 operating hours, whichever comes first.
speed with clutch engaged.
3. Oil at operating temperature (82-93 °C) IMPORTANT
180-200 °F When the transaxle is new or rebuilt, change
the oil filter after the first 50 hours and again
! CAUTION after 1000 operating hours.
Before checking clutch pressures, park safely,
chock the steer wheels, raise the front of the
truck, block the truck by the frame, return
all controls to neutral, and disengage the
parking brake.
06(S)-1-2 • Transaxle Specifications and Description SM 661, Aug ’01

Locations
Control valve
Hydraulic pump
Oil filter
Solenoid valve
Pressure tube Inching rod
Lube tube
To/from oil cooler

Oil dipstick tube
Temperature sensor
Oil drain plug and screen
Figure 1. Locations

Axle housing
Transmission housing
Converter housing
Torque converter
Figure 2. Transaxle Housings
Description
Torque Converter
The torque converter provides a fluid coupling between
the engine and transaxle. The converter is filled with
transmission fluid and encases an impeller, a stator, and a
turbine.
The fan-like impeller—assisted by the stator—drives the
fluid; the turbine is driven by the fluid. The impeller is
connected to the engine flywheel by the drive plate; the
turbine is splined to the clutch shaft. The stator is splined
to the stator support, which bolts to the converter housing.
The torque converter is not serviceable and must be
replaced as a unit.
Figure 3. Torque Converter

Charging Pump
The transaxle charging pump (Figure 4) is mounted on the clutch assembly, driven by the torque converter turbine,
converter housing and is driven by the impeller hub gear can rotate over the hubs of the forward and reverse drive
via the pump idler gear. The pump provides pressure for gears without engaging them. However, when the inner
operating the clutch packs, supplies cooled oil to the and outer discs are pressed together, the outer discs drive
torque converter, pressurizes the oil in the torque con- the inner discs, which in turn drive either the forward or
verter to prevent cavitation, and circulates oil for cooling reverse drive gear. The forward drive gear directly drives
and lubricating the transaxle. The truck’s hydraulic system the power output gear (Figure 7) mounted on the differen-
pump is in the same housing with the charging pump. (See tial pinion shaft. The reverse drive gear drives the power
Group 29 for pump details.) output gear via the reverse idler shaft gears.
Transmission Solenoid Valves

The transmission case (Figure 5) contains the clutch Solenoid-operated direction control valves (Figure 5) are
assembly, forward/reverse drive gears, a reverse idler gear, mounted on the transmission case. They switch flow to the
and a power output gear (Figure 7) that drives the differen- forward or reverse clutch pack, or neither, in response to
tial drive pinion. an electrical signal from the operator’s direction control
lever.
The differential pinion gear shaft (Figure 7) is mounted in
tapered roller bearings at both ends in the transmission
case and can be adjusted for mounting distance, as well as Transaxle Control Valve
ring and pinion gear contact.
The transaxle control valve (Figure 4) is mounted on the
converter housing. The valve directs flow for lubrication
Forward/Reverse Clutch Packs and clutch pack actuation. The assembly contains an inch-
ing valve that controls the amount of pressure delivered to
The clutch assembly contains two clutch packs. Each
the clutch pack discs and, thus, the extent of slippage
clutch pack (Figure 6) contains alternating outer and inner
through the clutch. All components within the valve
discs and a piston to press the discs together. The outer
assembly are described under “Operation” later in this
discs have tangs on their outer diameters that mesh with
Section. The transaxle oil filter mounts to the transaxle
the (forward or reverse) clutch drum. The inner discs have
control valve.
splines on their inner diameters that mesh with the (for-
ward or reverse) drive gear. The outer discs and entire
Pump drive gear
Transaxle
Converter charging pump
housing
Main
Pump hydraulic
idler gear system
pump
Stator
support
Impeller
hub gear
Transaxle control
valve
Figure 4. Components on Converter Housing

Forward clutch
Reverse clutch Solenoid valves
Clutch assembly
Inner disc
Outer disc
Drive gear, reverse

Reverse idle shaft
Figure 5. Transmission Components
Piston
Figure 6. Clutch Components, Reverse Gear
Differential
The differential (Figure 7) is mounted on the transmission mounted in the transmission case. The differential bearing
case. The pinion on the transmission output shaft drives a preload and ring gear clearance (backlash) is maintained
ring gear bolted to the differential case. The differential by adjustment nuts on the differential bearing carriers.
case is supported by opposed tapered roller bearings
Pinion
Power output
gear
Differential
Adjustment nut
Ring gear
Figure 7. Differential Components

Drive Axle
The axle housing (Figure 8) encloses the differential and The axle shafts drive hub assemblies mounted at the ends
contains the axle shafts . The axle shaft ends spline into of the axle housing on opposed tapered roller bearings. A
the differential side gears (Figure 9). The rotation of the brake shoe assembly is mounted behind each hub on the
differential case drives the differential side gears and pin- axle end and acts on a brake drum that bolts to and
ions, which drives the two axle shafts at the differential encloses the hub.
rate needed for cornering.
Axle housing
Brake shoe assembly
Hub Bearing
Axle shaft
Bearing
Brake drum
Figure 8. Drive Axle Components
Differential
case
Side
gear
Axle shaft
Pinion
Figure 9. Axle Shaft and Differential

Operation
Transaxle operation is controlled by the transaxle control
valve (Figures 10 and 11).
The sequence of operation and the elements of the direc-
tion control valve shown below are described in the text
and schematic on the next two pages.
Inching spool Inching balance Inching rod

spring
Inching return springs
Modulator spool
Cooler bypass
spool
Lube relief spool
Accumulator
spool
Oil filter Filter bypass spool Regulator

spool
Figure 10. Transaxle Control Valve

Oil from the charging pump enters the transaxle control Cooling/Lube Circuit:
valve through an internal passage. Then it flows through
Flow from the filter passes through a cooler relief valve
the filter (or if the filter is clogged, through a bypass to the
that enables oil to bypass the cooling system if clogged,
cooling/lubrication circuit) and to the pressure regulator,
then exits the transaxle valve assembly and goes to the oil
which maintains pressure for the clutch actuation circuit,
cooler. The lube relief valve maintains pressure in the
and passes a large volume of flow to the cooling/lubrica-
cooling/lubrication circuit to a set pressure.
tion circuit. The clutch actuation circuit and the cooling/
lubrication circuit are best described separately: Cooled oil returns to the transaxle control valve, where it
is directed through the external lube tube, to the end of the
Clutch Actuation Circuit:
clutch shaft. Bores through the length of the clutch shaft
Flow from the filter then goes through the inching valve, conduct oil to the torque converter for driving the turbine
exits the transaxle control valve assembly, goes through and to the clutch packs and various bearings for lubrica-
the external pressure tube, and then to the solenoid valves. tion.
A small amount of flow through inching valve also goes
The priority lube sleeve on the clutch shaft moves with the
through the modulating valve to sump.
clutch piston to increase lube oil flow to clutch discs that
If one of the solenoid valves is open, it conducts oil to the are engaging.
corresponding clutch piston through a path that includes a
From the clutch packs and torque converter, the oil drains
bore in the oil distributor sleeve, a groove in the clutch
back to the sump (transmission and axle housings).
shaft, and a bore in the clutch shaft that leads to the clutch
cylinder.
Fluid entering the clutch cylinder moves the piston, which
presses the clutch discs together. As the piston reaches its
end of travel, pressure builds in the circuit, but is limited
to a maximum level by the pressure regulating valve.
As the operator depresses the inching pedal, a variable ori-
fice in the inching valve drops pressure downstream of the
inching valve. This reduces pressure on the clutch piston
accordingly, which lets the discs slip.
When the operator puts the truck in neutral, shifts to the
opposite direction, or turns off the truck, the open sole-
noid valve closes and springs return the clutch piston,
which releases the clutch discs and forces oil back through
the solenoid valve to sump.
When the inching valve relieves pressure, oil displaced by
the returning piston goes to sump through the modulating
valve.
The modulating valve and accumulator work together to
absorb shock caused by direction changes and to smooth
clutch application.

COOLER RELIEF
VALVE
CLUTCH COOLER
CONVERTER
LUBE
INCHING
PADAL
CONTROL
VALVE BLOCK
LUBE RELIEF
Figure 11
ACUMMULATOR
PRESSURE INCHING VALVE

REGULATING VALVE
FILTER ASSEMBLY
MODULATING
VALVE
06(S)-1-10 • Transaxle Specifications and Description

SUCTION
SCREEN
FULL FLOW FULL FLOW

SOLENOIDS SOLENOIDS
REV FND
Transaxle Hydraulic Schematic
CLUTCH PACK ASSEMBLY
SM 661, Aug ’01

Sectional View Along Turbine Shaft
Figure 12

Sectional View Along Drive Axle
Figure 13

Section 2
Transaxle Troubleshooting
Troubleshooting Techniques To identify and correct a transaxle fault, consider the prin-
ciples of operation, as given in Section 1, along with
The following information serves as an aid to isolating symptoms and causes indicated on the next page.
problems in a transaxle that is not functioning correctly.
Verification of the suspected problems usually requires
When troubleshooting a “transaxle” problem, keep in performing the stall checks, pressure checks or solenoid
mind that the transaxle is only the central unit of a group electrical checks described later in this Section. Inspection
of related power train components. Proper operation of the and overhaul of the suspect components is described in
transaxle depends on the condition and correct function- various locations within this Group.
ing of the other related components. Therefore, to prop-
erly diagnose a suspected problem in the transaxle,
consider the transaxle fluid, charging pump, torque con-
verter, transaxle assembly, oil cooler, filter, connecting
lines, controls, and engine as a complete system.
SM 661, Aug ’01 Transaxle Troubleshooting • 06(S)-2-1

Symptoms and Causes Low or No Clutch Pressure
The following lists typical transaxle troubles and possible • Parking brake on.
causes. • Low transaxle fluid level.
• Pressure regulating valve stuck.
Truck Won’t Move in Either Direction • Inching valve stuck.
• Low or no clutch pressure. (See below.) • Modulating valve stuck or plugged.
• Parking brake on. • Inching/brake pedal not returned to full up posi-
• Pressure regulating valve stuck open. tion.
• Inching valve stuck. • Defective or worn charging pump.
• Modulating valve stuck or plugged. • Broken or worn clutch shaft or piston sealing rings.
• No current to solenoid valves. • No current to solenoid valves.
• Solenoid valves stuck. • Solenoid valves stuck.
• Broken inching return springs.
High Clutch Pressure
• Broken inching balance spring.
• Clutch disc faces severely worn or glazed. • Faulty pressure regulating valve.
Truck Moves only in Forward or only in Reverse Low Cooler Return Pressure - Low Charging
Pump Output
• No current to solenoid valve.
• Low fluid level.
• Solenoid valve stuck closed.
• Suction screen has restriction.
Truck Moves in Forward or Reverse while in • Defective or worn charging pump.
Neutral
Overheating
• Solenoid switched on due to electrical fault.
• Solenoid valve stuck open. • Low fluid level.
• Clutch disc burned and engaged. • Worn charging pump.
• Worn oil sealing rings.
Clutch Slips When Not Inching • Dirty oil cooler.
• Low clutch pressure. See “Low or No Clutch Pres- • Restriction in cooler line.
sure.” • Cooler bypass valve stuck open.
• Brake/inching pedal overlap misadjusted
• Inching linkage or rod damaged or misadjusted. Noise In Converter
• Clutch disc faces worn or glazed. • Defective converter. Perform stall check.
Truck Will Not Inch Loss of Power

• Inching valve sticking. • Low engine rpm @ converter stall. Tune engine.
• Inching return springs damaged or incorrect (oppo- • Overheating - See “Overheating” above.
site coiling). • Faulty converter. Perform stall check.
• Inching balance spring damaged or incorrect
(opposite coiling). High Oil Level on Dipstick
• Excessive leakage between inching spool and • Plugged breather.
valve housing. • Hydraulic pump seal failure.
• Inching linkage damaged.
Clutch Noise or Premature Failure
• Incorrect oil in transaxle.
06(S)-2-2 • Transaxle Troubleshooting SM 661, Aug ’01

Checks Solenoid Valve Electrical Checks

The following checks should be performed when indi- To check the solenoids in the direction control valves,
cated by troubleshooting or at the specified PM intervals. operate the direction control with the truck running and
listen to or feel each solenoid to determine if it operates.
Fluid Level Check If either solenoid valve does not appear to be operating,
remove the leads from the valve and check that 12 volts
Check fluid level as described in the “Transaxle Drain and are present at the solenoid only when the truck is on, the
Fill” Section in this Group. parking brake is off, and the appropriate direction is
selected at the shift lever. Also check that voltage drops to
Fluid Leakage Checks 0 when the lever is shifted to neutral or the opposite direc-
tion.
Check the fluid lines and fittings between the transaxle
and the cooler located beneath the radiator. If leakage can- If this test or other troubleshooting indicates that a sole-
not be stopped by tightening a fitting, replace the defective noid valve is not receiving electrical current or is activat-
parts. ing at the wrong time, consult the wiring diagrams in
Group 14 and troubleshoot the direction control circuitry.
The cooler can be further checked for leaks by disconnect-
ing the lines from the cooler and applying 5 psi air pres- If the valve is receiving the correct electrical signal but not
sure to the fittings. If the cooler is leaking and will not operating, replace the valve.
hold this pressure, it must be replaced.
Inspect the transaxle drain plug. If the plug shows leak-
age, torque the plug 171-209 N•m (126-154 lbf-ft). If
tightening does not stop the leak, replace the plug O-ring.
IMPORTANT
This transaxle uses only Clark # 2776236
transaxle fluid.
General Mechanical/Electrical Checks

Prior to performing pressure and stall tests, the following
mechanical checks should be made:
1. Be sure all control lever linkage is properly con-
nected and adjusted in each segment and at all con-
necting points.
2. Check wiring and electrical components that actuate
the transaxle.
3. Check the service brake and inching pedal for correct
adjustment and travel. Be sure the inching pedal
moves freely and returns fully.
4. Be sure all components of the cooling system are in
good condition and operating correctly. Air clean the
oil cooler if necessary.
5. The engine must be operating correctly. Be sure it is
correctly tuned and adjusted to the correct idle and
no-load governed speed specifications.

Stall RPM Test Transaxle Pressure Checks

IMPORTANT Transaxle problems can be isolated by the use of pressure
Perform the stall rpm test before you make tests.
transaxle pressure checks. When the stall test indicates slipping clutches, measure
clutch pack pressure to determine if the slippage is due to
Stall tests are described in Group 00. Refer to the stall low pressure or to clutch disc material failure.
tests Section in Group 00 and follow the procedure given
there. Measure regulator pressure to help determine if low clutch
pressure is caused by a faulty pressure regulator, inching
Stall rpm is the rpm at which the engine runs with full valve, or charging pump.
power applied, the transaxle engaged, and truck move-
ment stopped by an immovable object or by the service Also refer to ”Symptoms and Causes” on page 2 of this
brakes (right foot pedal). Section for other suggested causes of low clutch pack
pressure.
Stall test indications are as follows:
Measure cooler return pressure to determine if pressure in
• Normal engine stall rpm: the clutch lubrication circuit is sufficient and whether a
LPG 1790-1890 suspect converter is sufficiently charged (filled and pres-
surized). Cooler return pressure will also be low if regula-
Gas 1850-1950 tor pressure is low.
Diesel 2150-2250
If clutch discs are glazed or otherwise failing, clutch over-
• Low engine stall rpm: haul is needed to correct performance problem.
LPG 1600-1700 If the converter is damaged, converter replacement is

required to correct performance problem
Gasoline 1650-1750
Diesel 1900-2000 Minimum Tools Required
A loss of engine power is indicated and an engine tune-up • Hydraulic transmission test manifold, or conven-
or repair is required. tional pressure gauge with 0-300 psi (0-2070 kPa)
pressure range, with hose and fittings.
• Very low engine stall rpm: • Tachometer
LPG 1100-1200
Test Preparation
Gasoline 1150-1250
Preliminary checks and stall rpm test must be completed
Diesel 1300-1400
prior to pressure checks.
Faulty stator support shaft or a convertor malfunction is
indicated and replacement of converter or stator support IMPORTANT
shaft is indicated. Be sure that transaxle fluid level is correct
and oil warmed to operating temperature
• High engine stall rpm: and that all mechanical checks have been
LPG Above 1890 completed.
Gasoline Above 1950
Diesel Above 2250
Either slippage of the clutch pack or converter fin damage

is indicated. Pressure checks (see next subsection) will
show whether the clutch pack must be repaired or if the
converter must be replaced.
06(S)-2-4 • Transaxle Troubleshooting SM 661, Aug ’01

Pressure Test Procedures 6. When each pressure check is completed, stop the
engine, remove pressure gauge, and reinstall plug or
1. Raise the front of the truck and block the steer
fitting(s).
wheels as described in Group 22.
IMPORTANT
2. Return all controls to neutral and release the parking
brake. Do not apply the inching pedal while making
clutch pressure checks. Apply the inching
3. Connect tachometer. pedal only when making inching control
4. Remove plug or disconnect fitting, then connect pres- pressure test .
sure gauge, or tee and pressure gauge, as indicated in Do not apply parking brake when making
illustration below. pressure checks. The parking brake turns off
the solenoid valves.
5. Operate engine at the specified rpm while taking the
pressure readings indicated in illustration below.
Make a record of each pressure reading for your ref-
erence.
Regulator Pressure: 1310-1690 kPa (190-245 psi) @

1800 rpm. Put direction control in neutral. Connect
gage to test port.
P
Regulator pressure
P P
Reverse clutch Forward clutch
pressure pressure
Forward Clutch Pressure: 1240 kPa (180 psi), mini-

Cooler Return Pressure: 345-862 kPa (50-125 psi) @
mum, @ 1800 rpm; Place direction control in forward.
1800 rpm. Put direction control in neutral. Splice
Connect gauge to test port.
gauge into line with tee.
Reverse Clutch Pressure: 1240 kPa (180 psi), mini-
mum, @ 1800 rpm. Place direction control in reverse.
Connect gauge to test port.
Inching Control Pressure: Depress inching pedal
while performing forward or reverse clutch pressure
test. Pressure must rapidly fall from full clutch pres-
sure to 310 kPa (45 psi) then more slowly to 0-35 kPa
(0-5 psi).
Neutral Check: When direction control is in neutral,
clutch pressure should be 0 kPa (0 psi). Also check
with parking applied and direction control in forward
or reverse; pressure should be 0 kPa (0 psi).

Section 3
Transaxle Oil and Filter
Oil Level Check

1. With the directional control lever in the neutral posi- IMPORTANT
tion and the parking brake on, run the engine at fast TRANSAXLE OIL SPECIFICATION. Use
idle to allow the transaxle to reach normal operating only Clark transmission fluid part # 2776236.
temperature.
2. With the directional control lever in the neutral, run
the engine at normal idle and check the oil level on
the dipstick. Add oil as needed to bring the level to
the full mark on the dipstick.
Dipstick
SM 661, Aug ’01 Transaxle Oil and Filter • 06(S)-3-1

Oil and Filter Replacement • Check O-rings for damage and scratches; replace if
damaged.
Check transaxle oil every 50-250 hours or monthly. Drain • Use a Standard-type cleaning solvent to clean the
and refill transaxle oil and replace the external filter every screen.
1000 hours or every year, whichever comes first.
• Allow screen to dry before reinstalling it. Do not
NOTE dry screen with rag—loose fibers could block
screen.
Transaxle should be drained with truck at
normal operating temperature. 3. Remove the external transmission oil filter.
4. Install:
1. If necessary in order to obtain sufficient clearance
under the truck, safely elevate and block the entire • A new external transmission oil filter
truck as described in Group SA. • A clean sump screen
2. Remove drain plug and allow oil to drain completely • A clean drain plug.
into a pan of at least 20-liter (5-gallon) capacity. 5. Fill the transaxle through the dipstick opening with
Clean plug of all debris. Clean sump screen. transmission fluid, Clark part # 2776236. Use 18.5
liters (19.6 quarts).
6. With the directional control lever in the neutral posi-
tion and the parking brake on, run the engine at fast
idle to allow the transaxle to reach normal operating
temperature.
7. With the directional control lever in the neutral, run
the engine at normal idle and check the oil level on
the dipstick. Add oil as needed to bring the level to
the full mark on the dipstick.
External transmission
oil filter
Drain plug
06(S)-3-2 • Transaxle Oil and Filter SM 661, Aug ’01

Section 4
Transaxle Oil Cooler
Oil Cooling System Blockage Check

Check supply and return lines for kinks and pinches when Measure the pressure at each of these points with a pres-
you suspect that flow is blocked or below normal. sure gauge tee’d into the line, as indicated in the illustra-
tion below. The truck should be in neutral and running at
1800 rpm with the oil temperature at 60-105° C (140-220°
Flow Check
F). If the pressure difference between the two points is
Flow rates through cooling system lines may be checked 276-414 kPa (40-60 psi), the cooler, fittings, or hoses are
with a flowmeter, if one is available. Flow should be 0.5- at least partially blocked and causing the cooler bypass
0.6 L/s (8-10 gpm). valve to activate.
If the pressure difference is greater than 60 psi, the cooler
Pressure Check bypass valve is probably stuck closed.
A clog or other restriction in the system causes an abnor- If the pressure drop in the system is excessive, measure
mal pressure drop across the inlet and outlet points on the the pressure difference across each hose and the cooler
control valve. separately to locate the blockage.
Supply to cooler
Return from cooler

P
SM 661, Aug ’01 Transaxle Oil Cooler • 06(S)-4-1

Oil Cooler Removal Oil Cooler Installation

The oil cooler is a separate unit located under the engine- Oil cooler installation is the reverse of removal.
cooling radiator. To remove the oil cooler.
Tighten mounting nuts and bolts to 40-45 N⋅m (30-33 lbf-
1. Drain the transaxle fluid as described in Section 3 of ft). Reconnect fittings and tighten according to the
this Group. hydraulic fitting tightening procedure in Group 40.
2. Remove counterweight as described in Group 38. Fill transaxle as described in Section 3 of this Group (06).
3. Disconnect oil line fittings at cooler. Cap lines.
4. Remove the mounting nuts: The cooler is secured by
a carriage bolt at each end. The nuts for these bolts
are accessible through a hole in each wheel well.
5. Hold down the rear lip of the lower shroud and pull
the cooler from the back of the truck. (If necessary
unbolt the lower shroud and drop it down for clear-
ance.)
Torque 20~25 N.m

Cooler (14.8~18.5 lb.ft)
Lower shroud
A
Torque 40~45 N.m
Cooler line
(30~33 lbf.ft)
Heat shield
Torque 40~45 N.m
(30~33 lbf.ft)
DETAIL A
Transaxle Oil Cooler and Lines
06(S)-4-2 • Transaxle Oil Cooler SM 661, Aug ’01

Section 5
Transaxle Removal and Replacement
SM 661, Aug ’01 Transaxle Removal and Replacement • 06(S)-5-1

Transaxle Removal ! WARNING

1. Remove the upright as described in Group 34. Place Place a block under the counterweight to pre-
a block under the counterweight to prevent tip-back. vent tip-back when the transaxle is removed.
2. Remove the drive wheels as described in Group 22. Also, make sure any lifting gear you use,
Leave front of truck elevated on blocks. including sling, chain, hoist, or eyebolt, is of
sufficient capacity and is safety-inspected
3. Tilt back steer column. Raise the seat deck. Discon- and approved.
nect the battery positive cable. Remove the floor
plate as described in Group 38. 8. Support the flywheel-end of the engine by some reli-
4. Remove the drain plug and drain the transmission as able means, such as a floor jack or block under the
described in Section 3 of this Group (06). flywheel housing.
9. Remove the access plate from the transmission and
! WARNING remove the bolts that hold the transmission drive
Hydraulic fluid is toxic to the skin, eyes, and plate to the engine flywheel (Figure 2).
respiratory tract. Avoid skin and eye contact. 10. Remove the bolts that mount the transmission hous-
Good general ventilation is normally ade- ing to the engine flywheel housing (Figure 2). Slide
quate. the torque converter away from the engine.
5. Disconnect parking brake cables at cowl, as shown in 11. Slide the converter away from the flywheel.
Group 23. 12. Remove the bolts from the suspension mounts for the
6. Disconnect the four lines at the hydraulic pump (Fig- operator’s cell, as shown in Group 38.
ure 1) as shown in Group 29. 13. Slightly hoist the front of the cell until the transaxle
7. Also disconnect/remove (Figure 1): can clear the cowl (Figure 3). Do not over-extend any
of the flexible lines connected to the cowl-mounted
• Inching cable from inching rod
components.
• Brake line at union of flexible line and metal line
• Transaxle temperature sensor wire
• Transaxle oil cooling lines
• Electrical connectors for solenoid valves
• Cables, wires, or hoses anchored to the transaxle.
Figure 1. Items to Disconnect from

Transaxle. Also disconnect connec-
tor from temperature sensor (on
side not shown), and cables, wires,
and hose anchored on transaxle.
06(S)-5-2 • Transaxle Removal and Replacement SM 661, Aug ’01

saxle from the engin. Do not drop the torque

converter.
c. Pull the transaxle forward so that the housing

flanges separate and clear the dowels. Use a pry-
bar if necessary.
d. Raise the jack so that the flange on the converter
housing can clear the frame cross-member.
e. Bring the transaxle slowly forward with the jack,
until the flange on the converter housing clears
the cross-member. Then lower the jack slightly
and pull the transaxle from the truck. Make sure
the torque converter stays with the transaxle.
Using a lift truck:
Figure 2. Transaxle-to-Engine Mounting a. Spread the forks so that the transmission case and
the axle housing can both rest stably on the forks.
14. Check that all wiring, hoses, and cables are out of the b. Place the forks under the transaxle so that the tips
way. Then, pull the transmission from the front of the nearly touch the frame cross-member. Raise the
truck using either a jack or lift truck as follows: forks until they touch the transaxle.
Using a jack (Figure 3): c. Remove the four bolts from each transmission-to-
frame mounting bracket.
a. Place a rolling jack under the transmission hous- d. Pull the transaxle forward so that the housing
ing and raise the jack until it contacts the housing. flanges separate and clear the dowels. Use a pry-
b. Remove the four mounting bolts from each trans- bar if necessary.
mission-to-frame mounting bracket. e. Tilt the upright back to enable the mounting
flange on the converter housing to clear the cross-
! CAUTION member. Pull the transaxle forward, adjusting
upright tilt as necessary, until the transaxle is
Make sure the torque converter stays with
clear of the truck. Make sure the torque converter
the transaxle when you separate the tran-
stays with the transaxle.
Axle to frame
mounting bolts
Figure 3. Truck and engine are

properly blocked. Operator’s
cell is raised. Transaxle is rest-
ing on jack.
Frame cross member

Transaxle Replacement 6. Bring the transaxle to the engine so that converter

pilot, dowels, alignment stud, and mounting flanges
1. Make sure the torque converter is installed in the mate properly (Figure 4).
transaxle, as described in the transaxle overhaul Sec-
tion in this Group (06). 7. Install the housing-to-housing mounting bolts.
Torque to 40-45 N•m (30-33 lbf-ft).
2. Install alignment studs in flywheel (Figure 5).
3. Remove the access cover from the converter housing.
4. Sightly hoist the operator cell so that the transaxle
can clear the front cowl. Do not over-extend any of
the flexible lines connected to the cowl-mounted
components.
5. Prepare to place the transaxle in the truck with a roll-
ing jack or with a lift truck as follows:
Using a jack (Figure 4):
a. Place a rolling jack at the front of the truck. Hoist
the transaxle onto the jack.
b. Roll the transaxle up to the frame cross-member.
c. Raise the jack so the converter housing flange can
clear the cross-member.
Housing-to-housing Drive plate mounting
Using a lift truck: mounting bolt bolt and typical allgnment
a. Position the forks under the transaxle so that it is stud
stably supported under the transmission case and Figure 5. Mounting the Engine Housing and Flywheel to
axle housing, with the converter housing beyond the Transmission Housing and Drive Plate
the tips of the forks.
Axle to frame
mounting bolts
Figure 4. Truck and engine properly

blocked. Operator’s cell is raised. Tran-
saxle is resting on jack.
Frame cross member
06(S)-5-4 • Transaxle Removal and Replacement SM 661, Aug ’01

8. Install the axle-to-frame mounting bolts (Figure 4). 10. Torque all the drive plate mounting bolts 20-25 N⋅m
Torque the mounting bolts to 450-500 N•m (332- (15-18 lbf-ft).
367 lbf-ft)
11. Reinstall/reconnect the following items (Figure 6):
9. Rotate the transmission drive plate until a vacant fly- • Inching cable at control cover.
wheel hole and a drive plate mounting hole are
• Brake line at union of flexible line and metal line.
within the access port (Figure 5). Screw in, but do not
Torque 16 N⋅m (12 lbf-ft).
tighten the drive plate mounting bolt. Repeat at each
flywheel/drive plate mounting hole, removing the • Transaxle temperature sensor connectors.
alignment stud. • Transaxle oil cooling lines. Tighten fittings per
hydraulic fitting tightening procedure in Group 40.
• Solenoid valve connectors.
12. Install/connect all other items removed or discon-
nected in steps 1 through 6 of” Transaxle Removal,”
using the referenced Sections for specific procedures.
! CAUTION
Do not use old transmission fluid. Use only
Clark Transmission Fluid part number
2776236. See the transmission drain and fill
Section in this Group (06) for details.
13. Fill the transaxle. Run truck until warm. Recheck

Figure 6. Fastening the Drive Plate to the Flywheel fluid level.
Figure 7. Items to Reconnect

to Transaxle. Also reconnect
connectors to temperature sen-
sor (on side not shown).

Section 6
Transaxle Overhaul
SM 661, Aug ’01 Transaxle Overhaul • 06(S)-6-1

General Practices to Follow Cleaning Parts

The following procedures should be applied throughout
the process of disassembling, inspecting, cleaning, repair- ! WARNING
ing, replacing, and reassembling the transaxle compo- Gasoline is not an acceptable cleaning solvent
nents. because of its extreme combustibility. It is
Specific disassembly and reassembly procedures are given unsafe in the workshop environment.
later in this Section. Follow those procedures closely.
• Proper cleaning requires complete disassembly.
• Wash steel parts with machined surfaces in a com-
Disassembling Components mercial solvent.
Before disassembling the transaxle, you must drain the • Clean the inside and outside of bearing caps, hous-
transaxle fluid, disconnect the necessary controls, link- ings, etc. Cast parts which do not have machined or
ages, and hydraulic lines, and remove the transaxle from polished surfaces may be cleaned in hot solution.
the truck as described in Section 5. Observe the following • Wash castings or other rough parts in solvent or
practices during disassembly: clean in hot solution tanks using mild alkali solu-
• Cleanliness - Work in a clean place. It is important tions, heating parts thoroughly before rinsing.
that no dirt or foreign material enters the unit dur- • Rinse all parts thoroughly. Dry immediately with
ing repairs. Dirt is an abrasive and can damage clean rags, except for parts with rough surfaces.
bearings. It is always good practice to clean the Lightly oil parts and wrap them in corrosion-resis-
outside of the unit before starting the planned dis- tant paper if they will not be used immediately.
assembly. Store parts in a clean, dry place.
• Assemblies - When disassembling the various
assemblies, such as the clutches, idler shaft, and NOTE
wheel ends, lay all parts on a clean bench in the Do not use rags to dry parts with rough sur-
same sequence as removed. This procedure will faces, such as castings. Fibers left by rags can
simplify reassembly and reduce the possibility of restrict flow through the suction screen.
losing parts.
• Using Tools to Move Parts - Always apply force • Clean bearings thoroughly in clean, approved sol-
to shafts, bearings, housings, etc., with restraint. vent until completely cleaned. Dry bearings using
Movement of some parts is restricted. Never apply moisture-free compressed air. Be careful to direct
force to the part being driven after it stops solidly. air stream across bearing to avoid spinning. Lubri-
The use of soft hammers, bars and mauls for all cate bearings with clean oil and wrap them in a
disassembly work is recommended. lint-free cloth or clean paper to protect them until
installation
• Bearings - Remove bearings that will be reused
with pullers designed for this purpose. Lubricate • Do not spin bearings when drying them. Bearings
bearings with clean oil and wrap them in a lint-free may be rotated slowly by hand to facilitate drying.
cloth or clean paper to protect them while not in
use. Inspecting Parts
• Snap Rings - Remove snap rings with pliers
Closely inspect all transaxle components after cleaning
designed for this purpose. Snap rings removed in
and before reassembly to determine whether they require
this manner can be reused, if they are not sprung or
replacement.
loose in the groove.
Careful and complete inspection of all parts is very impor-
tant. Replacement of all parts showing indication of wear,
over-stressing, or damage will save time and money at a
later date.
06(S)-6-2 • Transaxle Overhaul SM 661, Aug ’01

Inspect: When replacement is necessary, use only genuine Clark

parts to assure continued performance and extended life
• Steel parts for notches, visible steps or grooves.
from your unit.
Look for scuffing, deformation, or discoloration
related to improper lubrication. Recommended inspection procedures for various types of
• Bearing balls, cages or retainers, rollers, and race- parts are as follows:
ways for pitting, discoloration, and spalled areas.
Bearings
• Gear teeth for signs of excessive wear, pitting, or
cracking along contact lines. Check tooth contact • Replace bearings that are pitted, discolored, or
pattern. spalled. Always replace bearing cups and cones as
• Machined surfaces of cast or malleable parts for a set. Do not replace a bearing or race separately.
cracks, scoring, and wear. Look for elongation of • Replace bearings with excessive clearances.
drilled holes, wear on machined surfaces and nicks • Check bearing fits. Bearing inner races should fit
or burrs in mating surfaces. tight to the shaft; outer races slightly tight to
• Fasteners for rounded heads, bends, cracks or dam- slightly loose in housing bore. If bearing spins
aged threads. freely in bore, however, housing should be
• All housings for cracks or leaks, loose studs, or replaced.
cross-threaded holes.
Gears and Shafts
IMPORTANT • Check gear teeth for frosting and pitting. Frosting
Any damage that affects the alignment or of gear tooth faces presents no threat of transmis-
structural integrity of the housing requires sion failure. Often in continued operation of the
replacement. Repair by welding or straight- unit, frosted gears will “heal” and not progress to
ening should not be attempted. Such pro- the pitting stage. And in most cases, gears with
cesses can affect the housing metallurgy and light to moderate pitted teeth have considerable
cause it to fail completely when under load. gear life remaining and can be reused. But gears
with advanced-stage pitting should be replaced.
Repairing and Replacing Parts • If the Magnaflux process is available, use it to
check parts for damage.
Replace lower-cost parts such as thrust washers, seals, • If gear teeth show areas where the case-hardening
etc., that protect the transaxle from premature wear and do is worn through or cracked, the gear must be
not add greatly to the cost of rebuild. replaced.
Replace heavily worn but unbroken parts. • Inspect all shafts to be sure they are not bent or
Steel parts such as shafts or gears are not repairable. If cracked and that splines are not damaged.
worn or damaged, replace them, along with mating parts
as necessary. Splines
Seals and washers should be routinely replaced. Fasteners • Check splines on all shafts and gears for abnormal
with self-locking patches may be reused if secured with wear. If splines are severely worn or pitted, replace
several drops of 277 (Clark part # 1802302). the specific part affected.
Transaxle housing repairs are limited to removal of nicks Clutch Discs

or burrs on machined surfaces or replacement of damaged
studs. • All damaged discs must be replaced with new
ones.
Since the cost of a new part is generally a small fraction of • Inspect clutch plates for excessive wear (shown by
the total cost of downtime and labor, avoid reusing a ques- worn dimples or friction surfaces), excessive heat-
tionable part which could lead to additional repairs and ing (blue color indicates excessive heating), and
expense soon after initial reassembly. To aid in determin- warp.
ing the reuse or replacement of any transaxle part, also
consider the unit’s history, hours of use, application, etc. • Examine clutch plate internal and external teeth for
evidence of excessive wear.

O-Rings and Gaskets Threads should be clean and dry before application
of thread compound.
• Replace all O-rings at overhaul.
• Gaskets - Be sure all gaskets are installed. An
• Replace all gaskets at overhaul.
omission of any gasket can result in oil leakage.
• O-rings and seals should be lubricated with trans-
• Capscrews and Threaded Fasteners - Use only
mission fluid (Clark part # 2776236) before assem-
threaded fasteners of the correct part number and
bly.
material specification. Replace all fasteners that
have a questionable condition. Threads should be
Oil Seals
clean and dry before application of thread com-
• Replace all oil seals at overhaul. pound. Apply lubricant or thread compound only
• Use extra care when installing seals. Seal lips and as specified. Be sure all fasteners are installed
sealing surfaces can be easily nicked and damaged, (none omitted) and torqued to the correct specifica-
thereby destroying the sealing ability. tion.
• Bearings - Use of the proper bearing installation
Housings tool is recommended for the installation of bear-
ings. The proper tool applies equal force to both
• Check all housings for damage, cracks and wear.
bearing races, preventing damage to balls/rollers
Replace damaged housings, as needed.
and races while maintaining correct bearing align-
• Gasket sealing surfaces should clean and free of ment with bore and shaft. Avoid using a tubular or
nicks and burrs. sleeve-type driver, whenever possible.
• Torque Recommendations - Correct torque appli-
Threaded Fasteners and Snap Rings
cation is extremely important to assure long tran-
• Inspect all fasteners for damage and wear. Replace saxle life and dependable performance. Over-
all damaged fasteners. tightening or under-tightening can result in a loose
• Snap rings are to be installed with flat side away installation and, in many instances, eventually
from load. Replace any damaged or suspect snap cause damage to transaxle gears, shafts, and/or
rings. bearings. Use a torque wrench whenever possible
to attain recommended torque ratings. Torque rec-
ommendations are given in this Section with the
Reassembling Components specific assembly procedures.
These practices should be followed during reassembly: • Tool Reference - Some repair procedures in this
manual may show the use of specialized tools.
• Cleanliness - Be sure that interiors of all housings Their actual use is recommended as they make
are clean. It is important that dirt and other foreign transaxle repair easier, faster, and prevent costly
materials be kept out of the transaxle during reas- damage to critical parts.
sembly. Dirt is an abrasive and can damage pol- But for the most part, ordinary mechanic’s tools
ished surfaces of bearings and washers. such as socket wrenches, screwdrivers, etc., and
• Removing Burrs - Make sure all lead-in chamfers other standard shop items such as a press, mauls,
for oil seals, piston ring grooves, and O-rings are and soft bars are all that is needed to successfully
smooth and free from burrs. Inspect at assembly. disassemble and reassemble the transaxle.
• Initial Lubrication of Parts - Brush light coating
of transmission fluid, Clark part # 2776236, on IMPORTANT
bearings and bushing bores. Refer to the appropriate Customer Service
Lubricate all piston ring grooves, clutch plates and Parts Book for the correct service replace-
O-rings with transmission fluid # 2776236 before ment parts to be used during reassembly of
assembly. the transaxle.
• Use of Sealing Compounds and Thread Lockers
- Use only where specified.
Make sure there is no excess or free sealing com-
pound or thread locker that could enter the oil sys-
tem.

Overhaul Procedures Removing Transaxle Peripherals
Overhaul involves following the general practices given Use a chain hoist to lift the transaxle. For lifting, an eye-
earlier in this Section and performing the specific proce- bolt with a 9/16-18UNF thread can be screwed into one of
dures given in the remainder of this Section. the clutch test ports, shown in Figure 12, after removing
the port plug.
Please read the general practices before proceeding.
Position the transaxle in its in normal orientation. Remove
NOTE items as described below. Locations are shown in Figure
Cleanliness is of extreme importance in the 12.
repair and overhaul of this assembly.
1. If the transaxle was not previously drained, remove
Perform all disassembly and assembly work
the drain plug and drain the oil. Also remove strainer.
in a clean area. Overhaul the transaxle only
in a clean, dust-free location, using clean
tools and equipment. Dirt or grit will damage
the highly-machined surfaces and result in
premature failure of components. Cleanliness
of interior surfaces, orifices, etc. is extremely
important to the proper operation of the Figure 1. Drain Plug and Strainer
hydraulic circuit. The exterior surface of the
unit must be thoroughly cleaned of all dirt 2. Remove clutch pressure tube and clutch lube tube at
and foreign substances to prevent contamina- control valve cover and transmission case.
tion of the parts during overhaul. Protect all
components from dust and dirt while repairs
are being made. Be sure the work area is kept
clean.
Transaxle Disassembly
NOTE
Keep all parts in order as disassembly
progresses. Take care to properly identify
each part and its order of removal. If neces-
sary, keep notes and put markings on parts Figure 2. Clutch Pressure and Lube Tubes
using a non-destructive marker such as a felt-
tipped pen. 3. Disconnect brake line fittings at brake backing
plates. Remove bolt that holds brake line tee to con-
trol valve cover. Lift tee and connected lines away.
Figure 3. Brake Lines and Fittings

4. Remove transaxle oil dipstick tube, if not already 7. Remove transaxle oil filter.
removed, by disconnecting mounting bracket.
Figure 7. Transaxle Oil Filter
8. Remove transaxle control valve assembly. Remove

and dispose of control valve gasket.
Figure 4. Transaxle Oil Dipstick Tube
5. Remove torque converter assembly by carefully slid-

ing it off the turbine/clutch shaft and the stator sup-
port. Use care during handling and storage. Improper
handling could cause converter leaks.
See the “Transaxle Control Valve Overhaul” Section

in this Group (06), for overhaul procedures.
9. Remove the solenoid valves and temperature sensor.
6. Remove main hydraulic pump and gasket. The trans-

mission charging pump is in the same housing. Also
remove three O-rings from ports and pilot.
Figure 9. Solenoid Valves and Temperature Sensor
10. Remove the breather.
Figure 6. Hydraulic Pump and Transaxle Charging Pump
Figure 10. Breather

11. If you intend to overhaul the axle end and/or brake

assemblies, disassemble those components as
described in the “Axle End Overhaul” Section in this
Group (06), and the “Service Brake Inspection and
Overhaul” Section in Group 23.
Figure 11. Axle End Assembly
Torque converter (In housing)
Transaxle control valve

Dipstick
Transaxle oil filter
Main hydraulic pump/

Temp. sensor Transaxle charging pump
Brake line tee Drain plug and strainer

Brake line fitting
Axle end assembly
Brake line fitting

Solenoid valves Breather
Clutch test port
Figure 12. Transaxle Peripherals

Separating Converter, Transmission, Transmission Case to Axle Housing

and Axle Housings
Refer to Figure 13.
Before you separate the housings, the transaxle must be
1. If the axle shaft is not already removed, remove 10
removed from the truck (as described in Section 5) and
axle-to-hub mounting bolts (G) from each axle end,
peripherals must be removed from the transaxle (as
and pull axle shafts (H) out of differential.
described above). Then, proceed as follows.
2. Remove 17 transmission-to-axle mounting bolts (E
Converter Housing to Transmission Case
& J) from mounting flanges.
Refer to Figure 13.
3. Separate axle housing (F) from transmission case
1. Block under the converter housing (B) or hoist it so (D), tapping with rubber mallet if necessary.
that it is supported as you unbolt it from the transmis-
4. Remove and discard gasket (I) between housings.
sion case (D).
2. Access transmission-to-converter mounting bolts (A)
and washers from inside of converter housing (B).
Remove 11 bolts.
3. Separate converter housing from transmission case
(D), tapping with rubber mallet if necessary.
4. Remove and discard gasket (C) between housings.
D
C
I
H
G
A J
Figure 13. Separation of Transaxle Housing

Removing the Stator Support, Impeller Hub Gear 3. Remove hook ring seal (J).
and Bearing, Stator Oil Seal, and Pump Idler Gear
4. Lift out the impeller hub gear ( K).
Refer to Figure 14.
5. Remove the impeller hub bearing (L) by tapping
Before you remove these items, the transmission case lightly.
must be separated from the converter housing as described
6. Push the oil seal (A) out of the housing.
previously. Then:
7. To remove the pump idler gear, install an M8-1.25
1. Remove 4 stator support mounting capscrews (G)
bolt into the threaded hole in the shaft (B) of the
and washers.
pump idler gear. Pull the shaft from its bore with a
2. Using a soft-faced hammer, tap stator support (E) slide hammer or other suitable device, gripping the
from converter housing. Bearing (F) and bushing (H) installed screw. Do not pry on machined surface.
are pressed onto stator support and should be
replaced if worn or damaged, although it is advisable
to replace the entire assembly.
Figure 14. Converter Housing Contnts (Torque Converter Removed Perviously)

Removing Clutch Assembly and Reverse Idler Removing the Differential and Pinion Shaft As-
Shaft sembly
Before you remove these components, the transmission Before you remove these components, the torque con-
case must be separated from the converter housing as verter and axle housing must be separated from the trans-
described previously. mission case and the transmission case should be
anchored to the bench. Then:
1. 1.Remove reverse clutch outer thrust bearing set
(Figure 15, A). 1. Support the differential assembly (Figure 16, I) for
removal.
2. Remove the clutch assembly (Figure 15, B) and
reverse idler shaft (H) together: Use a gear puller to 2. Pull the lock pins (Figure 16, L) from the differential
loosen the idler shaft from its rear bearing (G). Grasp carrier adjusting nuts.
both shafts and pull from case.
3. Remove the adjusting nuts (Figure 16, M).
3. Locate and remove forward clutch outer thrust bear-
4. Remove the differential casing (Figure 16, I) and
ing (Figure 15, C) from transmission case or clutch
cone bearings (Figure 16, G and K).
shaft (turbine shaft).
4. If the inner bearing (Figure 15, I) needs replacing,
pull it from the idler shaft.
E
D
C
B
G
H
I
Figure 15. Clutch Assembly and Idler Shaft Removal
Figure 16. Differential and Pinion Removal

5. Remove output gear retaining ring (Figure 16, A) Removing Bearings, Cups, Shims, and Oil
from pinion shaft (inside transmission case). Distributor from Transmission and Differential
Housing
6. Hold or block the pinion shaft (Figure 16, F) or out-
put gear with a brass bar or similar soft material to With all other components cleared from transmission
prevent turning. Loosen and remove the pinion shaft case:
nut (Figure 16, N).
1. Pull the reverse idler shaft rear bearing. (Figure 15,
7. Use a brass bar to drive the pinion shaft (Figure 16, G).
F) from its bearings. Support pinion so that shaft
2. Pull the turbine (clutch) shaft rear bearing (Figure 15,
does not fall as it exits the case.
D).
8. Remove the pinion shaft outer bearing (Figure 16, O)
3. Inspect the clutch shaft oil distributor sleeve (Figure
and shims (Figure 16, Q).
15, E). If it appears worn or damaged, remove the
NOTE retaining set screw (F). Then, pull the oil distributor
Wire shims to transmission case for storage sleeve from the transmission case with a slide ham-
until reassembly. mer or gear puller.
4. If pinion bearings are to be replaced, drive out the
9. Remove output gear (Figure 16, B). cups (Figure 16, D and P) from inside transmission
case. Remove shims (Figure 16, C) from differential
Removing the Suction Tube side.
To remove the oil suction tube assembly from transmis- NOTE
sion case:
Wire shims to transmission case for storage
1. Remove the keeper from the bore with pliers (A). until reassembly.
Discard keeper.
2. Push the tube toward the converter end of case (B) to
free it from axle end of case
3. Rotate the tube (C) to provide clearance.
4. Pull the tube back toward the axle case (D) and
remove the tube.
5. Remove and discard O-ring.
Figure 17. Oil Suction Tube Removal

Differential Overhaul
Refer to Figure 18.
Differential Disassembly
1. Unbolt the ring gear (A) from the differential casing.
2. Using a small drift pin or rod, drive the differential
pinion pin lock pin (B) from the casing (E).
3. Remove pinion pin (C).
4. Remove items G-K from differential casing.
5. If bearings or cups (D, F) need replacement, drive
cups from casing.
Differential Reassembly
Before reassembly, clean, inspect and lubricate all parts.
IMPORTANT
Replace both the pinion and ring gear as
matched set only.
1. Press bearing (D, F) cups to bottom of bores if they

are being replaced. Cups must be replaced if bearings
are being replaced.
2. Insert the side gears (H) and washers (I) into the dif-
ferential assembly. Figure 18. Differential Casing Assembly/Disassembly
3. Insert washers (K) into grooves in casing.

! CAUTION
4. Insert both pinion gears (G, J) into position on the
side gears. RING GEAR BOLTS. Use only new ring
gear bolts. Used bolts can failed prematurely.
5. Rotate the side gears and pinions until the bores in
the pinions (G, J) align with the pin (C) hole in the
casing.
6. Insert the pinion pin (C) into the casing. Rotate the
pinion pin so that one of its slots can receive the lock
pin (B).
7. Drive lock pin (B) into the casing so that the lock pin
engages the pinion pin (C).
8. Mount the ring gear (A) to the casing (E):
a. Use a vice with soft jaws to hold the casing.
b. Clean and dry all bolts and ring gear threads.
c. Apply Loctite Primer T (Clark part #1803836)
and Loctite 271 (Clark part #1802302) to all
threads.
d. Use alignment studs to position the ring gear.
e. Install 12 mounting bolts with washers, and
torque to 190-240 N•m (140-177 lbf-ft).

Clutch Overhaul
! CAUTION
Disassembling the Clutch SPRING UNDER HEAVY COMPRESSION.
Carefully remove with press and special tool
Figure 19 shows the contents of the reverse drum (R). The shown in figure 23.
contents of the forward clutch drum (S) are the same as
the reverse clutch drum except that the forward clutch’s 6. Slide off, piston return spring (H).
drive gear is smaller and the outer thrust bearings differ
(as shown in Figures 15 and 38). 7. Remove clutch piston (O) by turning clutch upside
down and tapping the shaft on a block of wood or by
1. Slide off clutch drive gear (B), and inner thrust bear- applying compressed air to bore between distributor
ing and washers (C). seal rings (R). (Outermost bore is for reverse piston;
2. Press the clutch gear bearings and spacer (A) from innermost for forward piston.)
the internal bore of clutch gear hub, if they need 8. Remove from piston, and discard, clutch piston seals
replacement. (L and M).
3. Pry retainer ring (D) out of the groove in the clutch 9. Repeat above procedures for forward clutch drum
drum (P) and remove clutch disc end plate (E). (Q) disassembly.
4. Withdraw the five inner clutch discs (F) and five 10. Remove three oil distributor seal rings (R) at end of
outer clutch discs (G). shaft by squeezing and unlatching them.
5. Remove clutch return spring retainer clip (H) with 11. Inspect turbine shaft. Check widths of seal ring
snap ring pliers. (To remove the clip you, must first grooves by installing new seal rings (R) from kit. If
compress the spring as illustrated in Figure 23.) side clearance exceeds 0.203 mm (0.008 in), shaft is
worn and must be replaced.
G
F
E
D
C
B
A R
O
M
K
J
I
H
Figure 19. Reverse Clutch Pack Contents

Reassembling the Clutch 5. Install retainer.

Forward and reverse clutch reassembly are the same. The
reverse clutch is shown below.
Retainer disc
NOTE
Retainer cup
Before reassembly, clean, inspect and lubri-
Spring
cate all parts with a light layer of Clark-
Transmission Fluid, part # 2776236.
Clutch Piston and Return Spring Reassembly

Retainer
1. Install new clutch piston inner and outer oil seal rings
in piston grooves. Make sure that outer O-ring is not Piston
twisted.
Groove for retainer clip
Inner seal Figure 21. Clutch Pack Assembly

Clutch piston
Filter Outer seal
Figure 20. Clutch Piston Assembly 6. Install piston return spring (Figure 21) over retainer.
7. Install retainer cup (Figure 21) against spring.
IMPORTANT
8. With a press (Figure 22), compress the return spring
Clutch PISTON Rings Must Be SEATED
and install retainer clip into groove in turbine shaft.
before you install the piston on the shaft and
Make sure sharp edge of clip faces up.
into the clutch drum.
Hold a cylindrical object, such as a screw- 9. Repeat assembly procedures for forward clutch.
driver shaft, against the new seal rings and
rotate the piston to seat the rings.
Make sure the seal rings are seated flush with
the inner and outer diameters of the piston.
2. Position the clutch assembly so that the open end of

the clutch drum faces up. (Refer to Figure 21.)
3. Apply transmission fluid, Clark part # 2776236, to
piston seal and inside of drum.
4. Install clutch piston, with oil seals, over turbine shaft
and into bottom of the drum. Rotate piston to check
whether seals are installed properly. The piston will
bind if either seal is out of position.
Figure 22. Press and Fixture. Fixture must be at least 25

cm (10 in) long with an inner diameter of 3.5 cm (1.4 in),
an outer diameter of 6.4 cm (2.5 in), and an opening to
allow installation of a snap ring.

Clutch Discs Reassembly

Refer to Figure 23.
1. Soak friction discs in transmission fluid, Clark part # Retainer ring
2776236.
2. Install the first outer clutch disc (steel disc) against End plate
clutch piston. Next, install first inner clutch disc
(friction disc). Alternate outer and inner discs to
install a total of six standard thickness outer steel
discs and five inner friction discs.
3. Install clutch disc end plate.
4. Install end plate retainer ring into groove in drum.
Pull up forcefully at two points on end plate to verify
that retainer ring is properly seated.
5. Check clutch disc clearance
a. Stand the clutch assembly on end with drum
opening upward. The stack of clutch discs and Inner disc
end plate will rest against the piston. (Friction disc)
b. Set up a dial indicator as shown in Figure 24.
Raise end plate against retainer ring. Measure the
distance end plate travels. (Flexible feeler gauge Outer disc
may be used.) (Steel disc)
c. If clearance is more than 3.38 mm (0.133 in), add
an outer (steel) clutch disk.
Groove for retainer ring
6. Repeat assembly procedures for forward clutch.
Figure 23. Clutch Discs Installation
Figure 24. Clearance between End Plate and Retainer Ring

Clutch Gear Reassembly 2. Check that gear assembly is inserted correctly.

1. Install inner thrust bearing set (thrust bearing 3. Repeat clutch gear assembly and installation proce-
between two thrust washers) onto clutch shaft (tur- dures for forward clutch.
bine shaft).
2. If removed, press clutch gear bearing set into clutch Oil Distributor Rings Installation
gear. Top surface of upper bearing should be just
1. After forward clutch is assembled, install three new
below top surface of gear. Letters on bearing edges
oil distributor seal rings on clutch shaft. Gently
should be visible after installation.
spread each ring and slide it into its groove. Squeeze
and latch each ring.
2. Apply transmission fluid Clark part # 2776236 to
Clutch gear bearing set
rings to facilitate assembly into oil distributor.
Inner thrust bearing set
Figure 25. Clutch Gear, Seal Ring, and Bearings
Clutch Gear Installation

1. Lower the gear assembly into the clutch pack and
rotate it as necessary to clear the teeth of each fric-
tion disk. Do not force the hub into the clutch pack. Figure 27. Oil Distributor Rings
Be sure the clutch hub is fully through the entire
clutch pack.
Transaxle Control Valve Overhaul
The entire control valve should be disassembled, cleaned,
and inspected at transaxle overhaul. However, the valve—
or its various subsections—may be disassembled sepa-
rately whenever troubleshooting indicates a problem.
Procedures are given in the transaxle control valve over-
haul Section of this Group (Group 06).
Figure 26. Installing Clutch Gear by Rotating into Clutch

Pack

Transaxle Reassembly
IMPORTANT Setscrew
Before proceeding, read the general practices
for inspecting, cleaning, replacing, and reas-
sembling components given at the beginning
Sleeve
of this Section.
Notes : Turbine shaft

rear bearing
• Use sealing compounds and thread lockers only
where specified.
• All lead-in chamfers for oil seals, piston ring Reverse idler shaft rear
bearing
grooves and O-rings must be smooth and free from
burrs. Inspect at assembly.
• Lubricate all piston ring grooves, clutch plates and Figure 28. Installation of Transmission Case Rear Com-
O-rings with transmission fluid, Clark part # ponents
2776236, before assembly. The Clark-specified
fluid has additives that are especially important for Installing the Suction Tube
conditioning new friction disks. If the suction tube has been removed, install it as follows.
• Brush a light coating of transmission fluid, Clark
1. Check cleanliness of O-ring groove in suction tube
part # 2776236 on bearings and bushing bores.
bore. Lubricate O- ring and tube end with transaxle
• After applying sealing compounds and thread lock- fluid. Install O-ring in groove.
ers, make sure there is no free or excess material
that could enter the oil system. 2. Push the tube end (A) into and through the bore in
the converter end of the transmission case.
3. Rotate the tube to align (B); then push the tube into
Installing Oil Distributor Sleeve, Reverse Idler the axle end of the case (B) until the tube end is
Shaft Bearing, and Clutch Shaft Bearing into firmly seated.
Transmission Case
4. With a socket, press the keeper into the bore (C) until
NOTE it seats against the tube. The tab ends of the keeper
Carefully align the oil distributor sleeve should point toward you.
before insertion. Use scribe marks on face of
sleeve to align with setscrew hole.
Suction
1. Install the oil distributor sleeve (Figure 28): Align the tube
setscrew hole in the sleeve with the hole in the case
and drive the sleeve in until the holes coincide. O-ring
2. Apply Loctite #242 (Clark part # 1802300) and
install the setscrew through the valve mounting base
and into sleeve. Torque setscrew to 16-20 N•m (142-
177 lbf-in).
3. Drive the turbine shaft rear bearing (Figure 28)
Keeper
fully into the transmission case.
4. Drive the reverse idler shaft rear bearing fully into
the transmission case.
Figure 29. Oil Suction Tube Installation

Installing the Pinion Bearings, Pinion Shaft, and To determine the shim pack thickness required for the ring
Output Gear gear and pinion set you are installing:
IMPORTANT 1. Note the number on the end of the pinion shaft.
REPLACE RING AND PINION AS A SET. 2. Locate the number on the chart below.
Pinion and ring gear must be replaced as a
new set if either is to be replaced. 3. Select the shim pack thickness next to the number
you located.
Determining Shim Pack Thickness 4. Check the shim pack height with a micrometer
The position of the pinion along the radius of the ring gear before installation.
is called the “pinion mounting distance.” This distance
must be kept within a specified range for the ring gear and IMPORTANT
pinion to mesh properly. Because manufacturing toler-
You must determine the thickness of and
ances vary among ring and pinion sets, the actual pinion
install the required shim pack whenever you
mounting distance may require shimming in order to
replace the ring gear and pinion set, or the
match the specified pinion mounting distance.
old shim pack.
The shim pack is shown in Figure 30A.
Shim Pack Thickness Chart
Mark on Shim pack Thickness Mark on Shim pack Thickness

Pinion (mm) (inch) Pinion (mm) (inch)
50 0.26 0.010 0 0.76 0.030
48 0.28 0.011 -2 0.78 0.031
46 0.30 0.012 -4 0.80 0.031
44 0.32 0.012 -6 0.82 0.032
42 0.34 0.013 -8 0.84 0.033
40 0.36 0.014 -10 0.86 0.034
38 0.38 0.015 -12 0.88 0.035
36 0.40 0.016 -14 0.90 0.035
34 0.42 0.016 -16 0.92 0.036
32 0.44 0.017 -18 0.94 0.037
30 0.46 0.018 -20 0.96 0.038
28 0.48 0.019 -22 0.98 0.038
26 0.50 0.020 -24 1.00 0.039
24 0.52 0.020 -26 1.02 0.040
22 0.54 0.021 -28 1.04 0.041
20 0.56 0.022 -30 1.06 0.042
18 0.58 0.023 -32 1.08 0.042
16 0.60 0.024 -34 1.10 0.043
14 0.62 0.024 -36 1.12 0.044
12 0.64 0.025 -38 1.14 0.045
10 0.66 0.026 -40 1.16 0.046
8 0.68 0.027 -42 1.18 0.046
6 0.70 0.027 -44 1.20 0.047
4 0.72 0.028 -46 1.22 0.048
2 0.74 0.029 -48 1.24 0.049
0 0.76 0.030 -50 1.26 0.049

Installing Pinion Shaft and Setting Preload 8. Install the outer bearing shim pack. If a new pinion
shaft is, start with a nominal shim pack of 1.575 mm
Refer to Figure 30A.
(0.062 in).
1. Drive outer bearing cup, if removed, fully into bore.
9. Drive outer bearing onto the pinion shaft.
2. Install the inner bearing shim pack, as selected
10. Install the old pinion shaft nut and torque to 270-
above.
340 N•m (200-250 lbf-ft). Hold or block the pinion
3. Drive the inner bearing cup into the bore firmly shaft with a brass bar or similar soft material to pre-
against the shim pack. vent the shaft from turning while tightening the nut.
Anchor case to bench if necessary,
4. Press (or expand with induction bearing heater) the
inner pinion bearing onto the pinion shaft until it 11. Unblock the pinion shaft and use a torque wrench to
butts against the shoulder of the pinion. measure the pinion shaft bearing rolling-torque pre-
load (Figure 30B). Preload torque should be 0.8-2.3
5. Position the output gear in the case with the long
N•m (7-20 lbf-in).
hub of the gear outward as shown.
12. If the preload torque is outside the specified range,
6. Insert the pinion shaft and inner bearing into the
you must remove shims to increase preload or add
case and through the output gear. Seat the bearing
shims to decrease it. To add or remove shims, remove
with a sharp blow to the pinion end with a soft-faced
the pinion shaft nut and bearing and repeat steps 8
hammer.
through 11.
7. Slip the output gear retainer ring on the pinion
13. After the preload torque proves to be within the spec-
shaft, but do not install it into its groove at this time.
ified range, replace the pinion shaft nut with a new
Bearing Installation Tip: To brace the pinion shaft
one. Do not reuse the pinion shaft nut. Torque nut
in preparation for driving on the outer bearing, install
270-340 N⋅m (200-250 lbf-ft).
the differential assembly adjusting nuts as shown in
Figure 32. Then install a T-bar bearing puller into the 14. Install the retainer ring into its groove, making sure
adjusting nuts and tighten finger-tight against pinion. it is fully seated.
15. If used, remove T-bar puller and adjusting nuts.
Figure 30A. Pinion Installation Figure 30B. Preload Torque Check

Installing the Differential Setting Differential Bearing Preload

Installing Differential Cage The differential bearing preload is the bearings’ resistance
to turning, which is controlled by how tightly the bearings
1. Press the left and right cups into the differential cage,
are sandwiched between their races. The change in dis-
if removed.
tance (deflection) between the differential carrier ears
caused by tightening the differential adjusting nuts is a
convenient indicator of preload. To measure the deflec-
tion:
1. Securely clamp transmission case to bench and set up
a dial indicator so that it is zeroed against a flat on a
carrier ear (Figure 33).
2. Tighten one or both of the adjusting nuts until the
pinion appears to correctly mesh with the ring gear
and there is a small amount of play (backlash)
Figure 31. Bearing Cup Installation between the pinion and ring gear.
3. Read the deflection on the dial indicator.
2. Place bearings in differential assembly (Figure 32).
Your goal is for this deflection to measure 0.076 mm
3. Position differential assembly between carrier “ears.” (0.003 in), without changing the temporary backlash
Block under ring gear to hold assembly in position. set in step 2.
4. Loosely install adjusting nuts through ears and into To change the deflection without affecting the back-
bearings. lash, tighten both adjusting nuts equally, or loosen
both equally: Use a clockwise rotation on both
adjusting nuts to increase the deflection (Figure 33).
Use a counter-clockwise-rotation on both nuts to
decrease the deflection. When the deflection is cor-
rect, precisely set backlash as described on the next
page.
NOTE
The deflection of one carrier ear should mea-
sure 0.075 mm (0.003 in). The total deflection
measured from flat to flat should be 0.15 mm
(0.006 in).
Figure 32. Differential Installation
Figure 33. Differential Bearing Perload

Setting Ring Gear and Pinion Backlash 4. Check the resulting backlash on three teeth around
the ring. Repeat adjustments until the preload and
The backlash measurement is the distance a ring gear
backlash measurements are both correct.
tooth can travel between pinion teeth with the pinion sta-
tionary. Because the pinion and ring gear teeth are bev- 5. Drive locking pins (Figure 34, D) through the upper
eled, you can change the backlash by changing how or lower holes in the differential carrier ears and
deeply the teeth mesh into each other. To adjust backlash between cleats in adjusting nuts. If necessary
without changing preload, you shift the ring gear along it
axis by tightening one adjusting nut while loosening the
Checking Ring and Pinion Gear Tooth Contact Pat-
other an equal amount. To measure and adjust backlash:
tern
1. Set up a dial indicator on a ring gear tooth (Figure
To check the ring gear and pinion for proper tooth contact
34, A). Hold or block the pinion so that it cannot
pattern (correct position):
rotate.
1. Apply a thin, even coating of gear checking com-
2. Rotate the ring gear through backlash (Figure 34, B)
pound, to the ring gear teeth.
and read the measurement.
2. Rotate the ring and pinion gears through a minimum
Backlash must be 0.20-0.28 mm (0.008-0.011 in).
of one revolution and apply a load (hold by hand) to
If the measurement is less than required, you need to the gears as they are turned.
shift the ring gear away from the pinion, if more than
When the ring gear is turned, the compound is
required, into the pinion.
squeezed away by the contact action of the teeth,
3. To shift the ring gear position, rotate the adjusting leaving bare areas that are the exact shape, size and
nuts equally in opposite rotations (loosen one nut, area of the tooth contact pattern.
tighten the other) as shown Figure 34, C.
3. Check the tooth contact
Tip: Insert a rod in the recess on the carrier ear and area on the sides of the
between cleats on the adjusting nut. Rotate the ring gear teeth. On an
adjusting nut with the rod as far as the recess old gear set, the contact
allows—this is one “notch.” Keep count of each pattern must match wear
“notch” you rotate the adjusting nut. Repeat on other pattern. On a new gear
adjusting nut using same number of “notches.” set, the tooth contact
pattern must be as
shown in Figure 35. If
the contact pattern is
incorrect, recheck the
pinion mounting proce-
dure and the ring-and-
pinion backlash read-
ing. Disassemble the
parts, add or remove
inner bearing shims as
needed to adjust pinion
position, and adjust dif-
ferential bearing nuts to
correct backlash.
Adding shims corrects a
“high” pattern. Remov-
ing shims corrects a
Figure 34. Ring Gear Backlash Adjustment “low” pattern.
Figure 35. Tooth Contact Pattern

IMPORTANT 3. Place a soft-faced hammer within reach.

Each time the ring gear or pinion is moved, 4. Hold the reverse clutch gear so that it does not dis-
the backlash and the differential bearing pre- engage any friction disks. Then, insert the end of the
load must be checked and reset as needed. clutch shaft into its bearing (Figure 38). Make sure
the forward clutch gear meshes with the output gear.
Installing the Clutch and Idler Gear
5. Insert the idler gear shaft end into its bearing while
The following should already be installed: oil distributor maneuvering the clutch and idler shafts so that the
sleeve, clutch shaft rear bearing, reverse idler shaft rear idler, clutch, and output gears mesh (Figure 38).
bearing, and differential pinion shaft (with transmission
output gear). Additionally, the clutch pack should be fully 6. Lightly tap the idler gear shaft with a soft-faced
assembled, including oil distributor seal rings. Then: mallet to seat the shaft and bearing into the bearing
pocket. Lightly tap on the clutch shaft with a soft-
1. Press the reverse idler shaft front bearing onto the faced mallet to seat the shaft into the bearing pocket.
idler shaft until it is fully seated against the shoulder.
7. Check for proper clutch shaft installation depth
(Figure 39):
a. Place a transmission case-to-converter housing
gasket on mating surface. Place a straight edge
against gasket and over clutch thrust washer.
b. If thrust washer touches straight edge, a clutch
disc may be out of position. Stop assembly of the
Figure 36. Installation of Front Bearing onto Reverse
unit, remove the clutch, make sure both clutch
Idler Shaft
gears engage all five friction disks, and repeat the
clutch/idler gear installation procedure.
2. Apply transmission fluid to forward clutch outer
c. Measure the gap between the straight edge and
thrust bearing assembly (thrust bearing between two
the thrust washer. If the gap is not 0.1-0.8 mm
washers) and to reverse clutch outer thrust bearing
(0.004-0.032 in) remove the clutch pack and rein-
and install them on clutch shaft.
stall it with a thinner or thicker reverse clutch
outer thrust bearing (Figure 37), as needed.
Reverse
Forward
Figure 37. Installation of Clutch Outer Thrust Bearings
Clutch(turbine) shaft
Reverse clutch gear
Idler gear shaft
Figure 38. Installation of Clutch and Reverse Idler

Assemblies Figure 39. Measuring Clutch Installation Depth

Installing the Pump Idler Gear and Bearing Installing the Stator Oil Seal, Impeller Hub Gear
and Bearing, and Stator Support
1. Insert retaining ring into the groove of pump idler
gear. 1. From converter side, drive the oil seal into its bore,
flush with the machined surface, with the beveled
2. Press the bearing into the hub of the pump idler
edge facing the transmission case.
gear.
2. If bearing and bushing have been removed from sta-
3. Apply clean transmission fluid Clark # 2776236 to
tor support:
the bearing.
a. Press bushing flush into splined end of stator
4. Insert the gear with bearing between the shaft mount- support.
ing holes in the converter housing. Check that holes b. Press needle bearing 4.0 mm (0.16 in) below
in housing and bearing align. flange surface.
5. Insert shaft (threaded end up) into outer bore and 3. Tap the impeller hub bearing into the converter
drive shaft in to below housing surface. housing.
4. Coat sealing ring with transmission fluid and slide it
onto stator support. Squeeze and latch sealing ring
into groove.
5. Oil the impeller hub gear. Place it in the converter
housing, and position it to mesh with the pump idler
gear.
6. Insert stator support assembly into converter hous-
ing and through impeller hub gear and bearing and
oil seal. Make sure stator support is in pilot and that
mounting holes align with holes in converter hous-
ing. (Use of alignment studs is advised).
7. Install four capscrews and tighten to 54-64 N⋅m (40-
48 lbf-ft).
Figure 40. Pump Idler Gear Installation
Figure 41. Stator Support and Oil Seal Installation

Joining Converter, Transmission, and Axle Hous- 2. Install at least two alignment studs in mounting holes
ings in transmission case mounting flange.
Clean all gasket mating surfaces. If there are any nicks, 3. Hoist the converter housing so that its mounting
remove them with emery cloth. Then join the housings as flange comes together with the transmission case
follows. (Refer to Figure 42.) mounting surface. Make sure the reverse idler gear
clears the bearing bore in the converter housing.
4. Loosely install four long mounting bolts with wash-
Transmission Case to Axle Housing
ers and seven short mounting bolts with washers
1. Place gasket over dowels on mounting flange on through converter housing and into transmission case
transmission case. Do not use gasket sealer. mounting flange. (Remove alignment studs.)
2. Install at least two alignment studs in mounting holes 5. Gradually torque the mounting bolts, in a criss-cross
in transmission case mounting flange. pattern, 60-65 N⋅m (44-48 lbf-ft).
3. With a hoist, bring the axle housing and transmission
Installing Axle Shafts and Axle Ends
case together, using the alignment studs for guides.
1. If axle end and/or brake assemblies were removed,
4. Loosely install six mounting bolts with washers
install them as described in the “Axle End Overhaul”
through the transmission case mounting flange and
Section in this Group (06), and the “Service Brake
into the threaded holes in the axle housing mounting
Inspection and Overhaul” Section in Group 23.
flange.
2. Insert O-ring into groove in axle shaft (Figure 42).
5. Remove the alignment studs and loosely install 11
Insert axle shaft into axle assembly and torque
mounting bolts with washers through the axle mount-
mounting bolts 90-110 N⋅m (67-81 lbf-ft).
ing flange, through the gasket, and into the threaded
holes in the transmission case mounting flange.
6. Gradually torque all of the above-mentioned mount-
ing bolts, in a criss-cross pattern, 68-79 N⋅m (50-58
lbf-ft).
Converter Housing to Transmission Case

1. Place gasket over dowels on mounting flange on
transmission case. Do not use gasket sealer. Figure 43. Axle End
Alignment stud
Axle shaft
Mounting bolt
Figure 42. Joining the Transaxle Housings.

Installing Transaxle Peripherals 5. Install clutch pressure tube and clutch lube tube by
connecting fittings and O-rings on tube ends and to
Locate peripherals on Figure 52.
control valve cover and transmission case.
1. Thoroughly clean the transmis-
sion sump oil strainer with an
approved cleaning solvent.
Dry with compressed air.
Install strainer and drain plug.
Tighten plug 171-209 N⋅m (126-
154 lbf-ft).
Figure 44. Drain Plug and Strainer
2. Install transaxle control valve with gasket and 10 fas-

teners. Torque fasteners to 22-27 N⋅m (16-20 lbf-ft). Figure 48. Clutch Pressure and Lube Tubes
Clutch pressure tube torque specs:

Tube End: 33-42 N⋅m (24-31 lbf-ft) ;
Boss End : 42-53 N⋅m (31-39lbf-ft).
Clutch lube tube torque specs:
33-42 N⋅m (24-31 lbf-ft).
6. Install oil dipstick tube. Connect and O-rings on
tube end and to transmission case. Fasten bracket to
transaxle housing.
3. Install oil filter cartridge. Tighten

per instructions on filter.
Figure 46. Transaxle Oil Filter
4. Install hydraulic pump: Replace three O-rings.

Install two mounting bolts and washers. Torque 90-
110 N⋅m (66-81 lbf-ft).
Figure 49. Transaxle Oil Dipstick Tube
Figure 47. Hydraulic Pump and Transaxle Charging Pump

7. Mount the solenoid valves; torque 30.5-37 N•m 8. Mount brake line tee and connected brake lines to
(22.5-27.5 lbf-ft). Mount temperature sensor and O- control valve cover with mounting bolt. Connect
ring ; torque 45-55 N⋅m (33-40 lbf-ft). brake lines to fittings on brake backing plates. Torque
fitting 15-19 N⋅m (11-14 ft-lb).
Figure 50. Solenoid Valves and Temperature Sensor Figure 51. Brake Lines
Torque converter (In housing)

Dipstick tube
Transaxle oil filter
Main hydraulic pump/

Transaxle charging pump
Temp. sensor
Drain plug and strainer
Pressure tube
Lube tube
Axle end assembly
Brake line fitting Brake line fitting

Solenoid valves Breather
Brake line tee Brake drum
Figure 52. Transaxle Peripherals

9. Install torque converter assembly by carefully slid- Filling and Initial Startup
ing it onto the turbine/clutch shaft and the stator sup-
Follow the fluid replacement procedures in Section 3 of
port. Use care during handling. Improper handling
this Group. Also, be sure to bleed brake lines before oper-
could cause converter leaks.
ating the truck as described in Group 23.
NOTE
Be sure to use Clark transmission fluid, part
# 2776236, after rebuilding clutch packs. This
fluid contains additives that condition clutch
friction discs and extend their life.
10. Install the breather: Apply Loctite 17009 to threads

and torque 33.9-40.6 N⋅m (25-30 lbf-ft).
Figure 54. Breather

Section 7
Drive Axle Ends Overhaul
Drive Wheel Removal Drive Axle Shaft Removal and

The drive axle ends can be overhauled with the drive axle Replacement
in the truck. If the drive axle is to be left in the truck: 1. Remove 10 mounting bolts and washers from each
1. Safely raise and properly block the front of the truck axle shaft flange.
as described in the lifting and jacking Section of 2. Pull axle shaft out of axle housing.
Group SA.
3. Remove O-Ring from hub.
2. Remove the drive wheels as described in Group 22.
4. Reverse steps 1 through 3 for installation. Use new
O-Ring, Torque mounting bolts to 90-110 N•m (66-
81 lbf-ft).
Axle shaft
O-ring
Mounting bolt
SM 661, Aug ’01 Drive Axle Ends Overhaul • 06(S)-7-1

Axle End Removal Axle End Assembly

The following procedures refer to the illustration on the 1. Press new cups into hub, if cups were removed.
next page.
2. Lube inner bearing with transmission fluid, Clark
1. Separate brake drum from hub. If necessary, screw part # 2776236, and install bearing.
jackscrews through holes in drum to force drum apart
3. Prepare surfaces and install oil seal:
from hub. Remove drum.
a. Remove nicks, scratches, and burrs from hub and
2. Bend back tab on locking washer to clear slot in lock spindle surfaces that will receive the seal.
nut. b. Apply a light coat of Loctite Primer N, Clark part
#1803267, and Loctite Gasket Maker, Clark part
3. Remove locknut from spindle. Special wrench, con-
#1802303 to seal outer diameter and hub inner
struction shown on page 4, may be used.
diameter.
4. Remove tongued washer from spindle. c. Press new oil seal into hub with special driver,
which can be constructed from drawing on page
5. Remove outer bearing from spindle.
4.
6. Remove hub from spindle.
IMPORTANT
7. Remove inner bearing. OIL SEAL LEAKS. The oil seal must be
8. Remove and discard oil seal from hub. replaced with a new one each time the hub is
removed. Use extreme care not to damage the
9. Extract inner and outer bearing cups from hub if seal during installation. Use the proper seal
bearings are to be replaced. driver, shown on page 4.
Axle Mounting Bracket Removal and 4. Install hub.
Installation 5. Lube outer bearing with transmission fluid, Clark

part # 2776236, and install.
1. Remove or install the brake assembly as described in
“Service Brake Overhaul” in Group 23. 6. Install tongued washer, locking washer, and locknut
(hand-tight) .
2. Remove or install the axle mounting bracket by slid-
ing it off or on the axle housing. Use anti-seize com- 7. While turning hub, torque locknut to 200-245 N•m
pound, Clark part #1802307, on the contact surfaces (147-181 lbf-ft) with special wrench shown on page
before installing the bracket. 4. Loosen locknut- then hand-tighten locknut until
bearing has no end-play.
Inspection, Cleaning, and Repair 8. Loosen locknut until tab on washer lines up with slot
in locknut. Bend tab on washer into slot on locknut.
Inspect bearings and cups for wear. Replace bearing and
9. Align inspection slot on brake drum with inspection
cup as a set if either is worn. Clean parts with a Standard
slot on hub. Install brake drum by sliding it over
type solvent.
studs mounted on hub. Tap drum with a soft-faced
hammer to seat it against the hub. Remount the wheel
as described in Group 22.
06(S)-7-2 • Drive Axle Ends Overhaul SM 661, Aug ’01

Axle housing
Axle mounting bracket
Spindle
Brake assembly Brake mounting bolt
Outer bearing and cup
Hub
Oil seal
Inner bearing and cup
Tongue washer
Lock washer
Lock nut
Brake drum
SM 661, Aug ’01 Drive Axle Ends Overhaul • 06(S)-7-3

190.00
26.76 33.67 100.0 15.0
14.76 6.24
0.79
0
1.0 X 45¡
5.
¡
R
30
C 129.92 Ð 0.05
C 84.7344
C 117.50
C 145.0
C 125.0
C 67.23
C 35.0
C 50.0
45.0 115.0
3.0 X 45¡
R
KNURLED
5.
R
0
5.
1.0 X 30¡ 0 0
3.
C 117.5 REF
C 125.0 REF
R
C 129.92 REF
R
0.
79
2.5 X 30¡ 0.79 REF
3.78
O-RING 4.826
25K40428 4.572
Hub Oil Seal Driver. Construct as shown.
.20" .75"
3.645"
1/2 Drive Socket
3/8" Square
Stock 1/4"
X 1" Long
1/4"
1/4"
Hub Locknut Wrench. Construct as shown.
06(S)-7-4 • Drive Axle Ends Overhaul SM 661, Aug ’01

Section 8
Transaxle Control Valve Overhaul
NOTE
A description of transaxle control valve func-
tion is given in Section 1, “Transaxle Specifi-
cations and Description.”
Problem diagnosis and pressure checks that
indicate control valve performance are given
in Section 2, “Transaxle Troubleshooting.”
Service Requirements Parts Cleaning, Inspection, and Lubri-

The control valve should be disassembled, cleaned, and cation
inspected whenever the transaxle is overhauled or when- Clean all parts with a safety-approved commercial solvent
ever indicated by troubleshooting. before inspection.
Inspection includes:
• Checking bores and spools for scratches, nicks,
burrs, and wear
• Making sure inching rod is not bent
• Making sure springs are not bent or cracked
• Checking the oil filter adaptor for thread damage
• Making sure all orifices are free of blockage.
Lubricate all components with transmission fluid, Clark
part #2776236, before reassembly. Lubricate and wrap
parts if reassembly will not be done immediately.
SM 661, Aug ’01 Transaxle Control Valve Overhaul • 06(S)-8-1

Assembly and Disassembly Procedures

The necessary procedures are generally obvious from the O-Ring (C): Lubricate O-ring with transmission oil
illustration given below, with the following notes: before assembly.
Separator Pin (G): This pin separates the cooler bypass Seal, Inching Rod (E): Replace with new seal (E). Press
spool from the lube relief spool. To install it: fit.
1. Insert the spool, spring, and washer that make up the Guide (A), Inching Rod: The bore through the inching
oil cooler bypass (F) into their bore. rod guide has a chamfered edge on one side. This side of
the guide must face the retaining ring.
2. Push against the washer with a small flat-tipped
screwdriver to compress the spring. The flat of the Filter Adaptor (L): Apply Loctite #242, (Clark Part
blade should face the pin bore. #1802300) to adaptor threads at installation. Tighten to
90-110 N•m (66-81 lbf-ft).
3. When the washer clears the pin bore, insert the sepa-
rator pin (G), withdraw the screwdriver, and tighten Caps: Torque caps (H, K, M, and N) to 58-72 N⋅m (43-53
the pin to 5.5-6.5 N⋅m (49-58 lbf-in). lbf-ft). Torque caps (D, I, and J) to 135-165 N⋅m (100-122
lbf-ft).
06(S)-8-2 • Transaxle Control Valve Overhaul SM 661, Aug ’01

GROUP 12
GROUP 12
IGNITION SYSTEM
(STANDARD ELECTRONIC IGNITION)
Ignition System Specifications and Description ....... Section 1
Ignition System Troubleshooting ............................... Section 2
Ignition System Inspection, Adjustments,

and Timing .................................................................... Section 3
Distributor Overhaul .................................................. Section 4
SM 661, Aug ’01 Group 12, Ignition System

Group 12, Ignition System
Section 1
Ignition System Description and Specifications
(Standard Electronic Ignition)
Specifications
• Ignition Type: Non-contact, electronic • Type II Distributor and Ignition Coil
• Firing Order: 1-3-4-2 − Pick-Up Air Gap:0.35 mm(0.014 in) minimum
− Pick-Up Coil resistance:430-450 Ω
• Rotation (viewed from cap): Clockwise
− Primary Coil Resistance:10.8-14.1 Ω between
• Ignition Timing: Gasoline 4° BTDC @ 680 rpm; terminals (+) and (-)
LPG 9° BTDC @ 680 rpm − Secondary Coil Resistance:22.1-29.9 Ω
between terminals (-) and center
• Centrifugal Advance: Beginning: 0° at 1000 rpm
(engine). End: 6.5° at 2600 rpm (engine) • Spark Plug Type:
Gas Engine: NGK BP4ES, Champion NY16
• Vacuum Advance: Beginning: 0° at 80 mmHg LPG Engine: NGK BP5ES, Champion NY12
(3.14 inHg.) End: 11.5° at 280 mmHg (11.0 inHg.) • Spark Plug Gap: 0.7-0.8 mm (0.028-0.031 in)
• Type I Distributor and Ignition Coil • Spark Plug Tightening Torque: 25 N•m (18.4 ft-lb)
− Pick-Up Air Gap: 0.8 mm(0.031 in)
• Plug Wire Resistance: 8,000 ohms per foot
− Primary Coil Resistance:1.08-1.3 Ω between
terminals (+) and (-)
− Secondary Coil Resistance:22.1-29.9 kΩ
between terminals (-) and center
− Ignition Coil Resistor Resistance:1.22-1.49 Ω
SM 661, Aug ’01 Ignition System Description and Specifications • 12-1-1

Ignition System Overview The ignition switch is an OFF/ON switch. Current flows
only when this switch is closed and returns by the ground
The purpose of the ignition system is to deliver a spark of through the engine or frame. The resistance of the primary
the proper intensity and duration to each cylinder at the winding of the ignition coil restricts the primary current
proper moment in the piston’s stroke. flow.
The ignition system consists of the distributor, ignition The ignition coil consists of two windings, a primary
coil, spark plugs, and primary (low tension) and second- winding and a secondary winding. The function of the
ary (high tension) wiring circuits. ignition coil is to transform the low voltage supplied by
The primary circuit is the low voltage circuit and is com- the battery in the primary winding into the high voltage
posed of the ignition coil primary winding, distributor output of the secondary winding required to jump the
electronics, and associated wiring, including battery, igni- spark gap at a spark plug.
tion switch, starter relay and neutral start relay. The distributor conducts and interrupts the primary wind-
The secondary circuit is the high voltage section and is ing current in the ignition coil at the correct time and dis-
composed of the ignition coil secondary winding, the dis- tributes the resulting high tension secondary current to the
tributor cap, the rotor, the spark plug cables (wires), and correct spark plug.
the spark plugs.
The battery supplies the voltage for producing current
through the ignition circuit.
Ignition System Components
12-1-2 • Ignition System Overview SM 661, Aug ’01

When the distributor interrupts the primary current, the This mechanism consists of weighted levers that revolve
collapsing field in the primary winding of the coil induces with the distributor rotor and act against a set of springs.
a very high voltage in the secondary winding. This voltage As the speed of rotation increases, the weights are moved
is carried by the high tension wire (cable) to the center ter- out and the timing is advanced. With this arrangement, it
minal of the distributor cap. The rotor connects this center is possible to have a retarded spark for idling and obtain a
terminal to the distributor cap terminals, which in turn are gradual advance in spark timing as the engine speed is
connected to the proper spark plug by high tension cables increased.
(wires).
The distributor also includes vacuum advance for opti-
The spark plugs provide a spark gap in the combustion mum part-throttle economy. With this system, spark tim-
chamber. The compressed air and fuel mixture is ignited ing is not only adjusted for the rotating speed but also for
when the high voltage jumps across this gap. the load applied to the engine. As load is decreased, tim-
ing is advanced, and as load is increased, timing is
The distributor incorporates a mechanical (centrifugal)
retarded until only the mechanical advance is used.
advance mechanism that varies the timing by advancing
the breaker plate as the engine speed increases.
Schematic Drawing of Electronic Ignition Circuitry
(BREAKERLESS TYPE)
DISTRIBUTOR
B BATTERY
SPARK PLUG
STARTER
IGNITION COIL B
ST STARTING SWITCH
IG CHARGE LAMP
RESISTOR
DIODE
WATER TEMP
GAUGE
PILOT LAMP
ALTERNATOR
OIL
PRESS. WATER TEMP
SWITCH SENDER
SOLENOID VALVE FUEL OUT CARBURETOR

(GASOLINE ONLY)
SM 661, Aug ’01 Ignition System Overview • 12-1-3

Distributor Components and Function Function

The signal rotor is mounted on the distributor shaft, which
Components rotates in sync with the engine crankshaft. As the distribu-
tor shaft rotates, each tooth of the signal rotor passes in
The distributor consists of the ignitor mounted on the close proximity to the ignitor. The ignitor senses the posi-
breaker plate, signal rotor, distributor rotor, and ignition tion of the passing tooth much as a “metal detector”
advance mechanisms. detects the presence of metal: The ignitor contains an
Ignition advance mechanisms include a mechanical cen- oscillator-type pick-up that stops oscillating when a metal
trifugal-weight type governor, and a diaphragm-type vac- tooth approaches it.
uum set. This stopping of the oscillation causes the ignitor to
switch off a power transistor built into the ignitor. This Off
condition blocks the flow of the primary current, which
collapses the magnetic field that built up during the On
time. The collapsing field cuts across the coil secondary
winding, inducing the high voltage that fires the spark
plug.
The clearance (air gap) between the teeth and the pickup
basically determines the duration of current flow, and thus
the duration of the spark. The wider the clearance or air
gap between the teeth and the pickup, the stronger the cut-
off and the longer the duration of the spark. This duration
is equivalent to the dwell angle in a contact-type distribu-
tor and can be adjusted as shown in Section 3.
Typical distributor Components. Type I distributor shown.

“Air Gap”—Clearance between Signal Rotor Tooth and
Ignitor Pickup
A. Breather L. Drive gear
B. Distributor cap M. O-ring Timing is controlled by precisely setting the position of
C. Contact carbon N. N.Lead wire the ignitor along the circular path made by the signal
D. Rotor O. O.Rotor shaft rotor’s teeth. You make this adjustment by rotating the dis-
E. Signal rotor P. P.Spring retainer tributor housing while observing the engine timing marks
F. Grounding wire Q. Q.Governor spring under a timing light.
G. Ignitor R. R.Governor weight
H. Breaker plate S. S.Distributor shaft
I. Vacuum control T. T.Lock pin
J. Packing U. U.Washer
K. Distributor housing
12-1-4 • Ignition System Overview SM 661, Aug ’01

Section 2
Ignition System Troubleshooting
(Standard Electronic Ignition)
SM 661, Aug ’01 Ignition System Troubleshooting • 12-2-1

Troubleshooting Tests 2. If no spark appears in step 1, remove the secondary

(high-tension) cable from the center terminal of the
The following tests should be used along with the trouble- distributor. Hold the wire terminal tip .25 to .38 inch
shooting chart on the next page to isolate ignition system [6-10 mm] from the engine block (ground). Crank
problems. the engine and check for spark across the gap.
Refer to Group 13 for complete electrical system schemat-
ics, if needed.
Spark Test
Distrubutor
! WARNING
Spark plug
GASOLINE OR LPG FUEL. Park truck in a Primary

well-ventilated area. Check for leaks and fuel cable
spills before performing these tests. Sparks Ignition coil
can ignite gasoline or LPG fuel vapors. Do Secondary
cable
not perform maintenance near open flame or
other sources of ignition, or while smoking.
LP gas is highly flammable.
! CAUTION
If spark appears, the problem is with the distributor.
While the engine is cranking or running, Perform the “Insulation Test” below and consult the
keep away from belts and fan and do not troubleshooting chart on the next page.
touch bare end of spark plug wire.
If no spark appears, suspect the coil, coil power sup-
1. Remove the spark plug wire from a spark plug. Hold ply, or coil resistor. Consult the troubleshooting chart
the boot end 6-10 mm (.25 to .38 in) from the engine on the next page and the inspection procedures in the
block (ground). Crank the engine and check for spark next Section.
across the gap. Repeat for each plug. If you cannot
hear or see the spark, go to step 2. If the spark Plug Test
appears, but you still suspect the plug is not firing
sufficiently, perform the “Plug Test” below. If there is spark from the boot end of the plug wire, but
you still suspect the plug may not be firing sufficiently,
Spark plug wire remove the spark plug to be tested from the engine.
Reconnect the plug to the plug wire. Crank the engine,
and sparks should form between electrodes. If the spark
plug is defective (worn, leaky or poorly insulated), no
spark will form. Replace the spark plug.
Distributor
Ignition coil
IMPORTANT
When removing spark plug wires from the
spark plug terminal, hold the cable cap or
boot firmly. Do not pull on the wire.
12-2-2 • Ignition System Troubleshooting SM 661, Aug ’01

Insulation Test of Distributor Cap and Rotor Troubleshooting Chart

1. Remove the distributor cap with the secondary (high- Verification of suspected problems usually requires per-
tension) wire installed. Crank the engine. If sparks forming the spark test, insulation test, and spark plug test,
form along the cap surface, this is an indication of a
The following lists typical ignition troubles and possible
breakdown in the insulating quality of the cap. Clean
causes and remedies.
or replace the cap.
Engine Does not Crank

Starter, battery, or other electrical system fault. See Group
14 troubleshooting.
Leak
Leak Engine Cranks, But Does Not Start
Distributor Spark Test Shows No Spark

cap
• Distributor
− Carbon tracking in cap or rotor. Replace.
Ignition coil − Broken or loose primary lead wire. Repair or
replace.
− Broken or damaged rotor. Replace.
− Distributor out of time. Retime distributor.
− Faulty electronic ignition unit. Replace.
− Ignitor gap too wide. Adjust.
− Broken wire or shorted circuit. Replace coil.
− Carbon tracking on tower. Clean or replace.
2. Remove the distributor cap. Remove and put the
− Dirty or wet connections in coil & distributor
high-tension (secondary) wire terminal close to the
cap towers. Clean or replace.
rotor. Crank engine. If sparks form this is indication
of a breakdown in the insulating quality of the rotor. • Coil to Distributor High Tension Cable
Clean or replace the rotor. − Loose or disconnected. Repair/install.
− Faulty wire or insulation. Replace.
− Corrosion.
• Wiring
− Bad secondary wire to distributor. Replace.
Leak
− Poor negative ground to block. Clean, repair,
tighten.
Rotor − Fuse.
− Firing order incorrect. Rearrange wires.
Secondary • Timing belt
cable
− Broken.
Ignition coil − Jumped timing cog.
Fuel System Fault

Refer to fuel system troubleshooting in Group 02.
Instrument Pod Fault

Refer to instrument pod troubleshooting in Group 13
SM 661, Aug ’01 Ignition System Troubleshooting • 12-2-3

Engine Runs, But Does Not Run Smoothly Engine Knocks

• Distributor
Engine Fault − Incorrect ignition timing (too far advanced).
• See Group 1 Troubleshooting − Disengaged or broken centrifugal advance
spring. Repair or replace.
Engine Misses and/or Backfires − Worn centrifugal advance mechanism. Replace.
• Spark Plugs
• Distributor − Incorrect heat range. Replace.
− Worn or loose distributor drive shaft. Replace − Fuel. Use correct spec.
assembly.
− Carbon tracking on cap or rotor. Clean or Engine Does Not Deliver Enough Power
replace.
− Broken primary lead wire. Repair or replace. • Distributor
− Faulty electronic unit. Replace. − Incorrect ignition timing (retarded). Adjust.
− Distributor installed 180° out of position. − Faulty centrifugal advance mechanism.
• Ignition Coil Fault Replace.
− Ignitor air gap out of adjustment.
• Coil to Distributor High Tension Wire
− Break in wire or wire loose. Replace, tighten. • Spark plugs fouled or worn.
− Faulty insulation. Replace. • Spark Plug wires contaminated or defective.
• Spark Plugs
− Plugs fouled or worn out.
− Flashover on porcelain insulator. Clean or
replace.
• Spark Plug Wires
− Faulty.
− Firing order incorrect.
12-2-4 • Ignition System Troubleshooting SM 661, Aug ’01

Section 3
Ignition System Inspection,
Adjustment, and Timing
SM 661, Aug ’01 Ignition System Inspection, Adjustment, and Timing • 12-3-1
Distributor Inspection and Air Gap

Adjustment
Distributor Cap
1. Remove the distributor cap and check its condition
for:
• Cracks
• Carbon tracking or flashover burn marks
• Corrosion, rusting or damage of terminals
• Burned center terminal or side inserts
• Center terminal pushed up inside cap and not
free in socket
• Moisture
• Dirt inside and outside
It is very important for the cap to be clean. Moisture
and dirt make a good path for flashover. Once a car-
bon track has started, the cap must be replaced.
2. Remove the spark plug wires from the distributor
cap. Inspect the cable socket terminals in the cap for
corrosion and burn damage. Clean the towers and ter-
minals, as needed.
3. Clean the distributor cap and terminals, or replace, as
needed.
Rotor
Remove the rotor and inspect it for:
• Carbon tracking or flashover burn marks
• Burned, pitted, bent or worn terminal tip
• Moisture, contamination, and dirt buildup Typical Distributor Components. Type I shown.
Clean or replace the rotor, as needed.
Centrifugal Advance
Install the rotor. Turn the rotor in the direction of rotation
and release it to confirm that the rotor returns to the origi-
nal position smoothly.
12-3-2 • Ignition System Inspection, Adjustment, and Timing SM 661, Aug ’01
Vacuum Advance Control Spark Plug Wire Inspection

Check the diaphragm in the vacuum advance unit and the 1. Check spark plug cables and boots for cuts, cracking,
line to the manifold for leakage. If the diaphragm is rup- brittleness, burns or excessive corrosion of the termi-
tured, the vacuum advance housing and linkage must be nals on both ends, and including general deteriora-
replaced. tion. If the cables are three years old or more, replace
them.
Pick-up Air Gap When removing a spark plug wire, be sure to hold the
cap or boot on the end of the cable. Do not pull on
1. Check the ignitor air gap. The air gap must be correct the wire.
to properly check timing.
Pick-Up Air Gap Setting. Type I.

2. Check plug wire resistance. Resistance should be
about 8,000 ohms per foot
3. To install new cables, remove one old wire at a time
and match it to a new one. Use all looms and separa-
tors and route the wires exactly as the old ones.
The use of a dielectric silicone grease at high-voltage con-
necting points such as coil and distributor cap towers and
spark plugs is recommended to ensure good electrical
connection and prevent corrosion.
Pick-Up Air Gap Setting. Type I.
Standard Pick-Up Air Gap Setting : Spark Plug Inspection and
Type I distributor : 0.8 mm (0.031 in) Replacement
Type II distributor ; 0.35 mm (0.014 in) minimum
NOTE Removing Spark Plugs
Always check and adjust ignition timing
after installing new ignitor module or adjust- 1. Remove the spark plug wires and move them out of
ing air gap. the way.
2. Use an air nozzle to blow dirt and contamination out
2. With a clean feeler gauge, measure the maximum air of the spark plug wells.
gap (at the position where a projection of the signal
rotor is aligned squarely with the ignitor pickup). IMPORTANT
Rotate the engine as necessary using the crank pulley
Do not allow dirt and contaminants to enter
and fan belt. If the measurement is not within specifi-
spark plug openings when the plugs are
cation, adjust the air gap setting.
removed.
3. To adjust the air gap, loosen the ignitor mounting
screws. The ignitor module position can be moved 3. Loosen, but do not remove, all of the spark plugs.
(varied) slightly using the positioning boss as a ful- Again blow dirt and contamination out of the wells.
crum. Adjust the air gap between the ignitor pickup
4. Remove and inspect the spark plugs.
and a projection on the signal rotor to specification.
After adjustment, tighten the two mounting screws.
Inspecting Spark Plugs Ignition Coil Inspection

1. Inspect spark plugs for the following conditions. If Ignition coils do not normally require any service except
any abnormality is found, replace the plugs: keeping all terminals and connections clean and tight. The
• Damage to insulator coil should be kept reasonably clean; however, it must not
• Wear of electrodes be subjected to steam cleaning or similar cleaning meth-
• Carbon and lead deposits ods that may cause moisture to enter the coil.
• Damage and deterioration to gasket
1. Check the ignition coil tower for tracking and obvi-
• Arcing or flashover tracking and burning of por-
ous damage. Be sure the tower is clean and dry.
celain insulator.
Check coil boot nipple for correct sealing and insu-
If spark plugs are: lating qualities. If flashover occurs here, the engine
probably won’t start.
• Fouled with carbon deposits, check for too rich
air-fuel mixture, dirty (clogged) air filter, or mis- 2. Check primary circuit wires for tight connections and
fire due to excessive spark gap. correct polarity. When the ignition coil is wired up
• Burned but white, check for too lean air-fuel incorrectly with the distributor, it can cause high
mixture, excessive spark advance, or insufficient speed missing with loss of power and performance
plug tightening torque. under heavy loads.
Installing Spark Plugs

1. Check the spark gap and adjust to the correct specifi-
cation. Use proper gauge and gapping tool.
DISTRIBUTOR
SPARK PLUG
SECONDARY
PRIMARY CABLE
CABLE
IGNITION COIL
IMPORTANT
New spark plugs do not always have correct
spark gap. Always check and adjust the
spark gap of new plugs. Use proper gauge
and gapping tool. Tighten spark plugs to the 3. Check the coil to distributor cap high-tension (sec-
specified torque. ondary) cable. Check the fit of the boot on the coil
and distributor cap towers. A high voltage leak at this
2. Clean the spark plug seat in the cylinder head. point will cause the engine not to start.
IMPORTANT
Lubricate threads on spark plugs with ANTI-
SEIZE grease, Clark part #1802307.
3. Use new seat gasket and screw plug in by hand.

4. Tighten to correct torque specification.
5. Correctly install the spark plug cables (wires).
Ignition Coil Tests Pick-Up Coil Tests

1. Test a defective coil by: (For Type II distributor only.) Measure resistance ; vlaue
• Measuring the resistance of the primary windings, should be 430-450 Ω. Make sure that ohm meter needle
secondary windings, and resistor with a circuit moves when screw driver passes near core of coil.
tester. If the specified values of resistance are
found as shown below, the coil circuits are not dis-
connected (broken) and not short circuited. If
incorrect values are found, replace coil and/or
resistor, as necessary.
Type I Distributor
− Primary Coil Resistance: 1.08-1.32 Ω between
terminals (+) and (-)
− Secondary Coil Resistance: 22.1-29.9 kΩ
between terminals (-) and center Ignition Timing Checks and Adjustment
− Coil Resistor Resistance: 1.22-1.49 Ω
Type II Distributor ! WARNING
− Primary Coil Resistance: 10.8-14.1 Ω between ENGINE FAN. Be careful of rotating fan
terminals (+) and (-) blades when using a timing light.
− Secondary Coil Resistance: 22.1-29.9 Ω
between terminals (-) and center NOTE
Correct ignition timing is vital to the proper
• Measuring the insulating resistance between the
and efficient operation of the engine. Incor-
primary terminal and case with a 500 V megger (if
rect timing can result in engine overheating,
available) or a volt-ohmmeter. It is considered nor-
with resultant reduced piston and valve life,
mal if the reading is 10 megohms or above.
and lowered fuel economy.
Replace coil, as necessary.
It is important that the ignitor air gap is set
2. When the coil is suspected of being faulty, remove it correctly before checking and adjusting the
and check its operation on a coil tester and replace it timing. Checking timing is counterproductive
if inoperative. Most coil testers compare the opera- if the gap is not set to specification.
tion of the coil being tested with one known to be in
good condition. This test should be made first with
Checking Ignition Timing
the coils at room temperature and then after warming
the coils five minutes by connecting the primary to a 1. Check and adjust ignitor air gap as explained earlier
battery of the same voltage rating as the coils. in this Section.
Recheck the comparison test to see if the expansion
due to heating has caused some defect. 2. Install a tachometer, or a combination test instru-
ment, such as the Clark Dynamic Engine Analyzer,
Part No. 1802047.
NOTE
Tachometer must be connected directly to
battery terminals. Other grounds are not
suitable.
3. Install a timing light.
NOTE
An ignition timing light, Clark Part No.
Type II Ignition Coil 1801971, or equivalent, with inductive spark
pickup is recommended. Install per manufac-
turer’s recommendations.
4. Clean the timing pointer or indicator and timing 9. With engine running at the noted idle speed, aim the
mark or notch on the crank pulley to make the mark timing light at the crankshaft pulley and timing indi-
more legible under the timing light. cator. Note timing marks as light flashes.
5. Start the engine and warm it up until it runs The initial ignition timing is correct when the timing
smoothly. mark on the crankshaft pulley is aligned with the cor-
rect position on the timing indicator, at idle speed.
6. Disconnect vacuum hose from vacuum advance on
distributor. Plug or clamp the open end of vacuum
hose to carburetor or manifold.
Initial Timing Specification:

• Gasoline: 4° BTDC @ 680 rpm
• LPG: 9° BTDC @ 680 rpm
If ignition timing is not correct, adjust as necessary.
7. Lower the engine speed by adjusting the carburetor See “Adjusting Ignition Timing,” below.
idle screw to obtain 680 rpm idle speed. See Group
02, “Fuel System” for idle adjustment. 10. Reset idle to 680 rpm.
It is standard practice to check engine initial timing

with engine idling at 680 rpm so that the automatic Adjusting Ignition Timing
advance of the distributor is completely retarded and Adjust timing with the engine warm and the vacuum
not affecting timing. This is very important to obtain advance hose disconnected and pulgged.
correct timing.
1. Loosen but do not remove the clamp bolt at the base
! of the distributor.
CAUTION
ENGINE FAN. Be sure to hold the timing
light to avoid rotating fan blades. Be careful
to stay away from the fan when leaning over
to see the timing marks.
8. The engine timing indicator (1) is located near the

crankshaft pulley (2) and may be seen from the right-
hand side of the truck.
2. With the engine running at correct idle speed (680

rpm), adjust the timing by slowly rotating the distrib-
utor in one direction or the other. Turn the distributor
• Clockwise to retard timing
• Counterclockwise to advance timing
3. Turn distributor body until the timing mark and indi- Vacuum Advance
cator are aligned correctly.
1. Connect the vacuum hose and check the total
4. Tighten nut or clamp bolt at the base of the distribu- advance while engine speed is increased gradually to
tor. no-load governed rpm.
5. Recheck the timing to be sure that it did not change 2. Vacuum advance is obtained by subtracting centrifu-
when distributor mounting bolt was tightened. gal advance from the measurement.
Total advance − centrifugal advance =
Checking Spark Advance vacuum advance
Vacuum Advance Specification:
After checking (and adjusting, if necessary) ignition tim-
• Beginning: 0° at 80 mmHg (3.14 inHg).
ing, check the centrifugal advance, then the vacuum
• End: 11.5° at 280 mmHg (11.0 inHg).
advance.
3. Analyze the results:
Centrifugal Advance • Excessive advance. Vacuum advance control
spring is weak. If spring is broken, abrupt rising
1. Make sure the engine is warm, the vacuum advance
of advance will occur.
line is removed and plugged, and idle is still set at
• Insufficient advance. Breaker plate is faulty or
680 rpm.
diaphragm is broken in the vacuum advance con-
2. Slowly accelerate the engine speed from idle to max- trol.
imum no-load governed rpm. Check the advance
4. Repair or replace component parts as required. (See
while engine speed is being increased.
distributor overhaul Section in this Group.)
Centrifugal Advance Specification:
• Beginning: 0° at 1000 rpm (engine).
• End: 6.5° at 2600 rpm (engine).
NOTE
Distributor rpm = 1/2 engine rpm
3. Analyze the results:

• Excessive advance: Centrifugal advance spring is
weak. If the spring is broken, abrupt rising of
advance will occur.
• Insufficient advance. Centrifugal advance weight
or cam is faulty.
4. Repair or replace the centrifugal advance mechanism
(mainshaft and weight assembly), as required. (See
distributor overhaul Section in this Group.)
5. Reset idle to 680 rpm.
Section 4
Distributor Overhaul
Replacing the Ignitor and Pick-Up Coil

The ignitor (with self-contained pick-up) on the Type I
distributor can be replaced without removing the distribu-
tor. On the Type II distributor, the pick-up coil assembly Signal
rotor
and ignitor are separate and can be replaced. To replace
these components : Gap
1. Remove signal rotor from the distributor drive shaft
with an ordinary bearing puller. Ignitor
2. Disconnect the wire leads from the terminals of the

ignitor module (Type I) or pick-up coil assembly Ignitor Pick-Up. Type I.
(Type II) and remove two mounting/adjusting screws.
To remove the Type II ignitor, remove the mounting
screws and the other leads as well.
IMPORTANT
Do not wipe off the grease on the back of the
ignitor unit because it is needed for heat radi-
ation of the unit.
Pick-up
coil
3. When reinstalling, set the pick-up air gap as show in Signal rotor
Section 3 of this Group. Gap Ignitor
Pick-Up Coil and Ignitor. Type II
SM 661, Aug ’01 Distributor Overhaul • 12-4-1

Removing the Distributor Installing the Distributor

1. Rotate the engine crankshaft to put the #1 cylinder 1. Rotate the engine crankshaft to put the #1 cylinder
piston at top dead center. piston at top dead center.
2. Disconnect the spark plug cables and the primary and 2. Align the match mark on the distributor drive pinion
secondary cables from the distributor. gear with the match mark on the distributor housing,
shown on figure below.
3. Remove the vacuum hose from the vacuum advance
control on the distributor. 3. With the match marks facing up, put the distributor
into the cylinder head so that the distributor pinion
4. Loosen and remove the distributor locking nut from
meshes with the distributor drive gear.
the base of the distributor. Remove the distributor
from the engine.
4. Fit the distributor assembly to the engine and align

the match mark on the distributor mounting flange
with the center of the distributor installation stud.
5. Install and tighten the distributor locking nut.

6. Install the vacuum hose.
12-4-2 • Distributor Overhaul SM 661, Aug ’01

Distributor Disassembly and Assembly Service Notes :
Removing the Signal Motor Shaft/Signal Rotor

Type I Distributor
Drive the signal rotor shaft from the signal rotor.
Removing the Drive Gear

1. Put match marks on the distributor shaft and drive
gear.
2. To remove the lock pin, place the drive gear on a soft
block (such as a wooden block).
3. Drive the lock pin out with a pin punch.
Installing the Drive Gear

Inset the drive gear into the distributor shaft so that match
Disassembly Steps (Type I)
marks placed before removal are aligned with each other.
1. Breather 12. Breaker plate
2. Distributor cap 13. Spring retainer ! CAUTION
3. Packing 14. Governor spring When the pin is driven in, the slit must be
4. Contact carbon 15. Governor weight positioned at right angles to the shaft.
5. Rotor 16. Lock pin
6. Vacuum control 17. Drive gear
7. Grounding wire 18. Washer
8. Lead wire 19. O-ring
9. Igniter 20. Distributor shaft
10. Rotor shaft 21. Distributor housing
11. Signal rotor

Installing the Breaker Plate

Install the breaker plate with its projection A seated in
groove B.
Installing the Signal Rotor

Install the signal rotor over the rotor shaft, making sure
that the rotor dowel pin is seated in the groove.
IMPORTANT
After reassembly, set the pick-up air gap as
shown in Section 3 of this Group.
12-4-4 • Distributor Overhaul SM 661, Aug ’01

Type II Distributor IMPORTANT

After reassembly, set the pick-up air gap as
Disassembly Steps (Type II) shown in Section 3 of this Group.
1. Breather 8. Heat sink

2. Distributor cap 9. Breaker assembly
3. Rotor 10. Vacuum control
4. Cover 11. Connector
5. Signal rotor 12. O-ring
6. Pick-up coil assembly 13. Distributor housing
7. Ignitor

GROUP 13
GROUP 13
ELECTRICAL SYSTEM
Cautions for working on the electrical system Section 1
Specifications and features of

electrical system ..................................................Section 2
Electrical wiring diagram & Arrangement

of electrical components .....................................Section 3
Instrument Pod ....................................................Section 4
Specification and operation of electrical

components ..........................................................Section 5
Troubleshooting of electrical system .................Section 6
SM 661, Aug ’01 Group 13, Electrical system

Group 13, Electrical System
Section 1
Cautions for working on the electrical system
As checking the electrical components − Remove the jumper (-) cable from the engine body
of the discharged machine.
As working or checking on the electrical components − Remove the other end of jumper (-) cable from the
make sure to study the features and specifications of rele- battery (-) terminal of the running engine.
vant components in advance so that the possibility of acci- − Remove the jumper (+) cable from the battery (+)
dent will be avoided. terminal of the running engine.
− Remove the other end of jumper (+) cable from the
Cautions for welding battery (+) terminal of the discharged machine.
Any electrical components on the machine may be dam-

aged by the high-voltage current occurred as welding. If
the welding shall be worked on the machine, therefore,
disassemble the (-) cables from the battery in advance.
Start-up with jumper cable

When the machine cannot be started up as the battery has
been discharged, make use the jumper cable to start-up.
Proceed as followings:
As connecting the jumper cables

− Connect one end of jumper (+) cable to the battery
(+) terminal of the discharged machine.
− Connect the other end of jumper (+) cable to the
battery (+) terminal of the running engine.
− Connect one end of jumper (-) cable to the battery
(-) terminal of the running engine.
− Connect the other end of jumper (-) cable to the
engine body of the discharged machine.
! CAUTION
Confirm the clips of jumper cable are
secured on the terminals.
Try to start up only when there is no problem
on the connection of jumper cables.
Never make the jumper (+) cable and the
jumper (-) cable contact each other.
As removing the jumper cables

− For removing the jumper cables, take working as
reverse order of connecting.
SM 661, Aug ’01 Cautions for working on the electrical system • 13-1-1
Section 2
Specifications and features of electrical system
Features of electrical system Battery

The electrical system of C20 model is consisted of start- • Gasoline/LPG
up circuits, instrumental panel and auxiliary circuits. Input − Type: 12Volt 60AH
and output of most circuits will be controlled by micro − Cold start current: 550Amp (18 degrees below
processor within the instrumental panel. zero)
− Capacity: 100minutes (27 degrees)
Start-up circuit • Diesel
− Type: 12Volt 100AH
The start-up circuit is consisted of electric power circuits − Cold start current: 800Amp (18 degrees below
such as engine start-up, battery charging, etc. zero)
− Capacity: 180minutes (27 degrees)
Instrumental panel
Start motor
The monitor circuit makes the operator to check the oper-
ational condition of machine always as concentrating the • Gasoline/LPG
required indicators. It indicates fuel level, engine temp., − Specification: 12Volt 1.2kW
battery level, work hour and failure of sensors. Addition- • Diesel
ally, monitoring for safe operation and controlling of − Specification: 12Volt 2.3kW
input/output will be functioned in accordance with the
condition of machine and or signal manipulated by the
operator. It is possible that starting at neutral position, pre-
vention of restart, restricted travel when parking and auto-
matic engine stop as critical failure.
Auxiliary circuit
The auxiliary circuit is consisted of lamps, horn and warn-
ing devices. It will be “ON” and “OFF” by the operator
according to the operational condition.
Specification
Voltage and Earthing

System voltage: 12Volt
System earthing: Engine body (Gasoline/LPG) or Trans-
mission (Diesel)
SM 661, Aug ’01 Specifications and features of electrical system • 13-2-1

Section 3
Electrical Circuit Diagram & Electrical Parts Arrangement
SM 661, Aug ’01 Electrical Circuit Diagram & Electrical Parts Arrangement • 13-3-1
Electrical Circuit Diagram

• Diesel
13-3-2 • Electrical Circuit Diagram & Electrical Parts Arrangement SM 661, Aug ’01
• Gasoline & Gasoline/LPG (Dual Fuel)
• LPG
Electrical Parts Arrangement
Electrical Devices
• Diesel
• Gasoline
• LPG
• Gasoline & LPG (Dual)
Instrument Pod
• Diesel
• Gasoline/LPG/Gasoline & LPG Dual
Lights
Battery Assembly
• Diesel
• Gasoline/LPG/Gasoline & LPG Dual
Section 4
Instrument Pod
6 7 8 9 10 11 12 13 14
15
2
5
4
3
16
17
19 18
1. Coolant Temperature Gauge 10. Hour Meter

2. Fuel Gauge 11. Optional
3. Transaxle Oil Temperature 12. Optional
4. Hydraulic Oil Filter (Optional) 13. Glow Plug Preheat
5. Engine Oil Pressure 14. Seat Belt
6. Air Filter (Optional) 15. Parking Brake
7. Alternator Charging Status 16. Work Lamp Switch
8. Service Icon 17. Rear Work Lamp Switch
9. Turn Signal 18. Strobe light switch
19. Function Key F1/F2
SM 661, Aug ’01 Instrument Pod • 13-4-1

Pod Symbols and Functions 5. Gauges and indicators

• Coolant temperature gauge
hot Five LEDs indicates
Functions whether engine coolant is in
norm cool (Blue), normal(two
1. General function
Green, Yellow), or hot (Red)
The instrument pod consists of indicator lights, an cold range. If the indicator regis-
hour meter, a circuit board and attached gauges. Pro- FX1186
ters in the cool (Blue) is still
vides the operator with important information about
on in 5 minutes when the
truck condition and shut down the truck in the event
engine is running, there is a problem with the gauge,
that certain critical conditions are present.
sender, or wiring harness. If the indicator registors in
2. Engine shutdown function the hot (Red) range, shut down the truck and have it
The instrument pod circuit board receives signals serviced.
from sensors in various locations and shut down the
• Fuel gauge
truck when coolant temperature, transaxle fluid tem-
* Diesel and Gasoline truck
perature are excessive or engine oil pressure is low.
Indicates fuel level remaining
Before shutting down the truck, the instrument pod
in the tank.
sounds alarm for 30 seconds and flashes indicator
lights. After shutdown, the truck may be restarted, LED Color Volume of Fuel
but if the fault condition persists, the truck is shut Green 80% above
down again in 30 seconds. FX1177 Green 60% above
Green 40% above
Seat switch application (optional)
Yellow 20% above
The instrument pod shuts down the running truck
Red 20% below
without warning when the operator leaves the seat
Red LED 10% below
over 3 seconds with the FWD/REV switch is
flashes
engaged. Directional switch must open and key
switch must always be turned OFF, to restart engine. * LPG Truck
When directional switch is open and parking brake is All 3 green LEDs will light up when LPG tank
not engaged, if the operator leaves a seat, after 3 sec- pressure is above 20 PSI and 1 red LED will
onds, the instrument pod will sound buzzer, and then turn ON and flash when the LPG tank pressure
honk horn. is lower than 20 PSI.
Setting the parking brake shall reset the alarm.(The
LED Color Volume of Fuel
engine is not shut down.)
Green LPG tank is full, three green
3. Neutral start function and Anti-restart function LEDs are on.
Neutral start function Green
The instrument pod will not allow the stater to be Green
engaged if directional switches are closed or key has Yellow Not used
been in start position once. Key switch must always Red LPG tank is empty (when pres-
be turned OFF to restart engine. sure switch is engaged), red LED
is on and flashes.
Anti-restart function
When engine is already running, the start motor does • Transaxle oil temperature
not rotate although the key switch is turned start Indicates that the transaxle oil tempera-
position. ture is excessive. If the light is on, shut
down the truck and service it. The truck
4. Anti-drive and parking brake reminder function
will go into shut down mode after the
When parking brake is engaged, the truck cannot be
light flashes for 30 seconds. (the buzzer
driven although the directional switch closed. A
sounds)
parking brake alarm shall be activated if key switch
is turned to the OFF position and the parking brake
is not applied. Applying the park brake will reset the
alram.
13-4-2 • Instrument Pod SM 661, Aug ’01

• Hydraulic oil filter (optional) • Optional

Indicates that the main hydraulic system
filter is dirty, restricting fluid flow. If the
light stays on, change the filter element.
Occasional flickering of the light does
not indicate a problem. • Optional
• Engine oil pressure
Indicates engine oil pressure is too low.
If the light is on, shut down the truck and
service it. The truck will go into shut
down mode after the light flashes for 30 seconds. • Glow plug Preheat (Diesel truck)
(the buzzer sounds) Indicates glow plugs are in the process of
preheating the diesel engine. When the
• Air filter (optional) ignition switch is turned to the “ON”
Indicates that the air filter element is position, a timer is set. This symbol dis-
dirty, restricting air flow. If the light
FX1179
plays until the timer cycle is completed.
stays on, change the filter element. Occa- The engine may then be started.
sional flickering of the light does not
indicate a problem. • Seat belt
At start-up, this light and a buzzer come
• Alternator charging status on for three seconds to remind the opera-
Indicates that the alternator is not prop- FX1178
tor to fasten the seat belt. There is no
erly charging the battery. Service is start interlock.
required to correct the problem.
IMPORTANT
• Service icon
You should always have your seat belt
LED will illuminate when pre-set service
securely fastened when operating your lift
time is reached. When LED is on, the
truck.
FX1184
pre-set service time has been reached
indicating that a PM is required. Refer to
• Parking brake
Service Manual for proper PM proce-
Indicates that the parking brake is
dures. Pre-set service time setting method - initial-
engaged. Anytime the parking brake is
ized by “key on + FWD + F1 + F2”, service time
on, the truck can’t be driven because the
display at hour meter. Here, F1 is for up set, F2 is for
transaxle solenoid valves switch is off. When the
down set (with interval times of 50 hours). When the
parking brake is not set and the key switch is turned
key switch is turned OFF, the pre-set service time
to the OFF position, the instrument pod will sound. If
setting time is saved. Pre-set service time counts
the parking brake is set, buzzer and horn will not
down opposite to operating time. To disable the Ser-
sound.”
vice Icon, set the pre-set service time to “-1000”
(display 1 0 0 0 ); If you push the F2 switch when • Work lamp switch
setting the pre-set service time, the time will be This switch is for the work lamp ON/
adjusted to “-1000”. OFF. Push the switch to turn the work
lamp ON. Push it again to turn the lights
• Turn signal
OFF. If the operator turns the key switch OFF, the
Indicates that the turn signal switch is
lights will be turned OFF automatically after 10 min-
actuated.
utes.
• Rear work lamp switch
• Hour meter This switch is for the rear work lamp
Indicates total engine oper- ON/OFF. Push the switch to turn the rear
ating time. Operating time work lamp ON. Push it again to turn the
is recorded only when the lights OFF. If the operator turns the key
engine is running. It is possible to make sure operating switch OFF, the lights will be truned
status through the hour meter indicator. OFF automatically after 10 minutes.

• Strobe light switch

When the work lamp switch and rear
work lamp switch are on at the same
time,strobe light is on./ Push two
switches again, and the strobe light is off.
• Function key F1/F2
Use these switches for setting the pre-set
service time. Refer to Service Icon
description for use instructions.
13-4-4 • Instrument Pod SM 661, Aug ’01

Connector Terminal Arrangement
PIN 31 PIN 40
PIN 21
PIN 30
PIN 11
PIN 20
1 2 3 4 5 6 7 8 9 10
Pin No Wire Color Remark Pin No Wire Color Remark

1 LW 485+ 21 RG Head & Tail & Lic RH
2 LB 485- 22 WB Charger
3 GY T/Sig LH 23 G P/Brake Switch
4 GR T/Sig RH 24 R IG
5 LW REV 25 GY Horn
6 - - 26 YR Hydraurk Filter
7 G Horn Switch 27 YG Gas/LPG Switch
8 GB Seat Switch 28 - -
9 YW E/Oil Pressure 29 GW Strobe Light
10 YG T/Oil Temp 30 RB Head & Tail LH
11 RY Rear Work 31 R B+
12 W Engine Shutdown 32 R B+
13 L Stop Switch 33 RB Start Relay
14 LR FWD 34 - -
15 RW Start 35 B GND
16 GR Air Filter 36 B GND
17 YR Engine Coolant Temp 37 - -
18 YL Fuel Sender 38 - -
19 RL Stop Light 39 R B+
20 LW Backup Alarm & Light 40 R B+

Section 5
Specification and Operation of Electrical Components
SM 661, Aug ’01 Specification and Operation of Electrical Components • 13-5-1

Battery
Function
As a part for supplying main electrical power of equipment, battery supplies 12V to all of electrical devices and enables
them to operate, also saves the electricity generated from alternator.
Diesel
Diesel Specification
Voltage 12(V)
Capacity (20 HR) 100(AH)
Reserve Capacity 180(MIN)
Cold Cranking Performance 800(A)
Gasoline/LPG Specification
Voltage 12(V)
Capacity (20 HR) 60(H)
Reserve Capacity 100(MIN)
Cold Cranking Performance 550(A)
! CAUTION
- Battery terminal is always to be assembled tightly. Any loosen parts cause failure of starting or spark to
electrical parts, causing severe damages or a fire to various electrical parts.
- You can not start engine well due to bad battery performance in cold operation, place forklift inside of
plant or in warm place after operating.
- Be careful not positive (+) terminal of battery to be touched with body in repairing or checking forklift.
Some sparks can cause severe damage or a fire to electrical parts.
- When disconnecting battery terminal, first disconnect negative (-) terminal prior to disconnecting posi-
tive (+) terminal. When assembling it, in reverse, first assemble (+) terminal prior to (-) terminal.
- Battery electrolyte consists of thin acid solution. Protect your body from it. If battery electrolyte reduced
below fixed amounts, refill it with distilled water.
13-5-2 • Specification and Operation of Electrical Components SM 661, Aug ’01

Engine Accessories
Alternator
Function
As a device generating electrical power by revolution force of engine, in normal condition, it supplies generated voltages
of about 13-15V to equipment and charges a battery.
Diesel
Circuit
Rating : 12V, 40A
Gasoline/LPG
Circuit
Rating : 12V, 50A

Starting Motor
Function
When electrical power is supplied to start coil of starting motor, the starting motor is rotated and it enables engine to
rotate as results.
Diesel
Rating : 12V, 2.0KW Circuit
Gasoline/LPG
Circuit
Rating : 12V, 1.2KW

Water Temp Sender

Function
This water temp sender is a device detecting coolant temp inside engine. This displays engine temp to operator through
instrument panel gage by using changes of resistance values depended upon temp changes.
Diesel
Specification
Resist.
Temp (°C) Resist (.Ω)
+25.0
50 153.9-20.0
80 51.9 -+4.9
4.4
100 27.4 -+1.9
1.2
120 16.1±1.2
LPG/Gasoline
Specification
Temp (°C) Resist (.Ω)
Resist.
38 190
54 109
65 74
77 54
88 40
99 30
110 24
116 21
120 17.2
Testing
Measure resistance with multi-tester as fig above and compare the resistance values depended upon coolant temp with
specification table.

Switch-Eng Oil Pressure

Function
It is a switch to sense whether to be normal for ENG oil pressure.
If pressure is more than setup value, output is open and as less than, it is shorted.
Diesel
Resist. Specification
As turn ENG 1(MΩ) or more
As stop ENG 0Ω
LPG/Gasoline
Specification
Resist.
As turn ENG 1(MΩ) or more
As stop ENG 0Ω
Testing
Measure resistance with multi-tester as fig above and inspect open or short. Commonly it displays short due to low pres-
sure when engine stop, and open when engine rotations respectively.

Eng Stop Motor (Diesel)

Function
It functions open and shut off a fuel shut-off valve to engine. If start switch is on, engine stop motor is rotated and as
results fuel shut-off valve is open. In reverse, if start switch is off, engine stop motor is rotated in reverse and as results
fuel shut-off valve is shut off.
Start switch
Relay
Fuse
Battery
Eng Stop Motor
Circuit
Functional Descriptions
In start switch off, a motor is not operated since battery voltage is not applied to ground of engine stop motor as fig above.
When start switch on, engine stop motor relay is on, relay COM terminal and N/O terminal are connected each other,
electrical power is flowed in sequence of battery-fuse-relay-engine stop motor (A)-stop motor (B-)-ground, as results stop
motor is rotated. At this time fuel shut-off valve is opening. When stop motor is rotated as much as about 180°, stop motor
inner switch is shut off. Simultaneously electrical power of stop motor is shut-off, stop motor is stop in conditions of fuel
shut-off valve open. When start switch off, relay is off, COM terminal and N/C terminal are connected each other, electri-
cal power is flowed in sequence of battery-fuse-stop (A)-stop motor (B)-relay COM-Relay N/C-ground, as results stop
motor is rotated. When stop motor is rotated as much as about 180°, the motor is stop since inner switch is connected to
stop motor (C) and electrical power is shut off. At this time, fuel shut-off valve is shut off and no fuel is supplied, engine
stops as results.

LPG Pressure Switch

Function
A switch to be ON/OFF depended upon LPG pressure in LPG tank. This switch is on when LPG pressure drops down by
fuel consumption.
Resist
Specification
Item Spec Pressure Resist (Ω)
Switch operating temper- 40±4 PSI (open) 40 PSI More Open (1M Ω more)
ature 40 PSI Less 0
Testing
Measure resistance with multi-tester as fig above and inspect open or short. It will be short when pressure is lower than
specification, and be open when pressure is higher than specification. (Open in case of full of LPG, short in case of
empty).

Switch-T/M Temp
Function
This is a switch to sense T/M oil temp. This switch is open in normal condition and is on when temperature is reached to
setup values.
Resist.
Temp Resist. (Ω)

121°C More 0Ω
121°C Less Open (1MΩ more)
Specification
Item Spec.
Switch-start temp 121/±/3°C
Switch-reset temp Avg. : 110°C
mini. : 105°
Ass’y torque 45-55Nm
Testing
Measure resistance with multi-tester as fig above and inspect open or short. It will be open when temperature is lower than
one in specification, and be 0 (Ω) when higher than specification.

Fuel Sender
Function
This detects amounts of fuel in fuel tank and enables that to be displayed on fuel gage of instrument panel. When float
moves upward and downward depended upon amounts of fuel, The resistance value is outputted depended upon heights.
Resist.
Specification
Item Spec
Switch operating temper- 40±4 PSI (open)
ature
Specification
Item Full 50% Empty
Resistor 28±2 (100) 244
Value(SL)
Floot 48 238 365
Length
(mm)
Testing
After removing fuel sender measure resistance value according to heights requirement of specifications.

Switches
Start Switch
Function
This Functions starting of forklift and supplying electrical power to some electrical parts.
Common key Start Switch
Specification
Item Spec.
Rated voltage DC 14V
ON current 8A, Heavy Duty Ignition Coil
START current 20A, Continuous
75A, Instantaneous
Individual key Start Switch
Specification
Item Spec.
ON current 20A, Continuous
START current 75A, Instantaneous

Switch Fwd. & Rev.

Function
This Functions to select travel direction of forklift. It is operated with three modes of neutral, forward, reverse.
Reverse Switch Forward Switch
Specification
Lever COM (G)-Fow. (R) COM (G)-Rev. (L)
Neutral Open Open
Forward 0Ω Open
Reverse Open 0Ω
Resist.
Horn(G) Reverse(LW)
COM(RW) Forward(LR)
Circuit

Switch - Indicator
Function
This functions to operate R/L direction indicator lamp.
Resist.
Right lamp-indicator start

COM
Left (YG) (LW)
COM (LW)
Left(YG)
Neutral Right (YR)
Right(YR)
Left lamp-indicator start
Circuit
Specification of switch - start

Lever COM (LW)- Left (YR) COM (LW)- Left (YG)
Neutral Open Open
As right start 0Ω Open
As left start Open 0Ω
Testing
Check for switch operation as specifications with multi-tester.

Brake Stop Switch

Function
This switch will be ON/OFF in turns by brake pedal.
Resist.
Brake ON
Brake OFF
Specification of switch - start (device ass’y condition)

Brake Output
ON 0Ω
OFF Open
Circuit (in removing)
Testing
When measuring resistance with multi-tester as fig above in condition of brake pedal released, the stop switch shall be off
and, and it shall be on when pressing pedal in reverse.

Parking Brake Switch

Function
This switch consists of two switches and functions respectively. Switch 1 communicate On/Off signal of parking brake to
instrument pod. Switch 2 is connected to F/R solenoid ground wire in series and limits traveling of forklift.
Switch 1
Resist.
Switch 1
Switch 2
Resist.
Switch 2
Switch 1 Switch 2
Circuit
Specification of switch - start (device ass’y condition)

Parking brake Switch 1 Switch 2 Drive
Removal Open 0Ω Possible
Parking 0Ω Open Impossible
Testing
Measure resistance according to switch operation specification by positioning multi-tester to resistance mode.

Seat Switch
Function
This functions to sense whether a driver takes a seat or not.
Resist.
Testing
Conditions Output
As taking a seat 0Ω
As standing up at seat Open

General Electrical Parts
Fuse / Relay Box

Function
This functions to prohibit electrical parts from damaging due to over-current.
F / UNIT
Relay
Specification
No. Capacity Contents No. Capacity Contents
F1 10A POD Battery+ F12 10A Directional Switch
F2 10A POD Battery+ F13 10A Fuel Pump (Gas/LPG only)
F3 10A POD Battery+ F14 10A Heater
F4 10A POD Battery+ F15 15A Wiper Motor
F5 10A STOP Switch F16 10A Optional
F6 10A T/Signal Light Spare1 10A
F7 10A STOP Motor(DSL Only) Spare2 10A
F8 10A ROOM Lamp Cassette Spare3 10A
F9 10A Ignition Spare4 15A
F10 10A Park Switch F/Unit
F11 10A Horn Relay
! CAUTION
Use only fuse of standard capacity in accordance with specification.
Using of fuse exceeding capacity cause severe damages to electrical parts.

Engine Stop Relay

Function
This relay supplies electrical power to engine stop motor(diesel) and start coil(gasoline/LPG) when turning start switch
on. Forklift can be started only when engine stop relay is operated.
Resist.
Circuit
Specification
Item Spec.
Rated load NO : 20A

NC : 15A
Testing
1. Position multi-tester to resistance mode and measure resistance between both terminals as above. Normal : 85±5Ω

Flash Unit
Function
This supplies ON/OFF outputs in order that lamp-indicator is blinked in regular interval.
Specification
Item Spec.
Rated voltage DC 12.8V

Start voltage DC 11~15V
Use temp. -20°C~60°C
Frequency 85 ± 20 C/MIN
Rated load MIN : 10(W)
MAX : 50(W)
Operation Descriptions
When applying 12V to B terminal, 85±20 C/MIN are output-
ted to output terminal (L) in the form of ON/OFF.
Load
Wiring Diagram

Start and Preheat Relays

Function
Start relay supplies electrical power to starting motor when starting engine. Preheat relay supplies electrical power to pre-
heat plug of diesel engine.
Resist. Circuit
Specification
Item Spec.
Current capacity 70A, 85°C

Coil resistance 72 ± 7Ω
Min. Start voltage 7.2V
Testing
When measuring with resistance mode, coil resistance value depicted on specification shall be measured.

Horn
Function
As alarm unit, this sounds with set-up sound pressure when turning horn switch on.
Battery
Specification
Item Spec.
Rated Current 3.5A, Max
Sound Pressure 110 ± 5dB
Frequency 415 ± 20Hz
Testing
When applying 12V to both terminals of horn as above, sound pressure in specifications (110 ± 5dB) shall be measured.

Backup Alarm
Function
This functions to alarm for reverse traveling by sounding.
Battery
Specification
Item Spec.
Sound Pressure 100 ± 5dB
Frequency 1000 ± 50Hz

Lights
Lamp-Work
Function
In case of working at night, this ensures forward or backward sights.
Battery
Specification
Item Spec.

Bulb spec. 55W, H3
Testing
Check work lamp for good conditions by applying 12V as fig above.

Lamp-Indicator
Function
This displays forklift's driving directions to left and right.
Battery
Specification
Item Spec.
Bulb spec. 10W
Testing
Check indicator lamp for good conditions by applying 12V as fig above.

Combination Lamp
Function
This functions to turn on indicator, reverse, brake and tail lamps.
Specification
Item Spec.

Stop/Tail : 23W/8W
Bulb spec. Turn Signal : 23W
Back : 10W
Testing
Check bulb condition inside of combination lamp and replace if required.

Lamp-Beacon
Function
This, by use of strobe lamp, functions to alarm to surroundings during working.
Battery
Specification
Item Spec.
Bulb spec. 2.5W, Max
Frequency 80~100 / Min
Testing
Check beacon lamp for good conditions by applying 12V as fig above. (Be sure to identify battery +/- terminals when
applying voltage. Connecting terminals in the opposite cause severe damages to parts.)

Section 6
Troubleshooting of Electrical System
SM 661, Aug ’01 Troubleshooting of Electrical System • 13-6-1

Troubleshooting
Fuel Gauge Malfunction
Fuel gage is not operated

properly.
(Key-OFF)
Disconnect the fuel sender

connector.
Attach the multi-meter (resistance mode) to two terminals

of fuel sender connector and measure the resistance.
Assemble the fuel sender connector and than

Are resistance values
disconnect the instrument pod connector.
28 to 244Ω?
Yes
No Measure the resistance between the frame

and No. 18 YL of connector at the cowl wire.
Fuel sender couldn't be operated
properly. Repair or replace it.
Replace the
instrument Is there any resistance?
pod.
Yes The value shall
be corresponded
to the resistance
No value.
There are some problems in wires.

End Check for broken or short-circuit and
then take measures.
13-6-2 • Troubleshooting of Electrical System SM 661, Aug ’01

Hourmeter Malfunction
Hourmeter failed to operation
Reference : Hourmeter may not be operated for

first 5-10 sec. after engin start. Hourmeter operats
Turn start switch ON.
only when the engine oil pressure is preheated
enough.
Is oil pressure Repair the oil pressure indicator

indicator turned ON? or the sensor.
Yes
(Refer to Engine oil gage malfunction.)
No
Replace the instrument pod.
End

Coolant Temp Gage Malfunction
Coolant temp gage will not

operate properly.
Disconnect the coolant temp

sensor connector from the engine.
Measure resistance values between the frame and the

coolant temp sensor terminal mounted on the engine.
Assemble the connector at engine properly

Are resistance values and disconnect the instrument pod
17~150Ω? connector.
Yes
No Measure resistance values between the frame

and No. 17 YR of connector at the cowl wire.
Temp sensor will not operate
properly.
Replace the
Are resistance values
instrument
17~150Ω?
pod.
Yes
No

then take measures.

Transaxle Oil Malfunction
Transaxle oil temp warning

operates.
Disconnect the connector from

transaxle.
Assemble transaxle connector properly and

Does the transaxle oil disconnect instrument pod connector.
temp warning still operate?
Yes
No Measure resistance values between the frame

and No. 10 YG of connector at cowl wire.
There are some problems in
transaxle. Check for it.
Replace the
Is resistance value 0Ω?
instrument
pod.
No
Yes

then take measures.

Engine Oil Gage Malfunction
Engine oil pressure LED

operates.
Disconnect the oil pressure

sensor connector from engien.
Assemble engine oil pressure connector

Does engine oil properly and disconnect instrument pod
pressure LED still connector.
operate? Yes
No Measure resistance values between frame

and No. 9 YW of connector at cowl wire.
engine oil pressure. Check for it.
Replace the
Is resistance value 0Ω?
instrument
pod.
No
Yes

then take measures.

Alternator Charge Malfunction
Alternator charging LED operates.

(Key ON)
Measure voltage of alternator L

Disconnect L terminal from alternator.
terminal(WB).
Key OFF
No
Position the key switch ON and measure

voltage between frame and WB of wire.
Are measured
voltages 13~15V?
Yes Is the measured voltage

Yes identical to battery
voltage?
Replace instrument pod.
No
Measure voltage between frame and No 22

There are some problem in WB of connector at cowl wire under the
alternator. Repair alternator. connector assembled conditions.
Replace the Is the measured voltage

instrument identical to battery
pod. voltage?
No
Yes

then take measures.

Preheat Plug Malfunction

(Applicable to diesel engine type only.)
Preheat plug LED operates Preheat plug LED does not

continuously. (more than 15sec) operate. (When key ON)
Leave for 20 sec or more with With key switch ON, check
key switch ON. preheat plug light is on.
Does preheat Is preheat plug light

plug still ON, and then OFF
operate? No within 15sec?
Yes Yes
Replace the instrument pod. Normal condition.
End End

Parking Brake Malfunction
Parking brake lamp(LED) will

not operate properly.
Disconnect the parking brake

switch connector.
Does parking lamp Disconnect connector at cowl wire and measure

still operate? voltages between frame and No 26(R).
(With disconnected parking brake connector)
Yes
No
There are some problems in brake

switch. Check for switch assembled
and operating condition and then Is the measured voltage
take appropriate measures. identical to battery
voltage?
No
Replace the
instrument
pod.
Yes

then take measures.

Work Lamp Switch Malfunction
Work lamp fails to turn ON or

OFF when operating switch.

work lamp.
Connect multi-meter(voltage mode) to two terminals of OHG

connector, and then measure voltage. (Measure after pressing
switch repeat 2 times)
Is the measured voltage Measure voltages between frame and No 30(RB)

identical to battery voltage? or No 21(RG) of connector at cowl wire.
(Measure after pressing switch - Repeat 2 times)
No
Yes
Work lamp does not operate

properly. Repair or replace it. Can you measure battery
voltage when pressing
switch?
Replace the
instrument
pod.
No
Yes

then take measures.

Rear Work Lamp Switch
Rear work lamp fails to turn ON or


rear work lamp.

connector and measure voltage. (Measure after pressing
Is the measured voltage Measure voltages between frame and No 11(RY)

identical to battery voltage? of connector at cowl wire.
No
Yes
Rear work lamp does not operate

switch?
Replace the
instrument
pod.
No
Yes

take measures appropriately.

Beacon Lamp Switch Malfunction
Beacon lamp fails to turn ON or


beacon lamp.

connector and measure voltage. (Measure after pressing
Is the measured voltage Measure voltages between frame and No 29

identical to battery voltage? (GW) of connector at cowl wire.
No
Yes
Beacon lamp does not operate

switch?
Replace the
instrument
pod.
No
Yes

take measures appropriately.

All of Instrument Pod Lamps Fails to Turn On
When start switch is ON,

Instrument panel lamp fails to turn on.
Yes
Are there any damages to Replace fuse. End
F9 fuse in fuse box?
No
Measure voltage of F9 No Check for start switch and

fuse. Is the value 12V? connections of battery cable.
Yes
Disconnect instrument panel No

connector. Are voltages between There are some problems in wires.
frame and 24R of connector at Repair it.
cowl wire 12V?
Yes
Measure resistance between No

frame and 35 and 36B of instrument There are some problems in GND
panel connector. Is the value 0Ω? wire. Repair it.
Replace the instrument pod.
End

Failure to Drive
Forklift fails to drive in spite of F/R

lever operation after starting.
No Drive it after
Is the parking brake End
releasing parking
released?
brake.
Yes
Is F12 fuse in fuse No Replacee it.

box normal?
Yes
Disconnect solenoid F/R cowl

connector and check wire for permitted No Check for travel limit S/W of
voltage. In forward-Forward solenoid 12V parking brake S/W.
In Reverse-Reverse solenoid 12V
Is it normal?
Yes
There are some problems in solenoid

valve or transaxle.
Take appropriate measures.
End

Failure to engine shut down (Diesel)
*If you want to shut down engine by force:

Forklift fails to shut down even though 1 : Check for F7 fuse, and replace it if burn.
start switch off. 2 : First disconnect engine stop motor and then
short COM and NC terminals of relay with wire.
No
Is F7 fuse in fuse box Replace it. End
normal?
Yes
Yes Check for start switch.

Is voltage of F9 fuse
(When F9 fuse removed, engine will be
in fuse box 12V?
shut down.
No
Is voltage of No 12 wire
No Is voltage of No No
of instrument pod 12V?
36 GB of stop
(Measure the voltage under
motor 12V?
assembled condition.)
Yes
Yes
There are some problems in stop
motor. Check for it.
Is voltage of No 12W No
wire 12V, after connector
removing?
There are some
problems in wires
Take appropriate
Yes Replace instrument measures.
pod.
Short-circuit is occurred to No 34W
wire with power source terminal.
Take appropriate measures.
End

Failure to engine shut down (GAS/LPG)
*If you want to shut down engine by force:

Forklift fails to shut down even though 1 : Disconnect engine shut down fuse from fuse box.
start switch off. 2 : Disconnected F9 fuse from fuse box.
3 : Disconnect IG wire connected to engine.
4 : Remove all spark plugs.
Start S/W OFF
No
Is F9 fuse in fuse box Replace fuse. End
normal?
Yes
Yes Check for start switch.

Is voltage of F9 fuse
(When F9 fuse removed, engine will be
in fuse box 12V?
shut down.)
No
Disconnect engine stop There are some problems in No 33

Yes
motor relay from fuse RY wire (Short-circuit with power
box. (Engine shut down?) source wire occurred). Take
appropriate measures.
No
Disconnect No 35 Y There are some problems in No 35

wire connected to Yes
Y wire (Short-circuit with power
engine. Engine shut down? source terminal occurred)
No

starter coil system of engine. If all spark plugs removed,
Check and take appropriate engine will be shut down.
measures.

Failure to Start (GAS/LPG)
When turning start switch to START,

it fails to start.
No Make sure the position of F/R lever in

Is start motor rotated? neutral, operation of start relay, and
(When starting) connections of battery cable. Check the
start motor.
Yes
Measure battery voltage There are some problems in

No
after starting 3-4 times. battery charge conditions. Check
Is battery voltage more and charge battery if required.
than 11V?
Yes
When start switch On, is Yes Check for starter coil of engine,
voltage of IG wire of distributor and spark plugs.
engine 12V?
No
If engine shutdown relay operated

Is F13 fuse in fuse Yes properly (start switch ON), check
box normal? No 35 wire and IG wire for broken
and repair if required. Check
voltage of No 12 W of instrument
panel connector, if the voltage is
No 12V, check for relay. If not, replace
instrument panel.
Replace fuse.
End

Failure to Start (Diesel)
When turning start switch to START,

it fails to start.
No Make sure the position of F/R lever in

Is start motor rotated? neutral, operation of start relay, and
(When starting) connections of battery cable. Check the
start motor.
Yes
Replace
fuse.
Is engine stop motor,
mounted to left of engine, rotated? No Is F7 fuse in fuse No
(Check the motor rotation visually box normal?
when start switch ON.)
Yes
Yes Is relay operated No

properly? (Key ON)
Measure battery voltage No

after starting 3-4 times. Yes
Is it more than 11V?
If voltages between No
12W of instrument panel
and frame is 12V, check
There are some
for relay, or replace
problems in battery
instrument panel if
charge conditions.
required.
Yes Check and charge
battery if required.
Check for fuel
supply system.
Check voltages between Y wire and
frame after disconnecting stop
motor connector. If the voltages is
12V, check stop motor or replace it
End if required. If not, check resistance
between COM terminal of relay and
Y wire of stop motor, and check
wire for broken or relay conditions
when resistance is 0Ω.

GROUP 22
GROUP 22
WHEELS AND TIRES
Wheels and Tires Specifications and

Description ............................................ Section 1
Cushion Wheels and Tires .........................Section 2
Pneumatic Wheels and Tires ....................Section 3
SM 661, Aug ’01 Group 22, Wheels and Tires

Group 22, Wheels and Tires
Section 1
Wheels and Tires
Steer Tire Types : Pneumatic rubber/Cushion rubber, non- The wheels and tires used on the truck come in pneumatic
marking, and urethane. or cushion types in a variety of sizes depending on truck
model and application. Pneumatic tires are mounted on
Drive Tire Types : Pneumatic rubber/Cushion rubber, non-
multi-piece rims with locking rings.
marking, and urethane.
Pneumatic Drive and Steer Tire Inflation Pressure : ! WARNING
Drive 20/25: 1000 kPa (145psi) For your safety and the safety of others,
30: 965 kPa (140psi) before you do tire or rim maintenance or ser-
vice, read the OSHA rules regarding owner
Steer: 861 kPa (125psi) responsibility. Do not work on tires or rims
unless you have been trained in the correct
Fastener Torques procedures. Read and understand all mainte-
nance and repair procedures on tires and
Steer Tire Mounting Nut Torque : Check mounting proce- rims. Serious injury or death can result if
dure in Sections 2 and 3 for cushion and pneumatic tires safety messages are ignored.
and wheels.
The Occupational Safety and Health Act (OSHA) speci-
Drive Wheel Mounting Nut Torques :
fies required procedures for servicing multi-piece rim
1 Piece (black) 640-720 N⋅m (470-530 ft⋅lb) wheels in 29 CFR Section 1910.177. It is the owner’s
responsibility to comply with OSHA.
Service Intervals In accordance with OSHA, the owner must provide a
Wheel Mounting Bolts Check and Tightening : Every 50- training program to train and instruct all employees who
250 hours of operation and each PM. service multi-piece rim wheels in the hazards involved
and the safety procedures to be followed. Do not let any-
Tire Condition : Daily inspection. one mount, demount, or service multi-piece rim wheels
Tire Pressure Check : Daily inspection. without correct training.
The owner should obtain and maintain in the service area
current copies of the United States Department of Trans-
portation, National Highway Traffic Safety Administra-
tion publications entitled “Safety Precautions for Mount-
ing and Demounting Tube-Type Truck/Bus Tires,” and
Multi-Piece Rim/Wheel Matching Chart” or other similar
publications applicable to the types of multi-piece rim
wheels being serviced.
SM 661, Aug ’01 Wheels and Tires Specifications and Description • 22-1-1
Section 2
Cushion Wheels and Tires
3. Check tire for damage from chunking or heat dam-

! CAUTION age. This is a judgment requirement for replacement.
SAFE PARKING. Before working on truck : In general, if the damage is greater than 12mm
(0.5in) deep and involves more than a 50×50mm
1. Park truck on a hard, level, and solid (2×2in) area, it will usually affect the tire perfor-
surface, such as a concrete floor with no mance and the tire should be replaced.
gaps or breaks.
2. Put upright in vertical position and fully
Drive Wheel Removal/Installation
3. Put all controls in neutral. Turn key switch
OFF and remove key.
Removal
4. Apply the parking brake and block the 1. Loosen lug nuts then use a portable jack of correct
wheels. capacity placed under the frame of truck to raise
drive wheel off floor. See “Lifting, Jacking, and
Blocking” in Group SA for correct, safe procedures
General Cushion Tire Maintenance and for jacking the truck.
Inspection 2. Remove lug nuts and lift the tire and wheel assembly
1. Inspect cushion tires and remove objects (nails, metal from drive axle hub.
fragments, etc.) embedded in the tread of the tire. Be
careful not to cause further damage to tire when
removing these objects.
2. Check tire for separation from the base band. If a thin
Drive axle hub
steel rule or similar tool can be inserted more than
12mm (0.5in) into the separation area from the side
of the tire, the tire should be replaced.
Lug nut
Tire and wheel

assembly
SM 661, Aug ’01 Cushion Wheels and Tires • 22-2-1

Installation 4. Loosen and remove O-ring, wheel nut, and washer.
1. Install wheel and tire assembly on drive axle hub. 5. Pull out on wheel hub slightly to loosen bearing, then
Begin tightening the lug nuts to seat the nuts in the remove outer bearing. Store in clean place.
beveled wheel openings. 6. Carefully remove wheel assembly from axle spindle.
2. Use a crisscrossing nut-tightening sequence to torque Support the wheel hub to avoid dragging the grease
the lug nuts to a pre-final torque of 54-81 N⋅m (40-60 seal at the back side across the thread on spindle end.
ft⋅lb).
3. Begin the crisscrossing sequence again and torque

the black lug nuts to 640-720 N⋅m (470-530 ft⋅lb).
IMPORTANT
Do not overtorque the lug nuts. Damage to 7. If no other maintenance is to be done on wheel bear-
the lug nuts, wheel, or drive-axle hub may ings, cover the wheel hub to protect the grease seal
result. and inner bearing from contamination during tire
replacement.
4. Lower truck to floor and remove jack.
Installation
Steer When Removal/Installation 1. Make sure the truck is safely supported on a suitable
jack or blocking.
Removal 2. Be sure axle spindle is clean and that wheel hub
1. Park the truck safely and use a jack of suitable capac- inside and bearings are clean and have been serviced
ity placed under the frame of truck to lift steer wheel and lubricated (packed correctly) before installation.
off the floor as described in “Lifting, Jacking, and NOTE
Blocking” in Group SA. Refer to Group 26, “Steer Axle”, for addi-
2. Remove hub cap by prying it from wheel hub. tional information on removing and servicing
steer wheels and bearings.
3. Install wheel on spindle. Be careful not to damage

seal lip when moving the hub over the end of spindle
and threads.
3. Clean the excess grease from around wheel nut.

Remove cotter pin from wheel nut.
22-2-2 • Cushion Wheels and Tires SM 661, Aug ’01

4. Install outer bearing after packing bearing cavity Cushion Tire Replacement
onehalf full with proper grease.
! CAUTION
Replacement of the original equipment tires
with tires other than those recommended by
CLARK may result in decreased operating
performance and stability.
1. The correct procedure for tire removal and replace-

ment requires a suitable press for pressing old tire off
5. Install bearing washer and wheel nut and hand wheel and pressing new tire onto wheel.
tighten wheel nut.
IMPORTANT
Cushion tires cannot be reused after once
being pressed on and removed from the
wheel. The correct press fit is destroyed after
one installation and removal. Replace with
new tire.
2. Position tire on press, making sure there is adequate

clearance for the tire to be pressed off of wheel.
6. While rotating wheel (hub) counter clockwise, torque 3. Use suitable tooling with the hydraulic press to cor-
the wheel nut to 27-31 N⋅m (20-23 ft⋅lb). rectly contact the base band of tire to press it off the
wheel.
7. Back the wheel nut up until it is loose.
4. Install new tire. Mount all tires with identification
8. While turning the wheel counter clockwise, torque
and type markings toward outside of wheel. Tire is to
the wheel nut to 2.3-2.8 N⋅m (20-24 in⋅lb, 1.7-2
be pressed on wheel with the outer edges flush.
ft⋅lb).
9. Back wheel nut off to nearest slot in nut and lock
with new cotter pin. Bend tabs on cotter pin.
10. Recheck for correct bearing adjustment by rotating
the wheel by hand. Wheel should rotate freely or
with only slight “drag.” Readjust bearings, as neces-
sary. Adjust torque on wheel nut as necessary to
avoid binding in bearings.
11. Pack the area around wheel nut with grease.
12. Replace the O-ring and install hubcap by tapping into
place with a rubber or plastic-faced hammer.
13. Lower truck to floor and remove jack.
SM 661, Aug ’01 Cushion Wheels and Tires • 22-2-3

Section 3
Pneumatic Wheels and Tires
SM 661, Aug ’01 Pneumatic Wheels and Tires • 22-3-1

5. Always remove all air from a single tire and from

! CAUTION both tires of a dual assembly prior to removing any
SAFE PARKING. Before working on truck : rim components, or any wheel components, such as
nuts and rim clamps. Always remove the valve core
1. Park truck on a hard, level, and solid to remove air from tire. Be sure all air is removed.
surface, such as a concrete floor with no
gaps or breaks. 6. Check rim components periodically for fatigue
cracks. Replace all cracked, badly worn, damaged,
2. Put upright in vertical position and fully and severely rusted components.
7. Do not, under any circumstances, attempt to rework,
3. Put all controls in neutral. Turn key switch weld, heat, or braze any rim components that are
OFF and remove key.
cracked, broken, or damaged. Replace with new parts
4. Apply the parking brake and block the or parts that are not damaged, which are of the same
wheels. size, type, and make.
8. Never attempt to weld on an inflated tire/rim assem-
Pneumatic Tire Maintenance bly.
Precaution 9. Clean rims and repaint to stop detrimental effects of
corrosion. Be very careful to clean all dirt and rust
The following instructions supplement the OSHA require-
from the lock ring gutter. This is important to secure
ments. In the event of any conflict or inconsistency
the lock ring in its proper position.
between these instructions and the OSHA requirements,
A Filter on the air filling equipment to remove the
the OSHA requirements shall be controlling.
moisture from the air line prevents a lot of corrosion.
The filter should be checked periodically to make
! WARNING sure it is working properly.
Before you do tire or rim maintenance, read 10. Make sure correct parts are being assembled. Ask
the OSHA rules regarding owner responsib- your distributor or the manufacturer if you have any
lilty. Read and understand all maintenance doubts.
and repair procedures on tires and rims. Do
not work on tires or rims unless you have 11. Do not be careless or take chances. If you are not
been trained in the correct procedures. Seri- sure about the proper mating of rim and wheel parts,
ous injury or death can result if the safety consult a wheel and rim expert. This may be the tire
messages are ignored. man who is servicing your fleet, the rim and wheel
distributor in your area, or the CLARK dealer.
1. Do not let anyone mount or demount tires without 12. Mixing parts of one manufacturer’s rims with those
proper training. of another is potentially dangerous. Always ask man-
2. Never sit on or stand in front of a tire and rim assem- ufacturer for approval.
bly that is being filled with air. Use a clip-on chuck 13. Do not use undersized rims. Use the right rims for
and make sure the hose is long enough to permit the the job.
person filling the tire with air to stand to the side of
the tire, not in front or in back of the tire assembly. 14. Do not overload rims. Ask your rim manufacturer if
special operating conditions are required.
3. Never operate a vehicle on only one tire of a dual
assembly. The carrying capacity of the single tire and 15. Do not seat rings by hitting with a hammer while the
rim is dangerously exceeded, and operating a vehicle tire is filled with air pressure. Do not hit a filled or
in this manner can result in damage to the rim and partially-filled tire/rim assembly with a hammer.
truck tip-over and driver injury. 16. Double check to make sure all the components are
4. Do not fill a tire with air that has been run flat with- properly seated prior to filling tire with air.
out first inspecting the tire, rim, and wheel assembly. 17. Have the tire in a safety cage when filling with air.
Double check the lock ring for damage. Make sure
that it is secure in the gutter before filling the tire
with air.
22-3-2 • Pneumatic Wheels and Tires SM 661, Aug ’01

18. When removing wheels, regardless or how hard or • Incorrect (low) tire pressure can reduce the sta-
firm the ground appears, put hardwood blocks under bility of a lift truck and cause it to tip over.
the jack.
IMPORTANT
19. Block the tire and wheel on the other side of the vehi- Check wheels and tires for damage every
cle, before you place the jack in position. Place time you check tire pressure. Make repairs
blocks under the truck frame as near as possible to when needed. Dirt can get into cuts and cause
the jack to prevent the truck from falling if the jack damage to the tire cord and tread. Remove
should fail. debris from all cuts.
20. Remove the bead seat band slowly to prevent it from
dropping off and crushing your toes. Support the 2. Check the condition of the drive and steer wheels and
band on your thigh and roll it slowly to the ground. tires. Remove objects that are imbedded in the tread.
This will protect your back and feet. Inspect the tires for excessive wear, cuts and breaks.
21. 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. Always stand to one side when you
apply hydraulic pressure.
General Tire Maintenance, Inspection,

and Repair 3. Check all wheel lug nuts or bolts to be sure none are
1. Park the truck as described in “Safe Parking” and loose or missing. Have missing bolts replaced and
check for correct tire inflation air pressure. loose bolts tightened to the correct torque before
operating the truck.
• Drive 20/25: 1000 kPa (145 psi),
30: 965 kPa (140psi) • Torque pneumatic steer tires to 225-250 N⋅m (165-
185 ft⋅lb).
• Steer 861 kPa (125 psi all models)
• Torque 1 piece black lug nuts for pneumatic drive
tires to 640-720 N⋅m (470-530 ft⋅lb).
! CAUTION
• Torque 1 piece black lug nuts for pneumatic dual-
Check tire pressure from a position facing drive tires to 640-720 N⋅m (470-530 ft⋅lb).
the tread of the tire, not the side. Use a long-
handled gauge to keep your body away from
the side. Inspection and Minor Repair
Inspect pneumatic tires and wheels carefully for.
1. Low inflation pressure.
2. Damaged tires. Check tires for cuts and breaks.
3. Damaged wheels or loosening of the lock ring on
multi-piece rims.
• If tires are low, do not add air. Have the tire and
wheel inspected by a person trained and autho-
rized to do tire and wheel maintenance. The tire
may require removal and repair.

4. Check for loose nuts or bolts not in position.

5. Check the nuts or bolts for damage.
6. Check the surface of the wheels for bent flanges.
7. Check all parts for rust or corrosion.
8. Mark the damaged areas with chalk so that the parts
can be removed from operation.
9. Remove all parts that are damaged and install new
parts in the same position.
10. Replace parts with the correct sizes and types. See
your parts manual.
Drive axle hub
11. Include your truck serial number when ordering
replacement parts.
3. Use a portable jack of adequate capacity placed

Wheel Dismounting and Remounting under the frame of truck to raise drive or steer wheels
Refer to “Lifting, Jacking, and Blocking” in Group SA for off floor.
information on jacking up or raising the truck for wheel 4. Once tire is off the ground enough to rotate freely,
removal. Always start with the truck parked safely. remove the lug nuts and lift the wheel from the hub.
Use caution when lifting tire and wheel.
Drive and Steer Wheel Dismounting
Drive and Steer Wheel Remounting
1. Remove the valve core from the valve stem to be sure
all air is removed from the tire. IMPORTANT
2. Loosen the five lug nuts on the wheel. See “Tire Installation” in this Section to
make sure the wheel and tire mounting orien-
tation is correct. Check the information for
correct tire-to-wheel mounting and wheel-to-
hub mounting.
1. Make sure the truck is parked on a flat, hard surface

and the jacking and blocking devices are secure to
hold the truck in a safe position.
2. Inspect the removed lug nuts for damage to the
threads. Also inspect all hub studs for thread damage.
Steer axle hub Replace any lug nuts or studs that have damaged
threads. Make sure studs are secure in the axle hub.

3. Set the wheel on the hub and start the lug nuts on the 2. Loosen the five lug nuts on the wheel.
hub studs. Tighten the nuts only enough to seat the
nuts into the beveled openings on the wheel and to
secure the wheel on the axle hub.
4. Use a crisscrossing nut tightening sequence to torque
the nuts to a pre-final torque of 54-81 N⋅m (40-60
ft⋅lb). Make sure all nuts seat into beveled spacer
holes correctly.
3. Use a portable jack of correct capacity placed under

the frame of truck to raise drive wheels off floor.
5. Begin the crisscrossing sequence again and tighten
the lug nuts to final torque. 4. Remove the five outer-wheel lug nuts and remove the
• Torque drive wheel 1 piece lug nuts to 640-720 outer wheel and tire from the dual-wheel spacer
N⋅m (470-530 ft⋅lb). studs.
• Torque steer wheel lug nuts to 225-250 N⋅m 5. Remove the valve core from the valve stem of the
(165-185 ft⋅lb). inner wheel to be sure all air is removed from the tire.
6. Carefully lower the truck and remove the jack. 6. Remove the five lug nuts securing the inner wheel to
7. Check tire pressure for correct inflation pressure. the dual-wheel spacer.
• Drive wheel pressure is 20/25: 1000 kPa (145 7. Remove the dual-wheel spacer and retain the wheel-
psi) mounting washers on the dual-wheel shoulder studs
30: 965 kPa (140 psi). installed on the dirve-axle hub.
• Steer wheel pressure is 861 kPa (125 psi).
8. Remove the tire and wheel from the drive-axle hub.
Use caution when lifting wheel and tire assembly.
! WARNING
If tires are not fully inflated, see “Adding Air
Pressure To Mounted Wheel/Tire Assem- Dual-Drive Wheel Remounting
blies” and follow the procedures for adding IMPORTANT
air to the mounted tires.
See “Tire Installation” in this Section to
Before you add air pressure to the tire, make
make sure the wheel and tire mounting orien-
sure the lock ring is correctly positioned in
tation is correct. Check the information for
the rim and side ring. The lock ring can sepa-
correct tire-to-wheel mounting and wheel-to-
rate from the rim with enough force to cause
hub mounting.
injury or death.
1. Make sure the truck is parked on a flat, hard surface
Dual-Drive Wheel Dismounting and the jacking and blocking devices are secure to
hold the truck in a safe position.
1. Remove the valve core from the valve stem of the
outer wheel to be sure all air is removed from the tire. 2. Inspect the lug nuts for damage to the threads. Also
inspect all studs for thread damage. Replace any lug
nuts or studs that have damaged threads. Make sure
studs are secure in the drive-axle hub and the dual-
wheel spacer.

3. Install inner wheel and tire assembly on drive-axle

hub shoulder studs. ! WARNING
4. Install five wheel-mounting washers on the shoulder If tire are not fully inflated, see “Adding Air
studs. Pressure To Mounted Wheel/Tire Assem-
blies” and follow the procedures for adding
5. Mount the dual-wheel spacer on the shoulder studs. air to the mounted tires.
6. Set the lug nuts on the shoulder studs and tighten the Before you add air pressure to the tire, make
nuts only enough to seat the nuts into the beveled sure the lock ring is correctly positioned in
openings on the spacer and to secure the wheel on the the rim and side ring. The lock ring can sepa-
spacer and drive-axle hub. rate from the rim with enough force to cause
injury or death.
ft⋅lb). Make sure all nuts are seating into beveled
Wheel Disassembly and Tire Removal
spacer holes correctly. 1. Remove valve core from the valve stem to be sure all
air is removed.
! WARNING
Before starting disassembly, remove the air
from the tire. Failure to remove the air from
the tire can result in serious injury.
2. Remove lock ring.

the black lug nuts to 640-720 N⋅m (470-530 ft⋅lb).
9. Mount the outer wheel on the studs of the dual-wheel
spacer and tighten the nuts only enough to seat the
nuts into the beveled openings on the spacer and to 3. Remove wheel wedge.
secure the wheel on the spacer and drive-axle hub. 4. Remove tire from wheel.
ft⋅lb). Make sure all nuts are seating into beveled
spacer holes correctly. See illustration above.
the lug nuts as described in step 8 and 9.
NOTICE
The outside diameter of the left or right
wheel or set of wheels must not differ more
than 6mm (0.25 in) per side.
12. Check tire presssure for correct inflation pressure :

• Drive wheel pressure is 1000 kPa (145 psi).

5. Remove the rubber inner tube protector (flap). 12. Clean the tire bead seat area. Remove all rust and
rubber with a wire brush or wheel.
6. Repair tire and/or tube, as needed.

7. Check for cracks in the wheel.
13. Clean wedge and lock rings. Make sure the seating
surface and bead seat areas are clean.
Cracks in the wheel are caused by :

• Deep rim tool marks.
• Overload on wheels.
• Too much air pressure in the tires. 14. Apply paint to the tire rim with a brush. Or, use an
• Using the wrong size tires. aerosol can of metal primer.
The parts must be clean and dry before you apply the
8. Check for cracks in the lock ring. paint. Make sure to apply paint to the outside or tire
9. Check for cracks between the stud holes in the wheel. side of the rim. This is important because air is on the
Cracks are caused by : metal surface of the tire side of the rim
• Loose wheel nuts. 15. Apply lubricant on the tire side of the rim base. Do
• Wheel not installed correctly. not use a lubricant that has water or solvent which
will cause damage to the rubber.
• Wrong size or type of parts used.
• Too much torque on the wheel fasteners. If the NOTE
wheel mounting parts are too tight, the studs or Clark dealers can supply the correct lubri-
bolts can break, causing cracks in the wheel cant, which contains a rust inhibitor.
between the stud holes.
• Too little torque on the wheel fasteners. If the
wheel mounting parts are too loose, damage to
parts and tire wear will result.
10. Check wedge ring for wear or damage. Corrosion
buildup will cause wear and damage to the wheel
wedge ring.
11. Clean the wheels. Remove rust and dirt.

Tire Replacement and Wheel 5. Install the wheel wedge.

Reassembly
1. Put the tube into the tire.
6. Put the side ring over the rim and install the lock ring
as shown.
IMPORTANT
Install washer 22.123 on tube over valve stem
before flap is installed, when specified. See
sketch. Refer to Service Parts List.
7. Connect air chuck and turn the tire over with the
2. Put the rubber tube protector(flap) over the tube. valve stem down. Put 21 kPa (3 psi) of air into the
tire.
3. Install the tire onto the wheel rim, against the bead
seat area.
8. Turn wheel to the other side. Check to make sure

lock ring is in correct location.
4. Put the wheel wedge over the rim.

9. Disconnect the air chuck. Use a mallet and hit the Directional-Tread Single Drive Tires
ring to make sure the ring is fully installed. • Tire arrow to point in the dirction of forward rota-
tion. Rotate wheel to bring arrow on tire above the
wheel center. Arrow must point toward front of
truck.
10. Put the tire in an OSHA-approved safety cage.
Directional-Tread Dual Tires
1. Inside dual tire arrow to point in the direction of for-

ward rotation. Rotate wheel to bring arrow on tire
above the wheel center. Arrow must point to ward
front of truck.
Tire-to-Wheel Mounting
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.
2. Outside dual tire arrow to point in the direction of
rearward rotation. Rotate wheel to bring arrow on tire
above the wheel center. Arrow should point toward
rear of truck.

Filling Tires with Air 2. Turn the regulator valve counterclockwise (CCW)
until you can feel no resistance from the regulator.
Follow these procedures when putting air into tires. All This will adjust the regulator presssure to a low pres-
wheel and tire assemblies must be filled in a safety cage. sure near zero.
The hose must 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.
3. At intervals, close the control valve and check the
pressure in the tire by reading the gauge. Do not put
too much presssure into the tire.
4. Continue to fill the tire to the correct air pressure
reading of Drive tire C20-25: 1000 kPa (145 psi) 3. Slowly turn the cylinder valve counterclockwise
C30: 965 kPa (140psi). (CCW) to open position.
Steer tire: 861 kPa (125 psi)
IMPORTANT
Put equal pressure in both tires of a dual
assembly. Do not put air into a tire that is flat
without first inspecting it and the wheel for
damage.
Filling Tires with Nitrogen

If your air supply does not have enough pressure to fill the
tire, you can use a pressurized cylinder of commercial 4. The tank gauge will now show tank pressure.
nitrogen gas to get the correct tire pressure. With the tire
in a safety cage, connect the nitrogen cylinder to the valve
stem with the use of an air chuck.
! WARNING
Use introgen only. Do not use oxygen or any
other gas to fill tires. Make sure all items of
equipment used (nitrogen cylinder, regulator,
gauges, hoses) are UL approved and in good
condition. Use the correct regulator and hose
for the pressures that are necessary. 5. Turn the regulator valve clockwise (CW) until the
regulator gauge reads the correct tire pressure. Fill
1. Be sure tank valve is closed to connect hose to valve the tire with nitrogen.
stem. Tank vlave is closed by turning handle on top
of tank clockwise to a stop.

6. Turn the tank valve clockwise (CW) and close the Checking and Adjusting Tire Pressure
valve.
! WARNING
Before you add air pressure to the tire, make
sure the lock ring is correctly positioned in
the rim and wheel wedge. The lock ring can
separate from the rim with enough force to
cause injury or death.
7. Disconnect the air chuck from the valve stem.
1. Attach a clip-on air chuck to valve stem. Stand by the

side of the wheel and put the correct air pressure in
the tire.
8. Turn the regulator valve counterclockwise (CCW) to

the off position.
2. If your air supply does not have enough pressure to

fill the tire, you can use a nitrogen cylinder to get the
correct pressure.
9. Use a tire pressure gauge to check the tire pressure. If

necessary, put more air into the tire. Do this as many
times as necessary to reach the correct tire pressure.
3. Put a clip-on type air chuck on the nitrogen cylinder
! CAUTION hose and attach it to the valve stem. Follow the pro-
Use a long-handled gauge so that your hand cedures described previously for adjustment of the
does not go inside the cage, or in front of any nitrogen cylinder valves.
component of a multi-piece wheel.
! WARNING
Use nitrogne only. Do not use oxygen or any
other gas to fill tires.

Split-Rim Wheel Assemblies ! DANGER

Split-wheel assemblies (two-piece rims held together with • Remove the air from th tire before loosenging
bolts) may be encountered either on older truck models or wheel mounting bolts or nuts, or doing any
as an option installed in the field. This brief discussion is work on split-rim wheels or tires. Split-rim
supplied to illustrate a typical split wheel design and to wheels can separate with enough force to
point out precautions in removing the mounting bolts for cause severe injury or death.
reference. • Before removing tires from split wheel assem-
Split-wheel assemblies are a special case requiring extra blies, remove all air pressure from the tires.
care when removing the wheel from the truck, to be sure • Before putting air pressure into tires with
that the mounting bolts and not the wheel clamping bolts split wheel assemblies, make sure the split
are loosened and removed, and that all of the air pressure wheel attaching bolts are installed and tight-
is removed before demounting the wheel or disassembling ened to correct torque value.
to remove the tire. • Always use a safety cage when inflating tires.
1. It is general practice for the wheel clamping bolts
that hold the wheel halves together to be installed
with the nuts and washers on the inboard (hidden)
side.
2. It is also general practice (however designs may
vary) for the wheel clamping bolts that hold the
wheel together to be placed in the outer bolt circle
nearest the tire bead seat and the wheel mounting
bolts to be placed in the inner bolt circle closest to
the hub. Always inspect split wheels to safety iden-
tify the correct wheel mounting bolts before remov-
ing.
Typical Split Wheel Assembly

GROUP 23(S)
GROUP 23(S)
BRAKE SYSTEM
(TA30 TRANSAXLE)
Braking/Inching System
Specifications and Description ............ Section 1
Service Brake Troubleshooting ................Section 2
Brake/Inching Pedals and Linkages

Adjustments ...........................................Section 3
Brake Bleeding ...........................................Section 4
Brake Master Cylinder Service ................Section 5
Service Brake Adjustment and Overhaul Section 6
Parking Brake Service ..............................Section 7
SM 661, Aug ’01 Group 23(S), Brake System (TA30 Transaxle)

Group 23(S), Brake System (TA30 Transaxle)
Section 1
Braking/Inching System
NOTE
INCHING. This Section only covers inching in re-
gard to the linkage between the brake and inching
pepals. The inching system is more fully covered in
Group 06(S), “Transaxle.(Standard)”
Specifications
Service Brake : Parking Brake :
Type : Drum and shoe. Master cylinder provide by reserve Type : Ratchet linked to service brake shoe at each wheel.
tank. Self-adjusting.
Holding Test: Rated load on 15% grade.
Fluid : Fluid provided by reserve tank.
Master cylinder residual pressure : 117 kPa.
Inching : also see standard transaxle specs in Group 06(S)
Shoe-to-Drum Gap : 0.45-0.60 mm (0.017-0.024 in).
Type : Inching pedal mechanically linked to brake pedal
Shoe Lining Thickness : 1.0 mm ( 0.039 in) minimum. and to inching spool on transaxle.
Drum Thickness : 20.6 mm (0.787 inch) minimum. Pedal Freeplay: None
Maximum Rebore Diameter : 303 mm (11.92 in). Overlap Adjustment : 1.5-4.5 mm.(0.06-0.18in)
Pedal Freeplay : 4-6mm (0.16-0.24in)
Star Wheel Adjustment Gap : 0.5-0.6 mm (0.020-0.023
in)
SM 661, Aug ’01 Braking/Inching System Specifications and Description • 23(S)-1-1

General Description ing pedal operates the brake master cylinder. The inching
pedal is mechanically linked to the brake pedal so that the
The service brake and inching system (diagrammed inching pedal, near the end of its stroke, also operates the
below) consists of : service brakes.
Service brake assembly — The drums, shoes, and wheel Inching control valve — A hydraulic valve in the tran-
cylinders. saxle control valve assembly that hydraulicly varies clutch
Brake Master Cylinder — This is a step-bore maste cyl- pack pressure so the operator can “inch” the truck.
inder with reservoir Brake oil is fed to the master cylinder Parking brake pedal — Operates the service brake shoes
from reservoir. via cables. See “Parking Brake Adjustment,” in this
Service brake and inching pedals and linkages — A Group, for details.
mechanical system through which the brake pedal or inch-
Service Brake and Inching System Arrangement
Parking Brake Inching Pedal Service Brake Pedal

Pedal
Reservoir
Brake
Master
Cylinder
Inching Control Valve

(on transaxle)
Service
Brake
Assemblies
Mechanical Linkage
Brake Line
23(S)-1-2 • Braking/Inching System Specifications and Description SM 661, Aug ’01

Inching Operation Service Requirements

The inching pedal allows the operator to vary transmission Operational checks and inspection of linkages, brake
slippage through the clutch pack so that travel speed and shoes, and brake lines are specified in the Periodic Service
lifting speed can be independent. Chart in Group PS.
The inching pedal also applies the service brakes. When Service brake linkage adjustment and lube are not nor-
the inching pedal is depressed to a certain point, a mally required.
mechanical linkage between the inching pedal and the
Brake shoes are self-adjusting and normally require
brake pedal begins to apply the service brake. When the
adjustment only after initial installation.
inching pedal is fully depressed, the clutch pack fully dis-
engages and the service brake fully applies. A leaking brake cylinder should be overhauled or
replaced.
Inching is more fully described in Section 1 of Group 6,
“Transaxle.” Parking brake should be adjusted if indicated by opera-
tional check.
Braking Operation
When the operator depresses the brake pedal, or depresses
the inching pedal far enough to operate the brake pedal,
the brake link operates a piston in the brake master cylin-
der.
The brake master cylinder receives flow from the reser-
voir. In general, the brake master cylinder allows pressure
to build in the wheel cylinder in proportion to the extent
the brake pedal is depressed.
When the operator applies the brakes, the brake master
cylinder piston shifts to provide pressure to the wheel cyl-
inders for braking. The amount of pressure is modulated
by the position of the piston. When the pedal is released,
pressure in the wheel cylinders vents to the sump and the
return springs on the shoes retract the wheel cylinders.
SM 661, Aug ’01 Braking/Inching System Specifications and Description • 23(S)-1-3

Section 2
Service Brake
Troubleshooting
SM 661, Aug ’01 Service Brake Troubleshooting • 23(S)-2-1

Service Brake Troubleshooting
Causes/Corrective
Condition Actions
Brake pedal drops to floor ...................................................................... B D F
Brake pedal spongy................................................................................. B C
Brake pedal kicks back when applied ..................................................... C E
Brakes stick, drag excessively, make noise, or overheat ........................ E F H
Insufficient stopping power; excessive effort required........................... F B E G
Excessive effort required to apply brake................................................. F B
Inching pedal does not apply brake at right time .................................... A D
Causes/Corrective Actions
A. Overlap adjustment incorrect... Adjust.

B. External leak in wheel cylinder or other component of braking system... Inspect/replace/repair.
C. Air in braking system... Bleed and recheck.
D. Linkage misadjusted or broken. Return spring damaged... Inspect/repair.
E. Brake master cylinder defective... Inspect/overhaul or replace.
F. Shoe linings worn or brakes misadjusted... Inspect/repair/adjust.
G. Shoe linings glazed, oily, or contaminated with other substance... Replace or clean.
H. Parking brake misadjusted... Adjust.
23(S)-2-2 • Service Brake Troubleshooting SM 661, Aug ’01

Section 3
Brake/Inching Pedals and
Linkages Adjustments
SM 661, Aug ’01 Brake/Inching Pedals and Linkages Adjustments • 23(S)-3-1

Introduction Overlap Adjustment

Figures 1 and 2 show : See Figure 1. When the inching pedal is depressed, the
strike bolt threaded into the inching pedal pushes against
• The service brake linkage, which links the brake
the strike lever on the brake pedal, applying the brake.
pedal to the brake master cylinder.
• The inching pedal linkage, which links the inching The clearance between the top of the strike bolt and the
pedal to the inching valve. strike lever should be 0.5 to 1.5 mm (0.02~0.06 in),
depending on operator preference.
• The inching pedal overlap, which allows the inch-
ing pedal to operate the brake pedal. 1. Measure clearance.
The illustrations and accompanying text serve as guide to If necessary, adjust as follows:
disassembly/assembly and adjustment.
2. Loosen jam nut.
Pedal Height Adjustment 3. Turn strike bolt to obtain desired clearance.
See Figure 1. The brake pedal must be at the same height 4. Tighten jam nut.
as the inching pedal. To adjust brake pedal height :
1. Loosen the eccentric stop’s mounting bolt and nut Inching Cable Adjustment
until the stop can be withdrawn from the hex hole in See page 4.
the brake pedal bracket.
2. Rotate the eccentric stop in the hex hole until it
stops the brake pedal at the same height as the inch-
ing pedal.
3. Torque the stop’s mounting bolt and nut 20-25 N⋅m
(14-18 ft⋅lb).
Freeplay Adjustment
When the brake pedal linkage is properly adjusted, brak-
ing should begin only after the pedal is depressed a certain
distance, This is “Freeplay” is Adjusted as follows :
1. Loosen the jam nut on the rod brake master cylinder
(Figure 1 or 2).
2. Depress the brake pedal 5~8mm (0.2~0.3 in).
3. Adjust the rod until you feel the push rod (Figure 3)
make clearance with the cylinder piston.
23(S)-3-2 • Brake/Inching Pedals and Linkages Adjustments SM 661, Aug ’01

Brake yoke Spring clip and pin
Brake pedal
Strik bolt
Jam nut
Jam nut
Inching pedal
Strike bolt
Brake Valve
mounting bolt
Brake Master Cylinder
Stop mounting bolt
Figure 1. Brake/Inching Pedals and Linkage
SM 661, Aug ’01 Brake/Inching Pedals and Linkages Adjustments • 23(S)-3-3

Inching Cable Adjustment

With the inching pedal fully up, the inching rod should be
just barely off its seat, so that there is no freeplay in the
inching cable.
With the pedal released, adjust the cable as follows :
1. Use the cable adjusting nuts to loosen the cable
until the inching rod withdraws into the transaxle
control valve as far as it will go.
2. Turn the cable adjusting nuts until the cable tightens
enough to just barely move the rod off its seat.
Tighten the cable adjusting nuts against the mount-
ing bracket.
IMPORTANT
INCHING ROD POSITION. Do not over-
adjust. Adjustment should extend the rod no
more than 1.0 mm (0.04 in) from its fully
seated position.
Cable adjusting nuts
Inching rod
Mounting bracket

(contains inching control valve)
Figure 2. Inching Valve Linkage
23(S)-3-4 • Brake/Inching Pedals and Linkages Adjustments SM 661, Aug ’01

Section 4
Brake System
Bleeding
Bleed brakes when : 4. Depress the brake pedal and watch fluid flow into the
jar. When the fluid appears to be free of bubbles,
• The brake pedal kicks back during braking or the
tighten the bleed screw, then release the pedal.
pedal feels spongy.
• The brake valve or wheel cylinders — or lines 5. Operate the brake pedal at various rates. If you feel
between — have been leaking and/or have been the pedal kick back, bleed the system again.
repaired or replaced.
• Troubleshooting otherwise indicates that air has
been introduced into the system.
Because the brake system is supplied with brake fluid

from the reservoir, brake bleeding is simplified. Proceed
as follows :
1. Park truck on level floor. Put direction control in neu-
tral. Lower forks to floor, tilt forward, and apply
parking brake.
2. Attach a clear hose to a bleed screw on one of the
brake cylinders. Place the other end of the hose in a
jar containing brake fluid, Clark part #8009013.
3. Open the bleed screw.
SM 661, Aug ’01 Brake System Bleeding • 23(S)-4-1

Section 5
Brake Master Cylinder Service
SM 661, Aug ’01 Brake Master Cylinder Service • 23(S)-5-1

Brake Master Cylinder Removal and

Replacement
1. Remove the spring clip and pin from the yoke on the
brake master cylinder rod. (See box below).
2. Remove and plug the feed line.
3. Loosen the two mounting bolts.
4. Replacement is reverse of removal. Bleed system and
test brakes as described in Section 4.
Mounting plate
Mounting bolts
Brake master
cylinder
Yoke
Mounting bolts
23(S)-5-2 • Brake Master Cylinder Service SM 661, Aug ’01

Brake Master Cylinder Overhaul

• Use the Clark overhaul kit to overhaul the brake
master cylinder.
• Clean all parts with a safety-approved commercial
solvent before inspection.
• Inspect all parts. Inspection includes :
- Checking bores and pistons for scratches,
nicks, burrs, and wear.
- Making sure springs are not bent or cracked.
- Making sure all orifices are free of blockage.
- Making sure boot is not torn or loose.
- Making sure push rod is not bent.
• Replace all seals. Do not reassemble with old seal.
• Coat all components with brake fluid, Clark part
#8009013, before reassembly. Lubricate and wrap
parts if reassembly will not be done immediately.
IMPORTANT
CLEANLINESS. Perform overhaul proce-
dure in a clean environment. Make sure all
parts are cleaned before, and kept clean dur-
ing, reassembly.
SM 661, Aug ’01 Brake Master Cylinder Service • 23(S)-5-3

Section 6
Service Brake Adjustment and Overhaul
External Inspection 4. Rotate the adjuster notch over the adjuster to Adjust
(at 6 o’clock position).
The brake linings, drum, and adjustment setting can be
inspected without removing the drum or hub.
Shoe-to-Drum Gap Adjustment
1. Jack up and block the front of the truck as described
in Group SA. The brake shoes are self-adjusting. However, manual
adjustment is required when shoes are replaced or if brake
2. Remove the wheel and examine the linings through shoes are binding against drums.
the shoe inspection notch in the drum.
If the linings appear to be worn to a thickness of 1 To decrease gap/increase gap (for each shoe) :
mm (0.04 in) or less at any point, replacement of 1. Measure the shoe-to-drum gap as described in
both shoes is required. “External Inspection.”
3. If the linings are OK, measure each shoe-to-drum 2. Through the adjuster notch, rotate the star wheel one
gap through the shoe inspection notch, first rotating click with screwdriver or adjusting tool.
the notch into alignment with the lower end of each
shoe. If the gap is not 0.10-0.35 mm (.004-.014 in), 3. Repeat steps 1 and 2 until proper gap is achieved.
adjust as described in “Shoe-to-Drum Gap Adjust-
ment.”
Shoe inspection
notch
Drum
Shoe
Adjuster
notch
Measure shoe to drum gaps
here.
Figure 1. Inspection and Adjustment Notches
SM 661, Aug ’01 Service Brake Adjustment and Overhaul • 23(S)-6-1

Internal Inspection and Repair Brake Shoe Removal

Jack up and block the front of the truck as described in Remove the cable Assembly, lever, adjuster, the guide
Group SA. Remove the wheel. The hub does not have to springs, lower return springs, upper return springs, and
be removed. shoes (Figure 6).
Brake Drum Removal and Replacement Brake Shoe Replacement

The drum fits tightly on the hub. To remove drum, install 1. Place the forward shoe — the shoe with the parking
M12 screws into the jackscrew holes to push the drum brake lever — on the cylinder rods (Figure).
away from the hub. To install the hub, align the adjuster
2. Install the parking brake cable, making sure it is
notch with the notch in the hub and drive the drum against
hooked on the lever and clipped to the backing plate,
the hub with a soft mallet.
3. Install the shoe hold spring and upper return spring.
4. Install cross-strut (with spring), making sure notch in
cross-strut end engages slot in parking brake lever on
forward shoe.
Jackscrew
5. Place the rearward shoe into position on the cylinder
Jackscrew
hole hole rods, making sure the spring-end of the cross-strut
engage the upper notch on the shoe.
6. Install the shoe hold spring and upper return spring.
7. Install the adjuster between the under notch on the
Adjuster notch shoes.
8. Install lower return spring, making sure long end of
Figure 2. Jackscrew and Adjuster Notch Locations spring is toward too forward shoe to avoid interfer-
ence with lever.
Inspection
Brake Shoes : If the linings are cracked or scored or the
linings are worn to 1 mm (.04 in) or less, the shoes must
be replaced. Both sets of shoes should be replaced when
one is replaced.
Brake Drum : The maximum allowed internal diameter
for the brake drum is 312 mm (12.28 in). Brake drum
walls should be free from scoring. Brake drums should be
machined each time brake shoes are replaced, to provide a
smooth and uniformly round braking surface.
Wheel Cylinder : Check for leakage under the boots at
each end of cylinder. If the cylinder leaks, or troubleshoot-
ing otherwise indicates a bad cylinder, disassemble and
inspect the wheel cylinder. If the cylinder surface is
scratched or pitted, replace the cylinder. Always replace
the cups.
General : Check for worn-out springs, warped backplate,
and loose or corroded fasteners. Check adjuster for proper
operation and replace if faulty.
23(S)-6-2 • Service Brake Adjustment and Overhaul SM 661, Aug ’01

Cylinder Removal and Replacement Adjuster Removal and Replacement

1. Remove the brake shoes as described previously. 1. Remove the under spring.
2. Remove the brake cylinder mounting bolts and 2. Remove the adjuster.
washer.
3. Install the adjuster between the under notch on the
3. Tap cylinder from backing plate with soft mallet. shoes.
4. When reinstalling : Seal the gap where the brake cyl- 4. Install lower return spring.
inder fitting extends through the backing plate with
silicon caulk. Tighten cylinder mounting bolts to
17.65-26.48 N⋅m (156-234 lbf⋅in).
Wheel cylinder
Shoe guide plate
Upper return spring
Upper return spring

Brake shoe
Cross strut
Brake shoe
Shoe hole cup &

Shoe hole cup & shoe hold spring
shoe hold spring
Spring & cable assembly

Lower return spring
Lever return spring
Adjuster
Lever
Figure 3. Brake Assembly

Wheel Cylinder Overhaul 3. Unhook the parking brake cable end from the lever
and pull the cable from the assembly.
1. Pull off rubber boots.
2. Push out internal parts (loosen with wooden dowel if
necessary).
3. Replace cylinder if scored or pitted.
4. Clean pistons, spring, and casing in solvent.
5. Install spring and pistons.
6. Install each cup from its respective end of cylinder.
Snap ring
7. Replace boots.
Figure 5. Parking Brake Cable

4. Disconnect the brake line from the fitting. Cap or
plug fittings.
5. Unbolt the brake assembly from the axle.
6. When reinstalling the brake assembly, torque the
mounting bolts to 220-230 N⋅m (162-170 lbf⋅ft) in a
staggered sequence. Torque fitting 15-19 N⋅m (133-
168 lbf⋅in).
7. Bleed the brake system as described in the brake
bleeding Section.
Figure 4. Wheel Cylinder-Disassembled
Brake Assembly Removal, and Installation

To access the service brake assembly, remove the axle hub
and brake drum as described in Group 6, in the “Drive
Axle Ends Overhaul” Section. Inspect the drum as
described earlier.
To remove the service brake assembly:
1. Remove the brake shoes as explained earlier.
2. Pull the snap ring that holds the parking brake cable
to the backing plate.

Operational Explanation 1. When lining gets worn out, which requires adjust-
ment, secondary shoe with auto-adjusting device is
of the Auto Adjuster kept separated from anchor at time of braking action
backward, helping to pull cable by its separated dis-
tance.
The cable pulls up adjusting lever via over-travel
spring and rotates adjusting wheel.
2. When braking is released, secondary shoe gets back
to anchor and then lever is forced to go back to origi-
nal position by lever return spring, making gap
between adjusting star wheel and lever.
3. As long as lining does not get worn out to the extent
of as much as needling next adjustment, adjusting
star wheel does not rotate since lever is unable to
move enough to fill up gap between adjusting star
wheel and lever, even if lever moves by backward
braking action.
4. No adjustment is made by forward braking because
anchor pin and secondary shoe keep same relative
position.
Figure 6. Auto Adjuster
Figure 7. Relation between star wheel and adjusting lever

at time of auto-adjustment

Characteristics
Corresponding to worn-out ratio of lining, clearance is
adjusted automatically and consecutively, always being
kept at constant level and therefore pedal stroke remains
unchanged.
Reliability is very high due to adjustment being made by
pulling cable at time of braking.
Due to installation of over-travel spring :
A. Adjusting parts are not damaged even by extra force
put to cable.
B. Especially, it helps prevent over-adjustment at time
of abrupt braking. (Its reasoning : After braking
torque occurs, shoe has a greater moving due to drum
deformation and even if trying to rotate adjusting
wheel, thrust-loading is working on adjuster which
enables over-travel spring to lengthen too far to rotate
adjusting wheel.)

Section 7
Parking Brake Service
Operation Removal and Replacement

The operator applies the parking brake by depressing a As shown in illustration below, with these notes:
foot pedal, which is then held down by a ratchet. The
• Remove return spring for better access to bracket
depressed pedal tensions cables connected to a brake shoe
mounting nuts.
at each brake assembly, thereby applying the brakes.
• Adjust position of interlock and indicator switches
The operator releases the parking brake by pulling up on a with pedal upstop against tab on bracket. Switch
release handle. This handle releases the ratchet, and a contacts should snap from their operated contact
return spring returns the pedal and cable to the off posi- position to their normal position when pedal is
tion. The ratchet also operates the parking brake interlock depressed one ratchet click.
switch and the parking brake indicator light switch.
• Torque switch mounting nuts 0.8-1.0 N⋅m (7-9
lbf⋅in). Torque bracket mounting nuts 20-23 N⋅m
Adjustment (177-210 lbf⋅in).
• Apply a thin coat of Clark lubricant, part
1. With the pedal fully raised, upstop against tab on
#1802155, to ratchet teeth and ball end of wire
bracket, adjust slack out of brake cables and tighten
rope prior to assembly.
adjusting/locking nuts.
2. Actuate and release pedal six to eight times.
3. Readjust and tighten nuts.
Ratchet Release handle

Upstop
Foot pedal
Switch mounting plate
Rod
Return spring
Switch
Adjusting locking nuts
SM 661, Aug ’01 Parking Brake Service • 23(S)-7-1

Parking Brake Cable Removal and 2. Remove the parking cable from the service brake
assembly by first removing the brake shoes as
Installation described in the “Brake Overhaul and Adjustment”
1. Disconnect each parking brake cable from the ratchet Section of this Group.
assembly as shown in the illustration below. 3. Pull out the C-clip that holds the parking brake cable
to the backing plate.
4. Unhook the parking brake cable end from the lever
on the shoe and pull the cable from the assembly.
Snap ring
5. Installation is the reverse of removal.
23(S)-7-2 • Parking Brake Service SM 661, Aug ’01

GROUP 25
GROUP 25
STEERING COLUMN AND GEAR
Steering System Specifications

and Description .................................... Section 1
Steering System Troubleshooting ........... Section 2
Steering Column and Component

Removal and Replacement .................. Section 3
Steering System Relief Pressure Check

and Adjustment .................................... Section 4
Steering Gear Overhaul ........................... Section 5
SM 661, Aug ’01 Group 25, Steering Column and Gear

Group 25, Steering Column and Gear
Section 1
Steering System Specifications and
Description
Steering System Type : Hydrostatic power steering with All truck models have a hydrostatic power steering sys-
load sensing, dynamic signal neutral circuit. tem, which is supplied with oil pressure from the main
hydraulic system pump. The steering hand wheel operates
Steering System Relief Pressure Setting : 8620-9300 kPa
the steering gear (steering control unit), which directs oil
(1250-1350 psi)
flow to the steering cylinder on the steer axle. A steering
Nominal Flow Rating : 23 L/min (6 gal/min) system pressure relief valve is built in the hydraulic pump
to prevent over-pressurization of the steering system. The
Inlet Pressure Rating : 12400 kPa (1800 psi)
pressure relief setting can be tested using the gauge port of
Return Pressure Rating : 690 kPa (100 psi) maximum the hydraulic pump. A steering priority valve, also in the
pump, diverts flow from the main hydraulic system to the
steering system when it senses the pressure increase
Service Intervals
caused by turning the steering hand wheel.
Check the steering system relief pressure annually or after The power steering gear is a remote positioning control
every 2000 hours of operation. Make a visual inspection valve that senses the input signal from the steering hand
of steering control unit hydraulic fittings periodically to wheel, multiplies this signal to assist in reducing the steer-
ensure that the fittings are tight with no leakage. ing effort, and causes the steering axle to turn the wheels
to the desired position by supplying hydraulic flow to the
Fastener Torques steering cylinder.
Steering Handwheel Nut : 35-40 N⋅m (25.5-29.5 ft⋅lb) The steering gear is connected to the bottom of the steer-
ing column. When the steering hand wheel is turned, it is
Steering Column Cover Hex Bolts : 2-3 N⋅m (18-27 in⋅lb; linked mechanically to the steering gear spool and causes
1.5-2.25 ft⋅lb) this spool valve to shift from its closed neutral position to
Directional Control Base Lock Nut : 0.8-1 N⋅m (7-9 in⋅lb; a “turn” position that allows oil under pressure to flow to
0.6-0.75 ft⋅lb) the steering cylinder.
Directional Control Base Flange Capscrew : 3.5-4.0 N⋅m When the steering hand wheel stops turning, centering
(2.5-2.9 ft⋅lb) springs in the valve automatically center the spool, stop-
ping the flow of oil to the cylinder.
Ignition Switch Ring Nut : 10-14 N⋅m (7.3-10.3 ft⋅lb)
The low pressure oil from the opposite side of the steering
Tilt Lock Assembly Base-to-Cowl Bolts : 20-25 N⋅m cylinder is returned through the opposite port in the gear.
(14.8-18.5 ft⋅lb) It is controlled by the same spool as the high pressure
Orbitrol Bracket Bolts : 34-38 N⋅m (25-28 ft⋅lb) port.
Lower Column Assembly Base-to-Steering Gear Bolts: In the event of a pump failure, the steering gear can gener-
34-38 N⋅m (25-28 ft⋅lb) ate sufficient hydraulic power by movement of the steer-
ing handwheel to serve as a limited steering method. An
Universal Joint Pinch Bolt : 20-25 N⋅m (14.8-18.5 ft⋅lb) internal check valve automatically closes to divert this
Wiring Harness Bracket Bolts : 11-13 N⋅m (8-9.5 ft⋅lb) generated oil flow to the proper port of the steering cylin-
der.
SM 661, Aug ’01 Steering System Specifications and Description • 25-1-1

The handwheel turning effort is considerably higher, how- are protected by the steering column cover. The cover can
ever, than with power steering. be removed for service to steering column components.
The entire column can be removed for service or replace-
The column tilt lock mechanism allows the operator to
ment. The steering gear, attached to the base of the col-
adjust the steering column. The column tilt lever knob
umn, can be removed without disassembling the other
releases the adjustment setting and the column returns to
parts of the steering column.
the up position by the use of springs. The tilt lock mecha-
nism, the directional control lever, and the ignition switch
Horn contact ring Column upper cover

Tilt lock assembly boot
Ignition switch
Column
lower cover
Lock ring
Tilt lock assembly

Ignition switch Directional control
wiring harness switch wiring harness
Directional control
lever assembly
25-1-2 • Steering System Specifications and Description SM 661, Aug ’01

Section 2
Steering System Troubleshooting
No steering Truck turns in wrong direction

• Hydraulic fluid level very low. • Hydraulic lines not installed correctly.
• Air in hydraulic oil.
Handwheel kickback
• Steering column sections not connected properly.
• Hose broken. • Check valve faulty (or not in system).
• Hydraulic pump contaminated or defective.
Slow steering response
Hard steering • Oil viscosity too high.
• Hydraulic fluid level low. • Contaminated or defective steering gear.
Chatter conditions
• Steering gear contaminated or defective.
• Loose mountings or linkage. Make certain all
• Relief valve setting too low ; adjust or replace.
mounting fasteners and other linkage is tight.
• System leaking.
• Pressure relief valve set too low and is out of
• Incorrect tire pressure. adjustment ; adjust or replace the relief valve.
• Axle load too heavy. • Insufficient pump flow. Check pump for leaks and
• Lack of lubrication. see Group 29, Section 2.
Unsatisfactory steering in either direction
• Defective steering gear.
• Malfunctioning, damaged, or worn priority • Air in system due to excessive wear in steering cyl-
demand valve (flow control valve). inder. Check for air in system. Excessive noise or
foamy condition of hydraulic fluid indicates aera-
High number of handwheel turns tion. Check that air is not entering the system
through poor threads, cracked, split, or worn hoses,
• Steering cylinder seal leakage. bad pump seals, bad O-rings, bad gaskets, or loose
• Worn steering gear. connections.
Worn cylinders result in leakage past the piston.
Steering handwheel spins freely Overhaul (see Group 26, Section 7) or replace the
steer cylinder.
• Air in system (cavitation).
• Incorrect system pressure due to worn pump.
• Low oil supply.
Replace the relief valve or repair or replace the
• Steering column detached from steering gear. pump (see Group 29).
• Defective steering gear.
Noise during turns
Jerky steering
• Worn bearing (s) in steering arm; replace bearings.
• Steering gear malfunction because of worn parts or • Worn pin in steering knuckle ; replace pin.
contamination. Steering gear may require overhaul.
• Worn bearings in steering knuckle ; replace bear-
ings.
• Steering knuckle is loose ; tighten castle nut.
SM 661, Aug ’01 Steering System Troubleshooting • 25-2-1

Constant noise from steering axle Low pressure at the pump

• Loose or worn hub bearing cones. Adjust or • Refer to the pump troubleshooting and overhaul
replace hub bearing cones. Replace bearing cones procedures in Group 29.
and bearing cups as a set.
Low pressure at the steering gear
Noise when axle pivots
• Refer to Section 5, “Steering Gear Overhaul.”
• Lack of lubricant in steering axle mounting.
• Steering axle mountings worn; replace mountings. Low pressure at the steer cylinder
• Steering axle mounting cap(s) loose ; tighten • Seals worn out at piston rod end of steer cylinder;
mounting cap(s). replace seals.
Fluctuating pressure Steer cylinder rod binding or sticking

• Faulty operation of relief valve. Fluctuating pres- • Binding of linkage. With hydraulic flow shut off
sure or loss of pressure in the system is usually from the cylinder and the rod end uncoupled, the
caused by scales, chips, sludge, or filings that have rod should slide freely in or out by hand. If the pis-
lodged between the relief valve and seat. A dam- ton is binding, overhaul or replace the cylinder.
aged spring or worn valve may also be the cause of
the trouble. Flush and refill the system and replace
the hydraulic return line filter element. If condition
still exists, replace the relief valve.
25-2-2 • Steering System Troubleshooting SM 661, Aug ’01

Section 3
Steering Column and Component Removal and Replacement
IMPORTANT
Before removing any component for overhaul, make sure the
correct repair parts, seals, and gasket sets are available.
Horn contact ring Column upper cover

Tilt lock assembly boot
Ignition switch
Column
lower cover
Lock ring
Tilt lock assembly

Ignition switch Directional control
wiring harness switch wiring harness
Directional control
lever assembly
SM 661, Aug ’01 Steering Column and Component Removal and Replacement • 25-3-1
3. Remove the lock ring nut securing the ignition switch

! CAUTION to the lower cover. Label all wires and terminals for
SAFE PARKING. Before working on truck : correct reconnection when reassembling.

surface, such as a concrete floor with no Ignition switch
gaps or breaks.
Ignition wire #11
lower the forks or attachment. Lock ring Ground

4. Apply the parking brake and block the Battery wire #6
wheels.
Starter wire #6
Steering Column and Component

Removal
Hand Wheel, Horn Contact Ring, and
Use the following steps to disassemble the steering col-
umn for service to the : Directional Control Assembly Removal
• Ignition Switch 1. Disconnect the negative lead at the battery.
• Horn 2. Gently pry the horn button from the steering hand
• Directional Control Lever Assembly wheel hub using a small, flat-bladed screw driver.
• Column Tilt Lock Assembly
• Upper and Lower Steer Column
• Steering Gear. Horn button
Determine which component requires service and check

the procedure for removing that component. Read the pro- Horn wire
cedure completely before beginning disassembly. Horn contact
ring wire
Horn wire
Ignition Switch Removal
1. Disconnect the negative lead at the battery. Hand wheel
2. Remove the four socket head bolts holding the two

halves of the column cover together. The directional
control assembly and the ignition switch are exposed.
3. Disconnect the horn wire from the steer column and

unplug the horn contact wire from the terminal on the
bottom of the horn button.
4. Remove the nut holding the hand wheel to the steer-
ing column.
5. Use a wheel puller to remove the hand wheel from
the steering column. Hand wheel has two M8×1.25
threaded inserts in the hub for this purpose.
25-3-2 • Steering Column and Component Removal and Replacement SM 661, Aug ’01
6. Unplug the horn contact ring wire from the terminal 9. Lift the directional control lever and boot off the die-
on the bottom of the handwheel. cast base.
Directional
control lever
Boot
Horn contact
ring wire
Horn wire
10. Unplug wires from directional switches. Label all
wires and terminals for correct connection when
7. Using a 2.5 mm allen wrench, remove the four socket reassembling. Remove the direction control switches
head bolts holding the two halves of the column by removing the mounting screws on the base.
cover together. Remove the top cover. Gently pull the
bottom cover away.
Mounting screw
Wiring
connedtors
and terminals
Directional Control Lever Detent Spring Removal

1. If not already disassembled, remove the four socket
bolts holding the two sides of the column cover
NOTE together. Remove the top cover.
Use care when removing the bottom cover as
2. Pry the two retainer clips from the posts on the direc-
the ignition switch wiring is attached.
tional control base securing the detent spring. Lift
spring off posts.
8. Remove the horn contact ring. Unplug the wire from
the terminal on the bottom of the ring. Retainer clips
Horn contact
ring
Detent spring
Column Tilt Lock Assembly Removal a. Remove the three screws securing the instrument
pod to the dash.
NOTE
The tilt lock assembly is not serviceable; only Instrument pod
the return springs are serviceable. The tilt
lock assembly should be removed only for
replacement as a complete assembly. Wiring harness
connector
1. Raise the operator’s seat deck and lift out the floor
plate.
2. Remove the left, right, and center cowl covers from
under the dash. See removal and replacement proce-
dures in Group 38.
3. See “Hand Wheel, Horn Contact Ring, and Direc-
tional Control Assembly Removal” to remove the
steering hand wheel, horn ring, and directional con-
trol assembly.
4. Unplug the ignition switch and directional control
switches. Label all wires for correct reassembly. Dis- b. Gently lift the instrument pod up exposing the
connect the ignition and directional control wiring harness connector. Unscrew jack screw in con-
harness from the main harness at lower right of cowl. nector and unplug the connector from the instru-
ment pod.
5. Loosen the pinch bolt of the lower universal joint
c. Remove the screws securing the dash panel to the
connection.
cowl.
Upper steering column

Dash panel
Tilt lock assembly
Cowl
Lower steering column
6. Slip the boot off the tilt lock assembly.

7. Remove the dash panel and instrument pod :
d. Remove the hydraulic control lever cover panel

and dash.
e. Remove the two bolts from the wiring harness

bracket located under the cowl.
f. Remove the four bolts holding the base of the tilt
lock assembly to the cowl.
Tilt lock assembly
Steering gear
2. If upper portion of the steering column has not been

removed, loosen the pinch bolt of the lower universal
joint connection.
3. Remove the two bolts and spacers securing the lower
column shaft and steering gear to the bracket on the
lower cowl.
Steering Gear and Lower Steering Column

Removal
NOTE
Lower steer column is not serviceable. It
should be removed only for replacement as a
Bracket
new assembly.
1. Put a pan under the truck to catch hydraulic fluid Spacers

which will drip when fittings are loosened. Label the
four hose fittings of the steering gear to make sure
they are reassembled correctly. Loosen and remove
the hydraulic fittings at the steering gear. Cap the
ends to prevent fluid leaks. Cap the steering gear Lower column shaft and
steering gear
ports to prevent dust and debris from getting into the
steering gear. Keep hydraulic ports and hoses clean.
4. Remove the bolts to detach the steering gear from 1. Attach the steering gear to the lower column base.
the lower steering column. Torque the two bolts to 34-38 N⋅m (25-28 ft⋅lb).
2. Set the column into position with the lower column
assembly aligned through the bracket mounted on the
lower frame cowl.
Lower
steering
column
Steering Bracket
control
valve
Spacers
5. Remove the lower shaft and steering gear assembly

Lower column shaft and
from the truck. steering gear
Steer Column and Component

Replacement 3. Coat the splines of the lower assembly with a light
coat of anti-seize lubricant and insert into the univer-
These steps cover the procedures for reinstallation of the sal joint pinch connector of the upper assembly.
steering column including the steering gear, the tilt lock Match the skip tooth on the spline with spline on uni-
assembly, directional control assembly, ignition switch, versal joint. Torque the pinch bolt to 25-30 N⋅m
and steering hand wheel and horn. (18.5-22.25 ft⋅lb).
IMPORTANT 4. Reconnect the clean hydraulic fluid lines to the clean
Make sure all parts are clean and dry before steering gear. Make sure the hoses are reconnected to
reassembling. the correct ports. Torque the fittings per Group 40,
It may be necessary to assemble the steering “Hydraulic Fitting Tightening Procedure.”
column in place and hand tighten fittings so
that the correct alignment of the entire col-
umn and parts can be checked. Once you
have the correct alignment, torque all fittings
to their correct specifications.
Steering Gear and Lower Steering Column Bracket
Replacement
NOTE
If the upper steering column has not been Steering gear
removed, the lower steering column must be
left loose at the universal joint pinch connec-
tion to allow some play in the column for
positioning the steering gear.
Column Tilt Lock Assembly Replacement Directional Control Assembly Reassembly

1. Set the tilt lock assembly onto the cowl. Replace the 1. Slip the lever boot onto the lever if it has been
four bolts and torque to 20-25 N⋅m (14.8-18.5 ft⋅lb). removed.
2. Make sure the flange capscrew and clamp are on the
Tilt lock assembly
directional control base.
Connector u-joint
pinch connector
with lower
column spline
Capscrew
Replace bolts
under cowl
Clamp
3. Install the detent spring on the posts of the base and

secure with the retainer clips.
2. Coat the splines of the lower assembly with a light Retainer clips
coat of anti-seize lubricant and insert into the univer-
sal joint pinch connector of the upper assembly.
Match the skip tooth of the lower column spline shaft
to that on the universal joint. Torque the pinch bolt to
25-30 N⋅m (18.5-22.25 ft⋅lb).
3. Set the harness bracket into place and secure with the
two bolts. Torque the bolts to 11-13 N⋅m (8.1-9.6
ft⋅lb).
4. If the wiring harnesses have been removed, reroute

them through the tilt lock assembly with the ignition Detent spring
wiring harness in the left hole and the directional
switch wiring harness in the right hole. Harnesses
must exit lower part of the steer column behind the
steer shaft (towards rear of truck). Reclamp to cowl if
necessary. Reconnect the assembly wiring harnesses
to the truck wiring harnesses. 4. Reset the forward or reverse switch onto the base and
secure with screws.
5. Slip the boot over the tilt lock assembly.
Mounting screw
R F
Wiring
connedtors
and terminals
5. Apply a thin coat of grease in the bore of the direc- d. Loosen the mounting screw on the forward
tional control lever. Slip the lever onto the directional switch and adjust the switch box to achieve conti-
control base. nuity through the switch.
Directional e. Remove #8 (4mm) screw and return lever to neu-
control lever tral detent. Switch must break continuity, If
and boot
switch does not break continuity, it must be read-
justed using the above steps.
f. When adjustment is correct, torque switch box
mounting screws to 0.8-1.0 N⋅m (7-9 in-lb; 0.6-
0.73 ft⋅lb).
g. Repeat procedure for Reverse switch.
Directional Control Assembly and Ignition

Switch Replacement
1. Disconnect the negative lead at the battery.
6. Tighten the capscrew/clamp of the directional control
lever assembly to 3.5-4 N⋅m (2.5-2.9 ft⋅lb). 2. Slip the directional control assembly onto the steer-
ing column shaft.
• Clean the capscrew and apply Loctite 262 before
applying torque.
7. Adjust the directional control using the following
illustration :
Directional control
Detent spring Forward switch assembly
Reverse switch
Directional lever
Wire #82
common Wire #82
Wire #73 common
Wire #78 normally
normally open
open 3. Clean the capscrew, apply Loctite 262, and tighten
a. Loosen mounting screws and set the directional the clamp bolt of the assembly to 3.5-4 N⋅m (2.5-2.9
switch boxes to approximately the middle of the ft⋅lb).
mounting slot on the assembly base. 4. Check the assembly for smooth operation and make
b. Connect a continuity meter on the forward switch necessary adjustments before proceeding.
from the Common terminal to the Normally Open
terminal. If the adjustment procedure is being 5. Connect the wiring to the directional control
performed with the directional control assembly switches according to the labels you made during
mounted on the steering column, connect the con- disassembly.
tinuity meter from the Normally Open terminal to 6. Connect the ignition wiring harness ends to the igni-
vehicle ground. tion switch terminals according to the labels you
c. Rotate the directional control lever in the forward made during disassembly.
direction (push lever up) until a #8 (or 4mm)
screw can be inserted into the middle detent on
the lever.
7. Set the ignition switch into the mounting hole on the Steering Hand Wheel Replacement
lower half of the column cover. Tighten the lock ring
nut to 10-14 N⋅m (7.5-10.3 ft⋅lb). 1. Reconnect the horn contact ring wire from the base
of the handwheel to the bottom of the horn button.
Ignition switch
Ignition wire #11
Lock ring Ground
Horn contact
ring wire
Battery wire #6
Starter wire #6
8. Reconnect the horn contact ring wire to the horn con- Horn wire
tact ring.
Horn contact 2. Apply a coat of insulating paste (Clark part no.

ring 2802205) to horn contact ring, then set the hand-
wheel into position and tap with a rubber or plastic
Horn contact mallet to seat it on the column.
ring wire
3. Tighten the nut onto the column to a torque of 35-40
N⋅m (25.5-29.5 ft⋅lb).
4. Screw the horn wire into the column and plug it into
its connection on the bottom of the horn button.
9. Slip the horn contact ring onto the steering column.

The groove in the ring should be on the lower portion
of the ring when it is replaced on the column. The
terminal should be on the right-hand side of the
Horn wire
truck.
10. Join both halves of the cover over the upper column.
The parting line of the boot must be aligned with the
parting line of the two cover halves. Set the direc-
tional control lever boot into the correct position. The
horn ring contact should be positioned so that the two
cover halves fit the groove in the ring. Tighten the
four socket bolts to 2-3 N⋅m (1.5-2.25 ft⋅lb).
5. Set the horn button into place and pop it into position
carefully. The horn symbol should be parallel to the
CLARK lettering on the hand wheel.
6. Reconnect the leads at the battery.
7. Replace the center cowl cover over the steering col-
umn. See Group 38 for instructions to replace the
cowl covers. Torque the screws to 8-10 N⋅m (5.5-7.5
ft⋅lb).
IMPORTANT 9. Set the floorplate back into the driver’s compartment

If you set the column loosely into place to and lower the operator’s seat deck.
assure correct alignment, recheck that all Start the truck to check the function of the ignition switch.
mounting brackets, the universal pinch joint, Make sure no fluid leaks are evident in the steering con-
and all fasteners are torqued to their correct trol valve hydraulic fittings. Remove the wheel chocks to
limits. See the individual steps in the reas- check all functions of the steering column, including igni-
sembly procedures to find torque limits. tion, directional controls, tilt lock mechanism, and steer-
ing gear for correct operation before returning the truck to
8. Replace the right and left cowl covers. The top lip of service.
the two covers must be inserted under the edge of the
dash before securing the covers in place. Torque the
cover set screws to 8-10 N⋅m (5.5-7.5 ft⋅lb).
Section 4
Stering System Relief Pressure Check and Adjustment
! CAUTION ! WARNING
SAFE PARKING. Before working on truck: Do not use your hands to check for hydraulic
leakage. Use a piece of cardboard or paper to
1. Park truck on a hard, level, and solid search for leaks. Escaping fluid under pres-
surface, such as a concrete floor with no sure can penetrate the skin causing serious
gaps or breaks. injury. Relieve pressure before disconnecting
hydraulic or other lines. Tighten all connec-
tions before applying pressure. Keep hands
and body away from pinholes and nozzles
3. Put all controls in neutral. Turn key which eject fluids under high pressure.
switch OFF and remove key. If any fluid is injected into the skin, it must
be surgically removed within a few hours by
a doctor familiar with this type of injury or
wheels.
gangrene may result.
Description and Operation Steering System Relief Pressure Setting

Steering system relief pressure settings above the speci- Check and Adjustment
fied values can cause failure of the hydraulic lines, dam-
age to seals in the steering gear, and ball joint breakage on This procedure requires installation of a pressure gauge at
the steer axle. the gauge port on the main hydraulic pump. The pressure
is measured while the steering handwheel is turned fully
The steering system’s pressure relief valve is part of the in one direction to put the steering system in bypass.
main hydraulic pump assembly. Steering system relief
pressure is adjustable and should be checked if indicated Steering system relief pressure setting may be checked
by troubleshooting. Use the gauge port on the pump to using a Mico Quadrigage (Clark Part No. 1800106) or
check steering relief pressure. with a conventional pressure gauge, 0-20,700 kPa (0-3000
psi).
Steering system relief pressure setting should be 8620-
9300 kPa (1250-1350 psi). 1. Tilt the steering column fully forward and raise the
seat deck.
NOTE
If relief pressure is not correct, the problem
may be caused by dirt in the valve or worn
parts, including steering control valve and
main hydraulic pump. Generally, if the relief
pressure measured when the steering system
is in bypass is not correct, the priority
demand valve should be replaced.
SM 661, Aug ’01 Stering System Relief Pressure Check and Adjustment • 25-4-1
2. Clean the port opening and connect the pressure

gauge (also cleaned) to the gauge port on the main
pump.
b. Clockwise adjustment of the relief valve seat

raises the pressure setting at which the valve
relieves pressure ; counterclockwise adjustments
lowers the pressure setting at which the valve
relieves pressure.
7. Restart engine and repeat steps to read and adjust the
relief pressure setting until correct relief pressure is
set.
3. Start the engine and let it warm up until it runs
smoothly. • Once you adjust to the correct relief pressure set-
ting, reset the core plug in the valve bore.
4. Check steering system relief pressure setting at full
• If the correct relief pressure cannot be gained, con-
throttle. Accelerate engine to full throttle and hold at
sider overhauling or replacing both the priority
this speed while taking the pressure readings.
valve and the pressure relief valve. See Group 29,
IMPORTANT “Hydraulic Pump Overhaul” for instruction to
Do not operate system over relief any longer remove, overhaul, and replace the valves on the
than required to read the pressure gauge. pump.
Prolonged time at relief pressure can result in 8. Disconnect the pressure gauge and close the engine
a damaged pump and valve. compartment.
5. Turn the steering handwheel in one direction until

steering cylinder reaches its stop (relief bypass).
Hold steering handwheel in relief position until pres-
sure reading is taken, and then release. Turn off
engine. Pressure should read between 8620-9300 kPa
(1250-1350 psi).
6. To adjust the steering pressure relief to 8620-9300
kPa (1250-1350 psi) :
a. Carefully remove the core plug of the steering
pressure relief valve on the main pump by prying
the plug out.
25-4-2 • Stering System Relief Pressure Check and Adjustment SM 661, Aug ’01
Section 5
Steering Gear Overhaul
IMPORTANT
NOTE
The following material does not show the load sensing port
on the steering gear (steering control unit). The port is
located in the center of the other four ports. The load sensing
port requires no special overhaul procedures.
SM 661, Aug ’01 Steering Gear Overhaul • 25-5-1

Disassembly 5. Remove meter (gerotor). Be careful not to drop star

(rotor).
Cleanliness is extremely important when repairing a steer-
ing gear. Work in a clean area. Before disconnecting lines,
clean port area of unit thoroughly. Use a wire brush to
remove foreign material and debris from around exterior
joints of the unit.
NOTE
Although not all illustrations show the unit in
a vise, it is recommended to keep the unit in
the vise during disassembly. Follow the
clamping procedures explained throughout
the text.
6. Remove seal from meter.

Meter (Gerotor) End
7. Remove drive spacer(s).
1. Clamp unit in vise, meter end up. Clamp lightly on
edges of mounting area, as shown. Use protective 8. Remove drive.
material on vise jaws. Do not overtighten jaws.
9. Remove spacer plate.

2. Remove capscrews. 10. 10.Remove seal from housing.
Control End
11. Remove housing from vise and place on a clean soft
cloth to protect surface finish. Use a thin-bladed
screwdriver to pry retaining ring from housing.
3. Remove end cap.

4. Remove seal from end cap.
25-5-2 • Steering Gear Overhaul SM 661, Aug ’01

12. Place assembly so shaft is horizontal. Rotate spool IMPORTANT

and sleeve until pin is horizontal. Push spool and Do not bind spool and sleeve in housing.
sleeve assembly forward with your thumbs just far Rotate spool and sleeve assembly slowly
enough to free seal gland bushing from housing. when removing from housing.
Remove bushing.
17. Push pin from spool and sleeve assembly.
18. Push spool partially from control end of sleeve, then
remove six centering springs from spool carefully by
hand. Note their position in the unit before they are
removed.
13. Remove quad ring seal from seal gland bushing.
14. Use a thin-bladed screwdriver to pry dust seal from

seal gland bushing. Do not damage bushing.
15. Remove two bearing races and the needle thrust
bearing from spool and sleeve assembly. 19. Push spool back through and out of sleeve. Rotate
spool slowly when removing from sleeve.
20. Remove seal from housing.
16. Remove spool and sleeve assembly from cap (14-

hole) end of housing.
21. Remove set screw from housing.

22. Screw a 1/8-inch-24 NC machine screw into end of
check ball seat. Then pull on screw with pliers to lift
seat out of housing.
23. Remove two seals from check valve seat.
24. Tip housing to remove check ball and check ball
retainer.

Parts Inspection 4. Lubricate check ball seat and seals thoroughly before
installing seat in housing. When installing seat do not
Inspect all parts for damage, cracks, broken parts, dam- twist or damage seals. Install check ball seat in hous-
aged threads, corrosion or erosion of surfaces, worn spots, ing; insert open end of seat first. Push check ball seat
nicks or scratches. to bottom of hole.
Check all mating surfaces. Replace any parts that have 5. Install set screw. Use a 5/16-inch Allen wrench to
scratches or burrs that could cause leakage. Discard all old torque set screw to 11 N⋅m (100 in-lb; 8.3 ft⋅lb). To
seals and replace with new ones. prevent interference of parts, make sure top of set
Clean all metal parts in clean solvent. Blow dry with air. screw is slightly below housing mounting surface.
Do not wipe dry with cloth or paper towel because lint or 6. Assemble spool and sleeve carefully so that the
other matter can get into the hydraulic system and cause spring slots line up at the same end. Rotate spool
damage. Do not use a coarse grit or try to file or grind while sliding parts together. Some spool and sleeve
these parts. sets have identification marks ; align these marks.
If parts are left exposed, cover them with a clean cover to Test for free rotation. Spool should rotate smoothly
prevent airborne dust from collecting on them. in sleeve with finger tip force applied at splined end.
Reassembly
Refer to Service Parts Book when ordering replacement
parts. A good service policy is to replace all old seals with
new seals at overhaul.
NOTE
Lubricate all seals (with exception of new
quad ring seal) with clean petroleum jelly
such as Vaseline. 7. Bring spring slots of both parts in line and stand parts
Do not use excessive lubricant on seals for on end of bench. Insert spring installation tool (avail-
meter (gerotor) section. able as Part No. 6000057) through spring slots of
Make sure all parts are clean and free of both parts. Position three pairs of centering springs
dust. Before assembly, lightly coat all internal (or two sets of 3 each) on bench so that extended
metal parts with oil. edge is down and arched center section is together. In
this position, insert one end of entire spring set into
spring installation tool, as shown.
Control End
1. Use a needle-nosed pliers to lower check ball retainer
into check valve hole of housing. Make sure retainer
is straight (not tilted on edge) in housing.
On those units which use the low torque centering

springs, there are two pairs of centering springs (or
two sets of each) and one pair (two) spring spacers.
The spring spacers are installed together between the
two sets of centering springs. The installation proce-
dure is the same as that used on the standard (three
2. Install check ball in housing.
pairs of centering springs) units.
3. Lubricate 5/8-inch diameter seal and 7/16-inch diam-
eter seal. Install seals on check ball seat, as above.

8. Compress extended end of centering spring set and 13. Install two bearing races and the needle thrust bear-
push into spool sleeve assembly withdrawing instal- ing in the order shown.
lation tool at the same time.
9. Center the spring set in the parts so that they push
down evenly and flush with the upper surface of the
spool and sleeve.
10. Install pin through spool and sleeve assembly until
pin becomes flush at both sides of sleeve.
14. Install 1-1/4-inch diameter dust seal in seal gland

bushing; flat or smooth side of dust seal must face
11. Position the spool and sleeve assembly so that the down towards bushing.
splined end of the spool enters the 14-hole end of 15. Install dry quad ring seal in seal gland bushing.
housing first. Smooth seal in place with your finger. Do not use
any seal that falls freely into pocket of bushing. Seal
should not “fall” into place but should require light
force to seat.
IMPORTANT
Be extremely careful that the parts do not tilt
out of position while being installed. Push
parts gently into place with slight rotating
action; keep pin nearly horizontal. Push the
spool assembly entirely within the housing
bore until the parts are flush at the meter end
or 14-hole end of housing. Do not push the
spool assembly beyond this point to prevent
the cross pin from dropping into the dis-
charge groove of the housing. With the spool
assembly in this flush position, check for free
rotation within the housing by turning with
light finger tip force at the splined end.
12. Place housing on clean, lint free cloth. Install 2-1/8-

inch diameter seal in housing.

16. Install seal gland bushing over the spool end with a Meter (Gerotor) End
twisting motion. Tap the bushing in place with a rub-
ber hammer. Make sure the bushing is flush against 18. Clamp housing in vise, as shown. Clamp lightly on
the bearing race. edges of mounting area. Do not overtighten jaws.
On those units which use the Teflon seal, install the
Teflon back-up ring into the recess cut into the seal
gland bushing. Install the Teflon seal over the spool
end, then carefully install the seal gland bushing over
the spool end using a rotary motion.
NOTE
The seal gland bushing which is used with the
Teflon seal is not the same as the seal gland
bushing used with the standard quad-ring
seal. The seal gland bushing with the Teflon
seal has an identification groove cut into the
outer diameter of the bushing. The grooved
bushings can only be used with the Teflon NOTICE
seals and the non-grooved bushings used only Check to ensure that the spool and sleeve are
with the quad-ring seals. flush or slightly below the surface of the
housing.
IMPORTANT
Clean the upper surface of the housing by
wiping with the palm of clean hand. Clean
each of the flat surfaces of the meter section
parts in a similar way when ready for reas-
sembly. Do not use cloth or paper to clean
surfaces.
19. Install 3-inch diameter seal in housing.
17. Install retaining ring in housing. After installing ring,

tap on ring or pry with screwdriver around entire cir-
cumference of ring to properly seat ring in groove.
20. Install spacer plate. Align bolt holes in spacer plate

with tapped holes in housing.

21. Rotate spool and sleeve assembly until pin is parallel 24. Install drive spacer(s) when used, in meter.
with port face. Install drive, making sure you engage
drive with pin.
IMPORTANT
Failure to properly install drive and pin may
cause unit to self steer.
NOTE
To assure proper alignment, mark spline end
of drive shaft with a line parallel to slot on
other end, before installing.
22. Install 3-inch diameter seal in meter (gerotor). 25. Install 3-inch diameter seal in end cap.
26. Install end cap on gerotor, and align holes.
27. Install 7 dry cap screws in end cap. Pretighten screws
to initial torque of 17 N⋅m (150 in⋅lb), then torque
screws to final torque of 31 N⋅m (275 in⋅lb) in the
sequence shown.
23. With seal side of meter toward spacer plate, align star
valleys on drive. Note the parallel relationship of ref-
erence lines A, B, C, and D in figure. Align bolt
holes without disengaging meter from drive. Be sure
star has engaged drive spline in position shown.
28. Inspect the assembly to be sure all parts have been

installed and fasteners correctly installed and tight-
ened.
(Reprint courtesy of EATON Corporation)

GROUP 26
GROUP 26
STEER AXLE
Steering Axle Specifications

and Description .................................... Section 1
Steer Axle Wheel Bearing Maintenance

and Adjustment .................................... Section 2
Steer Axle Removal and Replacement .... Section 3
Steer Axle Overhaul ................................. Section 4
Steer Cylinder Removal and

Replacement ......................................... Section 5
Steer Cylinder Overhaul .......................... Section 6
SM 661, Aug ’01 Group 26, Steer Axle

Group 26, Steer Axle
Section 1
Steer Axle Specifications and Description
Specifications Service Intervals

Cushion-Tire Steering Linkage Inspection and Lubrication : Every 50-
250 hours and each PM.
(1250-1350 psi). Steer Wheel Bearing Inspection and Lubrication : Every
500 hours of operation.
Steer Cylinder Type : Double-acting, piston-type.
Steer Cylinder Seals Leakage Check : Every 50-250 hours
Turning Arc : 83° maximum inside turning angle ; 60°
and each PM.
maximum outside turning angle.
Steer Axle Mounting Inspection : Every 50-250 hours and
Pneumatic-Tire
each PM.
Power Steering Relief Pressure Check : Every year or
(1250-1350 psi)
2000 hours of operation.
Steer Cylinder Type : Double-acting, piston-type
Turning Arc : 75° maximum inside turning angle; 54° Description
maximum outside turning angle.
The steer axle has the steer cylinder, steer knuckles, and
Bearing Grease : Grade No. 2 EP multi-purpose grease, steering links mounted on it. All these components can be
Clark Part MS-107C. removed, serviced, and replaced.
The steering gear (steering control unit) at the base of the
Fastener Torques steering column directs hydraulic fluid to one end or the
other of the steer cylinder to pivot the steer wheels.
Steer Axle Mounting Bolts : 170-190 N⋅m (125-140 ft⋅lb).
The steer axle is bolted to the truck frame. The steer cylin-
Cylinder to Axle Mounting Bolts : 240-270 N⋅m
der is connected to the steering knuckles by steer links.
(177-199 ft⋅lb).
Mounting trunnions allow the axle to tilt independently of
Steering Link to Steering Knuckle Nuts : 135-150 N⋅m the truck and “silent” mounts cushion the axle on the trun-
(98-110 ft-lb). nions.
Steer Knuckle King Pin Castle Nuts : See installation pro- All bearings used in the steer axle linkage have lubrication
cedures in Section 4, “Steer Axle Overhaul.” fittings and are serviceable. Axle removal, replacement,
and service for all components, including overhaul of the
steer cylinder, is explained in the Sections for this Group.
SM 661, Aug ’01 Steer Axle Specifications and Description • 26-1-1

Steer axle
Steer knuckle
Silent mounting Steering link

Steer cylinder
Steer Axle and Mounting-Cushion Tire Axle
Steer axle
Steer cylinder
Steer knuckle
Axle mounting
trunnion
Steering link
Steer Axle and Mounting-Pneumatic Tire Axle
26-1-2 • Steer Axle Specifications and Description SM 661, Aug ’01

Section 2
Steer Axle Wheel
Bearing Maintenance and Adjustment
IMPORTANT
2. Try to pull it in and out along the wheel spindle.

! CAUTION
Watch for excessive free movement in wheel bearings or
SAFE PARKING. Before working on truck: steering knuckle bearings. There should be a small
amount of free movement. If the wheel has excessive free
1. Park truck on a hard, level, and solid movement, the bearings require additional service and or
surface, such as a concrete floor with no adjustment.
gaps or breaks.
Wheel Bearing Lubrication
These procedures cover bearing lubrication for the two
types of steer wheels used on the truck ; pneumatic-tire
wheels which are mounted on a hub that contains the bear-
4. Apply the parking brake and block the ing components and cushion-tire wheels with the bearings
wheels. installed in the wheel. Use the procedures to clean, repack
and adjust bearings for both the cushion-wheel and the
pneumatic-tire hub.
Wheel Bearing Check
Pneumatic-Tire Cushion-Tire
Wheel Mounting Wheel
A wheel bearing check should be performed about every Hub
500 hours of operation or three or four times a year.
Wheel bearings need adjustment only after 2000 hours or
as needed. It is recommended that you clean and repack
the bearings before adjustment. Check hourmeter total
hours and refer to the truck’s PM schedule. See steer
wheel bearing lubrication procedure below.
To check the steer wheel bearings for excessive free play
or looseness :
Steer Axle Knuckle
1. Grasp the wheel with both hands and try to move it
by a rocking motion top-to-bottom. Pneumatic-tire (left) and cushion-tire (right) wheel-bear-
ing assemblies.
SM 661, Aug ’01 Steer Axle Wheel Bearing Maintenance and Adjustment • 26-2-1
The bearing components and arrangement are the same 4. Refer to the exploded view illustration of the cush-
for both the cushion and pneumatic types. Instructions for ion-wheel bearing assembly. Loosen and remove the
repacking/lubricating the bearing components apply to hubcap from wheel or hub. You may have to lightly
both types. tap hub cap with a hammer and chisel and use a pry
bar to loosen. Be careful not to damage mounting
surfaces. Remove O-ring from hubcap.
Bearing Disassembly
5. Clean the excess grease from around the wheel nut.
1. Be sure truck is parked and blocked up correctly and
safely to raise steer wheels off the floor. Refer to 6. Remove cotter pin, loosen and remove wheel nut and
“Lifting, Jacking, and Blocking,” in the Group “SA.” bearing washer.
2. Loosen lug nuts of pneumatic-tire wheels before 7. Remove outer bearing by pulling out on the cushion
completely raising rear wheels off the floor. wheel or pneumatic hub slightly to loosen bearings.
3. Lower truck onto blocking. Remove lug nuts and

then wheel assembly.
NOTE
Because of the heavy weight of the pneumatic
wheel and tire, it is suggested to first remove
the wheel and tire assembly from hub when
servicing the bearings to avoid damage to the
grease seal when the wheel hub is moved off
or on the spindle. It also makes the work
simpler and easier.
Steer Axle
Knuckle
Cushion
Tire and
Wheel
Spindle Bearing
Washer Wheel Nut
and Cotter
Pin
Bearing
O-ring
Hubcap
Cushion Wheel Bearing Assembly
26-2-2 • Steer Axle Wheel Bearing Maintenance and Adjustment SM 661, Aug ’01
8. Pull the wheel or hub off the spindle. Support the 1. Install new inner and outer bearing cups by pressing
wheel or hub to avoid dragging the grease seal at the into hub or wheel. Be sure cups are fully seated in
back side across the thread on spindle end. Spindle bore.
guard remains on spindle.
9. Clean the old grease out of center of the wheel or
hub.
10. To remove inner bearing and seal, lay wheel or hub
down with outer edge up (support hub on blocking).
Remove the inner bearing cone and grease seal, using
a brass drift pin, rod, or piece of pipe to drive the
bearing and seal out of the hub.
2. Pack the bearings with grease and install the inner

bearing in the hub or wheel.
Bearing
and Cone
Grease
Seal
3. Pack cavity between bearing and grease seal half full

11. Clean and inspect the bearing cups and cones for with grease.
wear or other damage. Replace, as necessary. 4. Install new grease seal in hub or wheel inner bore.
IMPORTANT Apply coating of grease to inside diameter of seal
lips prior to assembly, then install seal in hub or
Keep serviceable bearing cups and cones
wheel bore.
matched together. Always replace bearing
cups and cones as a set.
12. Inspect grease seal for wear and damage. Replace as

necessary. It is recommended to install a new grease
seal whenever old ones are removed.
13. Use a standard puller to remove bearing cups from
hub or wheel if bearings require replacement.
Bearing Reassembly
5. Carefully press or tap grease seal into place with a
The procedures for packing and reassembling the bearing soft-faced mallet until seal is seated in bottom of
are the same for the cushion wheel or pneumatic wheel bore.
hub. 6. Install hub or wheel on spindle. Be careful not to
NOTE damage grease seal lip when moving the hub over the
Use Grade No. 2 EP multi-purpose grease, end of spindle and threads.
Clark MS-107C. 7. Pack cavity in hub between bearings one-half full
with grease.
SM 661, Aug ’01 Steer Axle Wheel Bearing Maintenance and Adjustment • 26-2-3
8. Install the outer wheel bearing after it has been 17. Remount wheel and tire as applicable for pneumatic-
packed with grease. tire assemblies. See Group 22 for mounting proce-
dures and nut torques.
Wheel Bearing Adjustment

The steer wheel bearings are retained and adjusted by the
wheel nut.
NOTE
You should clean and repack the wheel bear-
ings before performing a wheel bearing
9. Install bearing washer and hand tighten wheel nut. adjustment. See “Wheel Bearing Lubrica-
tion” in this Section for the complete proce-
dure.
1. Make sure the truck is parked on a level, hard sur-

face, the upright is fully lowered, the drive wheels
are chocked, and the steer wheels are jacked and
blocked securely. Refer to “Lifting, Jacking, and
Blocking” for safe procedures.
2. Remove hubcap.
10. Rotate hub or wheel counter clockwise and torque 3. Remove and discard cotter pin.
wheel nut to 27-31 N⋅m (20-23 ft⋅lb).
4. Loosen wheel nut.
11. Back wheel nut up until it is loose.
5. After wheel nut is loosened, hit the top of wheel to
12. While turning the hub or wheel counter clockwise, loosen the bearings. This moves the bearings free of
torque the wheel nut to 2.3-2.8 N⋅m (1.7-2 ft⋅lb). their seated, running position.
13. Back up wheel nut to nearest slot and install new cot- 6. Rotate hub or wheel counter clockwise and torque
ter pin. Bend cotter pin tabs. wheel nut to 27-31 N⋅m (20-23 ft⋅lb).
14. Recheck for correct bearing adjustment by rotating 7. Back wheel nut up until it is loose.
8. While turning the hub or wheel counter clockwise,
with only slight “drag”. Readjust bearings by adjust-
torque the wheel nut to 2.3-2.8 N⋅m (1.7-2 ft⋅lb).
ing wheel nut as necessary to avoid binding in bear-
ings. 9. Back up wheel nut to nearest castellation slot and
install new cotter pin.
10. Recheck for correct bearing adjustment by rotating
16. Refit O-ring on hubcap and install hubcap by tapping
into place with a rubber or plastic-faced hammer.
with only slight “drag”. Readjust bearings by adjust-
ing wheel nut as necessary to avoid binding in bear-
ings.
11. Bend cotter pin tabs over.
13. Refit O-ring on hubcap if removed or replaced and
install hubcap by tapping into place with a rubber or
plastic-faced hammer.
26-2-4 • Steer Axle Wheel Bearing Maintenance and Adjustment SM 661, Aug ’01
Section 3
Steer Axle Removal and Replacement
SM 661, Aug ’01 Steer Axle Removal and Replacement • 26-3-1

installation of the axle without disturbing the

! CAUTION blocking.
SAFE PARKING. Before working on truck:
4. Loosen and remove hydraulic steering lines from
1. Park truck on a hard, level, and solid steering cylinder. Plug fittings and cap open ends of
surface, such as a concrete floor with no lines. Keep all hydraulic fittings and openings clean.
gaps or breaks.
wheels.
Steer Axle Removal

These procedures describe steer axle removal for both
cushion-tire and pneumatic-tire steer axles. The removal Disconnect cylinder lines here.
procedures are basically the same for both axles even

though the axles are different. Minor differences will be
explained in the text. ! CAUTION
1. Remove the counterweight before removing the steer Axle must be supported before any attaching
axle. Refer to Group 38, Section 2, “Counterweight fasteners are removed.
Removal and Replacement.”
5. If another lift truck is used to temporarily support
! axle while removing, put forks in center of carriage
WARNING
about 305 mm (12 in) apart. Move forks under axle
Do not remove the counterweight unless you and raise it just to remove its weight from mounting
have training and are familiar with the cor- bolts. Or use a portable floor jack to carefully sup-
rect procedures. Counterweights can fall if port the axle at its center section.
not handled correctly and cause severe injury
or death. 6. Loosen and remove nuts from axle mounting bolts,
front and rear.
2. Loosen lug nuts of steer wheels. • For cushion-tire axles, remove the mount plates
from the bottom of the trunnion mounts of the
! WARNING steer axle (Figure A.).
• For pneumatic-tire axles, remove the washers
Do not raise truck by hoisting on overhead
behind the nuts also (Figure B.).
guard or by jacking or lifting on counter-
weight. 7. Remove the mounting bolts.
8. Lower the axle allowing its weight to pull the silent
3. Block the drive wheels of the truck and raise and
blocks out of frame recesses. Watch the silent blocks
block the rear end. Remove steer wheels. See “Lift-
to be sure they release freely from frame. You may
ing, Jacking, and Blocking” in Group “SA” for safe
have to loosen blocks with a pry bar if they bind.
procedures to jack the truck.
9. Carefully withdraw the axle from beneath the truck
! CAUTION and move to safe storage.
Make sure truck is correctly raised and
safely blocked using hardwood blocks under
the frame. Be sure the blocking will permit
26-3-2 • Steer Axle Removal and Replacement SM 661, Aug ’01

NOTE Steer Axle Replacement

On pneumatic-tire trucks, removal of the
silent blocks after a long period of usage may Replacement is the reverse of removal. Refer to Figures A
be difficult. Routine removal of the silent and B for replacement.
blocks from the steer axle trunnions (pivot
pins) is not recommended unless they have ! CAUTION
obvious wear, damage, or failure. If removal Make sure truck is correctly raised and
by conventional pulling methods is not suc- safely blocked using hardwood blocks under
cessful, they then must be removed by the frame. Be sure the blocking will permit
destruction of the silent block assembly using installation of the axle without disturbing the
a cutting torch and/or hammer and chisel to blocking.
separate them from the axle trunnions. Be
sure that the axle trunnions are not damaged. 1. If silent blocks have been removed from axle, install
new silent block assemblies. Use a rubber or plastic
mallet to seat the silent mounts onto the axle trun-
nions.
2. Make sure that the silent blocks are positioned cor-
rectly front and rear on the steer axle trunnions at the
start of installation. Align the silent blocks square
with the axle.
3. Use a fork lift truck or mobile floor jack to tempo-
rarily support and raise the axle into place under the
truck. If another lift truck is used to handle axle, cen-
ter the forks with about 305 mm (12 in) spread
between them. Place steer axle assembly in secure
position on fork tips.
If hydraulic jack is used, be sure axle is securely sup-
ported on jack pad.
Silent mounting
Figure A. Steer Axle Mounting-Cushion
Axle mounting
trunnion
Figure B. Steer Axle Mounting-Pneumatic
SM 661, Aug ’01 Steer Axle Removal and Replacement • 26-3-3

9. As applicable, install pneumatic wheel and tire

! WARNING assemblies. See Group 22, “Wheels and Tires” for
Heavy components can fall and cause severe mounting procedures.
injury. Keep your body clear at all times. 10. Carefully raise the truck off the blocking as
described in “Lifting, Jacking, and Blocking.”
4. Install axle assembly into frame by slowly raising it Remove the blocking and lower the truck to the floor.
up while guiding silent block bushings into frame
sockets. 11. Install counterweight; refer to Group 38, Section 2,
“Counterweight Removal and Replacement.”
5. Install silent block mounting bolts through frame
socket holes and silent block, front and rear. 12. Check the axle and steering system for proper opera-
For cushion-tire steer axles, reset the two mounting tion. Start the engine and operate the steering gear to
plates under the silent blocks of the axle. move the steer wheels to maximum travel in both
directions. Note any unusual motion or noise.
6. Install nuts on silent block fasteners and tighten to If the system appears to be operating correctly, drive
170-190 N⋅m (125-140 ft⋅lb). the truck slowly. Fully steer the vehicle in each direc-
7. Remove temporary axle support from under truck. tion and check response.
8. Connect the hydraulic lines to steering cylinder. 13. Check steering cylinder hose line connections and
Tighten fittings to 12-14 N⋅m (106-123 in⋅lb; 8.8- cylinder rod seals for any evidence of oil leakage
10.3 ft⋅lb). before returning the truck to service.
IMPORTANT
Make sure all fittings and openings on the
hydraulic lines are clean.
26-3-4 • Steer Axle Removal and Replacement SM 661, Aug ’01

Section 4
Steer Axle Overhaul
IMPORTANT
! CAUTION
1. Park truck on a hard, level, and solid surface, such as a

concrete floor with no gaps or breaks.
2. Put upright in vertical position and fully lower the forks
or attachment.
remove key.
SM 661, Aug ’01 Steer Axle Overhaul • 26-4-1

Preparation For Steer Axle 2. Remove and discard cotter pin from kingpin castel-
lated nut. Remove the nut.
Disassembly and Overhaul
NOTE Kingpin castellated nut
Cleanliness is of extreme importance in the

• Before starting disassembly, thoroughly clean the

axle assembly of all accumulations of dirt, oil, cor-
rosion, and other substances to prevent contamina-
tion of the parts during disassembly and overhaul.
Kingpin retainer pin
• Work in a clean area.
• Keep all parts in order as disassembly progresses.
3. Drive the kingpin down and out of the assembly.
Take care to properly identify each part and its
Remove the steering knuckle. Note right and left
order of removal. If necessary, keep notes and put
knuckle parts.
markings on parts using a non-destructive marker
such as a grease pencil or felt-tipped pen. IMPORTANT
• See Section 2, “Steer Axle Wheel Bearing Mainte- Do not let the knuckle or pin fall when the
nance,” for procedures to remove the pneumatic- pin is removed.
tire assembly hub from the spindle/knuckle of the
steer axle. Removal of the hub assembly will make 4. Remove the kingpin retainer pin from the base of the
disassembly of the steer axle knuckle easier. kingpin.
• If necessary, see Section 3, “Steer Axle Removal 5. Remove the knuckle bearing washers, dust covers,
and Replacement,” for the procedures to remove upper and lower grease seals, bearings, and bearing
the steer axle from the truck. cups from the assembly.
• See Section 5, “Steer Cylinder Removal and
Replacement,” for the procedures to remove the Grease
steering cylinder and steering links from the steer Washer Seals
axle.
• See Section 6, “Steering Cylinder Overhaul,” to
disassemble the steer cylinder.
Steer Axle Disassembly

To disassemble the steering knuckle, kingpin, and bearing
from the steer axle, it is not necessary to remove the axle
from the truck.
1. Remove the snap ring from the bottom of the steering
link pin and remove the pin. Steering link is free to
be removed from the cylinder rod and knuckle.
Bearing Cup Bearing
Cylinder rod Steering link pin
Bearing cups may be removed by hand, by using a bearing
puller, or by tapping out using a brass drift pin.
Steering link
Snap ring
26-4-2 • Steer Axle Overhaul SM 661, Aug ’01

Parts Inspection 3. Set the retainer pin into the king pin and slide the
king pin into the steer axle/knuckle bore.
1. Clean all bearings, cups, seals, pins, and other parts
in an approved cleaning fluid. IMPORTANT
Make sure that retainer pin enters the hole in
2. Inspect all parts for scratches, chips and wear. Check the underside of the axle.
the steering arms of the knuckles to be sure they are
not bent or twisted. Check all threaded parts for dam- Kingpin castellated nut
age.
3. Replace all parts which show damage.
4. If parts are to be left exposed, coat all mating sur-
faces of parts with a light coating of engine oil.
Steer Axle Reassembly

Kingpin retainer pin
Recommended greasing procedure :
a. Use Grade No. 2 EP multi-purpose grease, Clark 4. Reset the kingpin castellated nut to the top of the
MS-107 or equivalent. kingpin. Torque nut to 50-60 N⋅m (36.5-44 ft⋅lb).
b. Pack all tapered roller bearings with grease 5. Rotate the steer knuckle three times through its full
before assembly. range of movement. Check to be sure that it is free to
c. Pack knuckle pin (bearing) seals with grease rotate in the bearings without binding.
before assembly.
d. Fill steer link sockets with grease through grease 6. Loosen the kingpin nut and retorque the nut to 30-35
fittings after axle is assembled. N⋅m (22.2-25.5 ft⋅lb).
1. Install the upper and lower knuckle bearing cups into 7. Advance the nut to the next castellated slot and lock
the knuckle housing bore. Tap into place with a brass the nut into position with a new cotter pin. Bend cot-
drift pin or equivalent. ter pin tabs over.
Grease 8. Replace steering link pin and snap ring to join the
Washer Seals
cylinder rod to the steering link and knuckle.
Steering link
Snap ring
9. Reinstall grease fitting in knuckle housing and lubri-

Bearing Cup Bearing cate with recommended grease.
IMPORTANT
Make sure that bearing cup is fully seated
against the shoulder in bore. There must be
no gap left between cup and the shoulder in
the bore at assembly.
2. Apply grease to upper and lower knuckle bearings

and install bearings, grease seals, and washers to
bores of knuckle.
SM 661, Aug ’01 Steer Axle Overhaul • 26-4-3

Section 5
Steer Cylinder Removal and Replacement
! CAUTION Steering link pin

Cylinder rod

gaps or breaks.
2. Put upright in vertical position and fully Steering link
Snap ring
NOTE
switch OFF and remove key. Mark left-side and right-side parts for cor-
rect reassembly.
wheels. 3. Tap steer link pin upward until it clears the steering
link bearing and remove the pin.
Steer Cylinder Removal 4. Remove steer link bearing from steering link-to-cyl-
inder rod end bore.
The steer cylinder can be removed from the steer axle for
overhaul or replacement without removing the steer axle 5. Rotate the steering link away from the cylinder rod
from the truck. The cylinder should be overhauled or end.
replaced if steering problems or troubleshooting informa-
6. Repeat steps 1 through 5 for the opposite side of the
tion indicate the cylinder is malfunctioning. See Group
steer cylinder.
25, Section 2, “Steering System Troubleshooting,” for
steering problem diagnoses. See Section 6 in this Group 7. Remove the four steer cylinder mounting bolts and
for steer cylinder overhaul procedures. washers from the steer axle. Removal torque on these
bolts can be as high as 405 N⋅m (300 ft⋅lb).
1. Place a drain pan under the steer cylinder and remove
the hydraulic lines from the cylinder fittings. Cap fit- Cylinder is now ready to be removed from the steer axle
tings and lines to prevent fluid from leaking and to body. Cylinder must be lifted off dowel pins positioning
protect the components and hydraulic system from cylinder to axle body.
dust and dirt. Label hoses and fittings for correct
reassembly.
Mounting bolt
! CAUTION
Remove fittings
Cylinder is somewhat heavy and bulky.
2. Remove the snap ring from the bottom of the steering When removing cylinder from mounting be
link pin. Steering link pin attaches steer cylinder rod prepared to lift and move the full weight of
end to steering link. the cylinder.
SM 661, Aug ’01 Steer Cylinder Removal and Replacement • 26-5-1

Parts Inspection 2. Position the steering link with the cylinder rod end.
Reuse steer link bearing if still serviceable. Install
Completely inspect all parts : new bearings if scoring or wear marks are evident or
1. Clean all bearings, cups, seals, pins, and other parts if the bearings do not operate smoothly.
in an approved cleaning fluid.
2. Inspect all parts for scratches, chips, scoring, and
uneven or heavy wear. Check steering links to be
sure they are not bent or twisted. Check all threaded
parts for damage.
3. Replace all parts showing excessive wear or signs of
damage. Steering link
Snap ring
4. If parts are to be left exposed, coat all mating sur-
faces of parts with a light layer of engine oil. Keep
all parts clean and covered. 3. Rotate steering link into cylinder rod end and align
bearing hole with rod end.
5. Remove and clean all grease fittings before reassem-
bling cylinder components. 4. Tap pin through steer link bearing hole with snap
ring groove on lower end.
Refer to Section 6, “Steer Cylinder Overhaul”, if pressure
check or troubleshooting tips indicate a problem with IMPORTANT
steer cylinder performance. Make sure bearing is properly aligned with
pin in the hole.
Steer Cylinder Replacement
5. Install the snap ring to the steering link pin.
1. Remount the steer cylinder onto the steer axle dowel
6. Repeat steps 1 to 5 for rod end-to-steering link con-
pins; set bolts and washers in place and torque
nection for opposite side.
mounting bolts to 240-270 N⋅m (177-199 ft⋅lb).
7. Clean and replace hydraulic hoses on correct, clean,
cylinder fittings. See Group 40, Hydraulic Fitting
Tightening Procedure” for replacement procedures.
Mounting bolt
! CAUTION
Cylinder is somewhat heavy and bulky. Remove fittings
When remounting cylinder to steer axle
body, be prepared to lift and maneuver the 8. Check to be sure all lube fittings are installed. Fill all
full weight of the cylinder as you set it into lubrication points with correct lubricant. See recom-
position. mended greasing procedure above.
9. Test function of steer cylinder before returning the
truck to service.
26-5-2 • Steer Cylinder Removal and Replacement SM 661, Aug ’01

Section 6
Steer Cylinder Overhaul
IMPORTANT
Steering Cylinder
Cushion-tire truck cylinder with “C” stamped on rod end;
Pneumatic-tire truck cylinder with “P” stamped on rod end.
SM 661, Aug ’01 Steer Cylinder Overhaul • 26-6-1

Preparation for Steer Cylinder Disas- 4. Remove gland from opposite end of steer cylinder.
sembly and Overhaul 5. Remove the seal and O-ring set from the piston. Dis-
card seals. Replace with new seal set at assembly.
Refer to Section 5 for removal of steer cylinder from the
steer axle body. Piston Seal
O-ring
IMPORTANT
Cleanliness is of extreme importance in the
1. Overhaul steer cylinder only in a clean, dust-free

location, using clean tools and equipment. Dirt or grit
will damage the highly-machined surfaces and will
result in leakage or premature failure of components.
Cleanliness of the hydraulic circuit is extremely
important to the proper operation and maintenance of
the system. Be sure the work area is clean.
6. Remove (inner) gland packing (O-ring) seal.
2. Before disassembly, the exterior of the steer cylinder Replace with new seals at assembly.
should be carefully cleaned to remove all dirt and
grease accumulation.
3. Be sure all hydraulic fluid has been removed from
the cylinder. Stroking the piston rod will help force
the fluid out. Rod Wiper
4. Before starting disassembly, the steer cylinder should
be carefully examined to determine if there is any Rod(U-Cup)
external damage. Seal
Steer Cylinder Disassembly

1. Clamp the steer cylinder assembly in a vise. Wrap
the cylinder in a course cloth to prevent slipping and 7. Remove the rod (U-cup) seal and rod wiper from
scratching. Use extreme caution when tightening vise gland and discard. Note direction of seal and wiper
and do not overtighten ; cylinder can be bent, dis- seating for correct reassembly. Replace with new
torted, and potentially destroyed. seals and wipers at assembly.
2. Remove one gland by pulling it from cylinder barrel
and pulling it off the piston rod. Parts Inspection
Gland Gland 1. Carefully clean all parts in an approved solvent and
place on a clean surface.
Cylinder 2. Check the piston for chips, cracks, and looseness on
Barrel
the rod. If loose, replace rod and piston assembly.
Piston Rod 3. Be sure the piston-seal groove in the piston is
smooth, true, and undamaged.
4. Check the piston rod for damage. Look for scratches,
grooves, gouges, pitting, corrosion or other evidence
Cylinder Cut-away of unusual wear. Minor surface damage may be
repaired by use of fine abrasion cloth or stoning.
3. Remove the piston and rod assembly from the cylin- Deeper damage will require replacement of piston
der. rod assembly.
26-6-2 • Steer Cylinder Overhaul SM 661, Aug ’01

5. Carefully inspect the cylinder internal bore for wear, 2. Install new piston seal over the O-ring seal.
scratches, corrosion or other damage. Check the out-
Piston Seal
side for damage. Inspect all welds for cracks. O-ring
6. Inspect the cylinder ports and threads to be sure they
are free of contamination and that the threads are
clean and not damaged.
7. Check the gland for cracks or damage that could
cause failure.
8. Deep gouges or pitted surfaces require replacement
of parts.
9. Put a light coating of hydraulic fluid on all parts. If
parts are to be left disassembled for a period of time,
such as overnight, they should be covered with a 3. Install new gland packing (O-ring) seal on inner end
clean cloth. of gland.
Inner Gland
Packing (O-
Steer Cylinder Reassembly ring) Seal
Check to make sure the overhaul kit you have is correct

and that all parts are included.
IMPORTANT
Be sure inside of cylinder and all parts are
clean before starting reassembly.
Assemble cylinder carefully to prevent dam-
age to seal lips and O-rings. Seals should be
lubricated with hydraulic oil to assist assem-
bly into cylinder barrel and gland.
Heating seal rings in boiling water before 4. Install new rod wiper and rod (U-cup) seal in outer
starting assembly will aid in assembly. end of gland.
1. Install new O-ring seal on the piston.
Rod Wiper
Rod(U-Cup)
Seal
IMPORTANT
Be sure the rod wiper and rod (U-cup) seal
are installed in the correct directions.
5. Lightly lubricate the cylinder and gland mating sur-

faces with hydraulic oil before assembly.
SM 661, Aug ’01 Steer Cylinder Overhaul • 26-6-3

6. Install the gland onto the cylinder bore rim, making Operational Pressure Test
sure gland is fully seated on cylinder.
Once cylinder is remounted on axle (see Section 5), con-
7. Install piston and rod assembly into the cylinder. nect pressure source in turn at each port. Extend piston
NOTE rod at each side and test with internal pressure of 13790
A special part is included in the parts kit to kPa (2000 psi). At this pressure no leakage must occur.
allow you to slip the gland over the rod end Typical operating pressure is 10342 kPa (1500 psi).
without damaging the gland seals.
8. Repeat above procedure for installation of opposite

gland.
26-6-4 • Steer Cylinder Overhaul SM 661, Aug ’01

GROUP 29
GROUP 29
HYDRAULIC SUMP, FILTERS, AND PUMP
Hydraulic Sump, Filters, and Pump

Hydraulic Pump Troubleshooting .......... Section 2
Hydraulic Filters and Fluid

Maintenance ......................................... Section 3
Hydraulic Pump Removal

and Replacement .................................. Section 4
Hydraulic Pump Overhaul ...................... Section 5
IMPORTANT
This Group (29) covers the hydraulic pump for the load han-
dling system, steering system, and standard brake system. It
also covers the charging pump for the standard transaxle,
which is contained in the same housing as the load handling
system pump.
NOTE
Other hydraulic-related components and circuits are
described and illustrated in Group 25, “Steering Column
and Gear,” Group 26 “Steer Axle,” Group 30, “Hydraulic
Control Valve/Lift Circuit,” Group 32, “Tilt Cylinders,” and
Group 34, “Uprights.” Refer to these other groups for
hydraulic components not coverend in this group.
SM 661, Aug ’01 Group 29, Hydraulic Sump, Filters, and Pump
Group 29, Hydraulic Sump, Filters, and Pump
Section 1
Hydraulic Sump, Filters, and Pump
Hydraulic Pump Type : Transmission-driven, gear-type NOTE
with integral load sensing priority flow valve and pressure See Group 30 for a description of the com-
relief valve. On the standard transaxle truck, the pump is plete hydraulic circuit.
tandem-mounted with the transmission charging pump.
Sump Type and Capacity : Tank is built into truck frame The hydraulic sump is installed in the right-hand side
with capacity of 37L (9.8 gallons) for cushion-tire trucks, compartment of the truck frame. The sump is equipped
40L (10.6 gallons) for pneumatic-tire trucks (2.0-2.5 with a return line filter, oil level dipstick, and suction
capacity) and 44L (11.6 gallons) for pneumatic-tire trucks screen.
(3.0 capacity). On the standard transaxle truck, the main hydraulic pump
Hydraulic Fluid Type : Clark Hydraulic Fluid MS-68 (or is mounted to the transmission and is gear-driven by the
other specification MS-68). transmission.
Filter Type : Disposable, glass micro-fiber element. On the standard transaxle truck, the main hydraulic pump
is tandem-mounted with the transmission charging pump.
Suction Screen : 100 mesh stainless steel screen mounted The main hydraulic pump and transmission charging
in sump. pump are removed and replaced as a single unit. The
transmission charging pump should be overhauled when-
Service Intervals ever the main hydraulic pump is overhauled.
The main hydraulic pump draws fluid from the sump. The
Hydraulic Fluid Level Check/Condition Sample : Every
pump includes a load-sensing steering priority valve. The
50-250 hours or each PM.
valve variably divides flow between the steering system
Hydraulic Fluid Change (Drain and Refill) : Every year or and the main hydraulic system, with priority given to the
2000 hours of operation. steering system.
Hydraulic Fluid Filter Replacement : After the first 50 The steering system pressure relief valve is in the pump
hours of operation, then every 6 months or 1000 hours of assembly. This valve limits the fluid pressure to the steer-
operation. ing circuit by rerouting fluid, avoiding possibly damaging
pressures from building in the circuit. A gauge port on the
Hydraulic Sump Suction Screen Cleaning : Every year or
pump allows you to test the hydraulic pressures for both
2000 hours of operation/ with every fluid change.
steering relief and lift/tilt functions. (See Group 30 for
Lift Speed Test : Every 50-250 hours or each PM. pressure testing procedures.)
Oil from the load handling, steering, and braking circuits
Fastener Torques returns to the sump tank through the full-flow return-line
filter. The throwaway hydraulic fluid filter fits in a can-
Pump to Transmission Fasteners : 151-183 N⋅m (111-135 nister mounted in the sump tank opening. A pressure
ft⋅lb). switch gauges flow conditions and lights a warning on the
Suction Hose to Pump Coupling: 20-27 N⋅m (15-20 ft⋅lb). dash panel to indicate flow restrictions. On hydrostatic
transmission trucks, drive circuit oil returns to the sump
Suction Screen to Sump Threading: 411 N⋅m (303 ft⋅lb). through a separate port after being filtered in the drive
Return-Line Filter Socket and Flange Mounting Cap- pump assembly.
screws 5-6 N⋅m (45-53 in⋅lb; 3.75-4.5 ft⋅lb).
Dipstick Fitting: 5-6 N⋅m (45-53 in⋅lb; 3.75-4.5 ft⋅lb).
SM 661, Aug ’01 Hydraulic Sump, Filters, and Pump Specifications and Description • 29-1-1
Serviceable items are the pump, the return line filter, and tings, clamps, and the return-line filter restriction switch
the suction screen. Other components, such as hoses, fit- are non-serviceable and should be replaced if faulty.
Steering gear
Supply line to steering gear

Hydraulic control valve
Gauge port
Supply line to hydraulic

control valve
Main hydraulic pump
Suction line
Sump suction screen
Sump
Steering gear
Return line Hydraulic control valve

filter assembly
Air breather
Return line from

control valve & steering gear
29-1-2 • Hydraulic Sump, Filters, and Pump Specifications and Description SM 661, Aug ’01
Hydraulic Sump, Filters, and Pump Schematic
Lift/Tilt/Aux
Circuit
Pump
Assembly Return line filter and
bypass valve
Steering
Circuit
Gauge
Port
Air breather filter
Load
Suction strainer sensing line
Sump Tank
Schematic for Standard Transaxle Truck
SM 661, Aug ’01 Hydraulic Sump, Filters, and Pump Specifications and Description • 29-1-3
Section 2
Main Hydraulic Pump Troubleshooting
The following is a list of problems and solutions relating Pump not developing sufficient pressure
to the main hydraulic pump and associated components.
For other hydraulic system troubleshooting, refer to • Leak in hydraulic control system ; check system
Groups 30 and 34. for and correct leaks.
• Inlet line restriction ; check for foreign material or
Noisy pump line kinks, check and clean suction screen.
• Suction screen dirty ; clean screen.
• Hydraulic fluid level low ; measure, and correct,
• Defective hydraulic pump ; continue other trouble-
fluid level.
shooting items, then consider rebuilding or replac-
• Fluid viscosity too high ; change to specified fluid. ing pump.
• Sump suction screen dirty ; check and clean.
• Air leak at pump inlet line ; check plumbing tight- Pump output low
ness.
• Inlet line restriction ; check for foreign material or • Cavitating pump ; see “Noisy pump” above.
line kinks, clean sump suction screen. • Air in fluid or wrong fluid ; drain and refill with
• Air leak at pump shaft packing ; replace packing. correct fluid.
• Defective hydraulic pump ; continue other trouble- • System relief valve set too low or too high, stuck
shooting items, then consider rebuilding or replac- or leaking; correct relief valve, pump may be OK.
ing pump. • Overheated fluid ; see remedies under “Overheated
pump and/or fluid” below.
Pump not delivering hydraulic fluid • Contaminated fluid ; correct contamination source
and replace fluid.
• Hydraulic fluid level low ; check, and correct, fluid • Gear face, body or cover nicked ; repair, rebuild.
level.
• Excessive side loading, wear plate tight in body
• Sump suction screen dirty ; check and clean. bore, pinched thrust plate ; inspect and rebuild.
• Inlet line restriction; check for foreign material or
line kinks, check and clean suction screen. Foaming fluid
• Air leak in suction line ; check plumbing tightness.
• Cavitating pump; see “Noisy pump” above.
• Fluid viscosity too high ; check fluid viscosity and
change to specified fluid. • Wrong fluid ; drain and refill with correct fluid.
• Defective hydraulic pump ; continue other trouble-
shooting items, then consider rebuilding or replac-
ing pump.
Failure to build pressure

• Hydraulic fluid level low ; measure, and correct,
fluid level.
• Defective relief valve or pump ; perform pressure
check to test valve and pump.
SM 661, Aug ’01 Main Hydraulic Pump Troubleshooting • 29-2-1

Overheated pump and/or fluid Shaft seal leakage

• Low viscosity fluid ; drain and refill with correct • Damaged or worn seal ; replace.
fluid. • Shaft scratched or worn or seal nicked ; repair (pol-
• Contaminated fluid ; drain fluid, clean suction ish) or replace and add new seal.
screen, replace filter, and refill sump. • Front cover bearing out of position ; replace front
• Cavitating pump; see “Noisy pump” above. cover assembly.
• Pump drive shaft misaligned ; check mounting and • Shaft seal housing bore scratched ; replace front
alignment. cover assembly.
• Axial loading on drive shaft ; check shaft end • Improper fit of shaft ; replace front cover assem-
clearance and shaft alignment; check for worn key/ bly.
spline. • Contamination; inspect and rebuild.
• Relief valve usually in bypass ; check relief set- • Pump run with wrong rotation ; replace shaft and
ting. pressure loading seals.
• Seal installed backwards ; inspect and rebuild.
External leakage
• Excessive system pressure ; replace pressure con-
trol valve on main hydraulic valve.
• Faulty or distorted pump seal gasket ; replace seal
gasket.
• Damaged surfaces on pump body or cover ; correct
and replace as required.
29-2-2 • Main Hydraulic Pump Troubleshooting SM 661, Aug ’01

Section 3
Hydraulic Filters and Fluid Maintenance and Change
IMPORTANT
Before removing any component for service,
make sure the correct repair parts, seals, and
gasket sets are available. Keep all parts clean
during maintenenace and fluid and filter
Return line filter Dipstick changes. Do not allow any contamination into
element canister the hydraulic fluid sump or other compo-
nents.
Air breather
To main control pump
Hydraulic sump
Sump suction screen
Return Line Filter
Suction Line Filter
SM 661, Aug ’01 Hydraulic Filters and Fluid Maintenance and Change • 29-3-1
Hydraulic Sump Fluid Level Check NOTE

In the event of failure of a major component
Check the hydraulic sump tank fluid level with : (e.g., main pump) in the hydraulic system or
• Truck on a level surface. with the possibility of other severe contami-
• Engine stopped. nation of the fluid, samples of hydraulic fluid
should be submitted to an independent com-
• Upright tilted fully back. mercial laboratory for analysis of the con-
• Fork and carriage fully down. taminant level.
• Fluid at room temperature.
1. Tilt steering column forward and open the engine Hydraulic Filters Change
cover. Hydraulic fluid return filter and dipstick
Replace the in-tank, return-line filter and sump breather
assembly is on right side of frame.
element every 1000 hours, at each fluid change, or when
Dipstick signalled by the filter indicator light.
1. Open the engine compartment for access to sump fil-
Air breather ter.
2. Remove the return filter cap and remove and discard
filter element. Fit new filter onto cap holder.
Hydraulic Fluid Return Filter and Dipstick Assembly.

2. Pull the dipstick out, wipe it clean, and push it back
into the dipstick tube. Remove the dipstick again and
Return filter
check the fluid level indication. canister
3. The hydraulic system fluid level should be between
the fluid level markings on the dipstick. These marks
represent an operating range for fluid levels.
NOTE
Approximately 37.4 L (9.9 gal) of hydraulic
fluid are required to fill the hydraulic sump
to the F (Full) mark on a cushion-tire truck. 3. Replace the cap but do not overtighten.
Do not overfill.
Approximately 40.1 L (10.6 gal) are required
on a pneumatic-tire truck. Do not overfill.
4. Add recommended fluid only. Remove the return fil-

ter cap, set a funnel in the opening, and slowly add
hydraulic fluid.
NOTE
Remove or pull dipstick part way out to vent
air from sump while filling.
5. Check the time (hours) of usage and condition of the

hydraulic fluid (age, color or clarity, contamination,
etc.). Replace fluid every 2000 hours of operation or
as necessary.
29-3-2 • Hydraulic Filters and Fluid Maintenance and Change SM 661, Aug ’01
Hydraulic Fluid Change Suction Screen Cleaning

Clean the suction screen in solvent and let dry completely.
Fluid Draining If contaminants remain on the screen, blow screen clean
with air from inside to outside. Replace the suction screen
1. Place a suitably-sized drain pan under the sump and if damaged.
open the drain. Drain pan should be at least 15-gallon
capacity.
! CAUTION
OSHA-approved eye protection rated for 200
kPa (30 psi) is required for air-cleaning oper-
ation.
Fluid Replacement
1. Replace sump drain plug.
2. Check condition of O-ring. Replace O-ring if it is
cracked, nicked, scuffed, hardened, or does not seat
properly.
3. Insert the clean suction screen into the sump opening
and tighten the hex head to 411 N⋅m (303 ft⋅lb).
Sump drain
2. When the sump is completely drained, loosen the Sump suction

suction hose clamp at the sump suction screen. screen
O-ring
Sump suction screen
4. Replace the suction hose and clamp on the screen fit-

ting. Torque clamp to 38 N⋅m (28 ft⋅lb).
O-ring
3. Disconnect and cap the pump suction hose.

4. Remove the suction screen by loosening the hex head Suction Hose
cap from the sump threads. Pull the suction screen
from the sump tank.
5. Check condition of O-ring. Replace O-ring if it is
cracked, nicked, scuffed, hardened, or does not seat
properly. 5. Install a new return filter element and breather ele-
Flush the sump with 2L (2 quarts) of new hydraulic fluid ment.
to clean away any dirt or other contaminants. 6. Set a large, clean funnel in place in the return filter
opening.
SM 661, Aug ’01 Hydraulic Filters and Fluid Maintenance and Change • 29-3-3
7. Refill the cushion-tire truck sump with 37.4 L (9.9

gal) new, clean hydraulic fluid ; refill the pneumatic-
tire truck sump with 40.1 L (10.6 gal) clean hydraulic
fluid. Use only Hydraulic Fluid MS-68, Clark part
number 1802155.
NOTE
Remove the dipstick to vent air from sump
while refilling.
8. Clean up any oil spills.
Check Operation of Hydraulic System
! CAUTION
Be sure there is adequate overhead clearance
before raising the upright.
1. Start the engine and cycle the hydraulic system sev-

eral times :
• Raise the lift carriage to the highest position and
lower fully down.
• Tilt upright fully forward and fully back in both
raised and lowered position.
2. Check for leaks in the hydraulic system. Clean up
any fluid spills.
! WARNING
Do not use your hands to check for hydraulic
search for leaks. Escaping fluid under pres-
sure can penetrate the skin causing serious
injury. Relieve pressure before disconnecting
which eject fluids under high pressure.
3. Turn engine off and check hydraulic sump fluid

level. Add fluid, as necessary, to bring the fluid level
to the correct FULL level as shown on dipstick. Do
not overfill.
4. Close the engine compartment. Remove blocks from
the wheels, if used.
29-3-4 • Hydraulic Filters and Fluid Maintenance and Change SM 661, Aug ’01
Section 4
Hydraulic Pump Removal and Replacement
! Hydraulic Pump Removal

CAUTION
SAFE PARKING. Before working on truck: The hydraulic pump and the transmission charging pump
are a combined unit. The hydraulic pump and transmis-
1. Park truck on a hard, level, and solid sion charging pump must be removed, overhauled, and
surface, such as a concrete floor with no replaced as a unit.
gaps or breaks. 1. Tilt the steering column fully forward and raise the
2. Put upright in vertical position and fully engine cover.
lower the forks or attachment. 2. Remove the floorboard.
3. Put all controls in neutral. Turn key 3. Remove and label lines from pump and cap the ends.
switch OFF and remove key. Place the open ends of lines in an out of the way
4. Apply the parking brake and block the position that will prevent oil spillage.
wheels.
Load Sensing
Line to Steering
Supply to
Steering Gear
Gear
To
Hydraulic
Control
Valve
Trasmission
From Hydraulic
Sump
Hydraulic Pump Plumbing for Standard Transaxle

Truck. Also load sensing line to steering gear connects to
pump on side not shown.
SM 661, Aug ’01 Hydraulic Pump Removal and Replacement • 29-4-1

IMPORTANT 3. Install the hydraulic lines on pump :

Keep all lines, fittings, and ports covered and • Lubricate all O-rings with a light coating of system
clean. hydraulic fluid or a compatible oil.
• Use two wrenches to tighten hose fittings to pre-
4. Remove the fasteners attaching pump to transmis- vent twisting lines. See Group 40 for hydraulic fit-
sion. ting tightening procedures.
5. Remove pump and O-rings. NOTE
6. See Section 5, “Hydraulic Pump Overhaul,” for ser- Always replace hydraulic sump return fluid
vice to the pump. filter when installing new or rebuilt pump.
See Section 3, “Hydraulic Filters and Fluid
Maintenance and Change.”
Hydraulic Pump Replacement
1. Be sure new or rebuilt pump is well oiled prior to 4. Replace the floorboard.
installation. 5. Close engine cover.
IMPORTANT
Keep all components clean while replacing. Pump Operation Check
2. Install pump on transmission using new O-rings. 1. Start the engine and note if pump is running properly
Install and tighten pump mounting fasteners to and not making any unusual noise.
torque 90-110 N⋅m (66-81 lbf⋅ft). 2. Check pump output. Cycle (raise and then lower) the
upright several times. Tilt the upright fully forward
and back, and again listen for any unusual pump
Transmission noise.
Case
O-rings ! CAUTION
Make sure there is sufficient headroom to
fully extend the upright.
Hydraulic Pump
Hydraulic Pump Mounting on Standard Transaxle Truck.
29-4-2 • Hydraulic Pump Removal and Replacement SM 661, Aug ’01

Section 5
Hydraulic Pump Overhaul
IMPORTANT Preparation for Pump Disassembly

On the STANDARD TRANSAXLE truck, the
hydraulic pump and the transmission charg- NOTE
ing pump are a combined unit. The hydraulic Pump disassembly involves separating the lift
pump and the transmission charging pump pump from the transmission charge pump. It
must be removed, overhauled, and replaced is recommended that the transmission charge
as a unit. pump be overhauled when the lift pump is
The following pump overhaul procedures overhauled. Instructions for overhauling
depict the pump assembly for the standard both pumps are included in the following
transaxle truck. procedures.
IMPORTANT • Overhaul pump only in a clean, dust-free location,

Before removing any component for over- using clean tools and equipment. Dirt or grit will
haul, make sure the correct repair parts, damage the highly-machined surfaces and will
seals, and gasket sets are available. result in leakage or premature failure of the pump.
Be sure the work area is clean.
• Plug openings before cleaning and brushing to
avoid contaminating internal parts. Clean exterior
of pump/valve with a good grade solvent, and dry
thoroughly. Use a wire brush if necessary to
remove dirt accumulations.
• Before beginning disassembly, scribe match marks
on the body and cover to ensure that pump will be
reassembled in the same manner as it was shipped
from factory. If the body or rear cover is replaced
during overhaul, scribe a match mark on the new
part as on the part it replaced. This ensures that
inlet and outlet with respect to rotation, is kept the
same.
SM 661, Aug ’01 Hydraulic Pump Overhaul • 29-5-1

Pump Disassembly 6. Remove and discard the charge pump ring-seal (21).
IMPORTANT 7. Remove and discard the charge pump flange O-ring

(28) and two smaller O-rings (23) from the transmis-
The transmission charge pump section of the
sion fluid inlet and outlet orifices on the flange.
pump assembly is present only on standard
transaxle trucks. 8. Push the drive shaft (18) squarely out of the flange
and remove the driven gear (17).
IMPORTANT
9. Remove the bushing seal (20) and the thrust plate
Keep parts in assembly order as removed to (19) from the flange body.
assure correct reassembly.
10. Remove the shaft seal (15) and the circlip (16) from
the flange adapter. Remove and discard the inner
Case Disassembly shaft seal (15) from under the circlip. Push the shaft
1. Remove the four bolts and washers (1 & 2). seal squarely and carefully out of the flange adapter
seal bore. An arbor press can be used to remove the
2. Lightly tap the lift pump to free it from the flange seals.
adapter (14) or the pump flange (22), depending on
pump configuration. Completely separate the units. IMPORTANT
Be careful not to damage the machined seal
3. Remove and discard the body O-ring (4) from the bore.
face of the flange adapter (14) or the pump mounting
flange (22), depending on pump configuration. 11. Proceed to “Lift Pump Disassembly.”
4. Proceed to “Transmission Charge Pump Disassem-
bly” if you are servicing the pump used in the stan- Lift Pump Disassembly
dard transaxle truck ; otherwise proceed to “Lift
Pump Disassembly.” 1. Carefully pull the pump body (9) and the valve body
(3) apart. Tap the pump body with a rubber mallet to
separate the two units if necessary. Valve disassem-
Transmission Charge Pump Disassembly
bly is explained in the next subsection.
1. Remove the lock nut (27), tab washer (26), woodruff 2. Remove the back-up seal (5) and bush seal (6) from
key (25) from the driveshaft (18) or (10), depending the rear (flange-adapter end) of the pump body.
on pump configuration.
3. Remove the back-up seal (5) bush seal (6) from the
2. Remove the drive gear with a suitable puller. front (valve-body end) of the pump body.
3. Remove and discard shaft seal (24) from the pump 4. Before removing the other internal components of
mounting flange (22). Push the shaft seal squarely the pump body, mark the bushes (7, 8) on the front
and carefully out of the mounting flange seal bore. and rear of the pump body for correct reassembly.
An arbor press can be used to remove the seals. Mark the four bushes to denote :
IMPORTANT • Bush on driveshaft flange-adapter end
Be careful not to damage the machined seal • Bush on driven gear flange-adapter end
bore in pump body when removing the seal • Bush on driveshaft valve-body end
because this will result in seal leakage. • Bush on driven gear valve-body end.
If seal bore or recess is scored, Loctite 5. With the pump body lying on its side, pull the drive-
hydraulic sealant must be applied to the shaft and gear (10) squarely from the pump body
outer diameter of the seal. bringing the flange-end bushes (7, 8) out at the same
time.
4. Loosen and remove the four allen capscrews and
washers (12, 13) securing the flange adapter (14) to 6. Remove the driven gear (11) and the remaining two
the pump mounting flange (22). valve-end bushes (7, 8).
5. Separate the adapter from the flange. Use a rubber

mallet to tap the two components apart if necessary.
29-5-2 • Hydraulic Pump Overhaul SM 661, Aug ’01

1. Bolt 14. Charge Pump Flange Adapter 27. Lock Nut

2. Washer 15. Shaft Seal 28. Charge Pump Flange O-Ring
3. Valve Body 16. Circlip 29. O-Ring
4. Body O-Ring 17. Driven Gear (for charge pump) 30. Spool Plug
5. Back-up Seal 18. Drive Shaft and Gear (for 31. O-Ring
6. Bush Seal charge pump) 32. Load Sensing Spring Seat
7. Bush 19. Thrust Plate 33. O-Ring
8. Bush 20. Bushing Seal 34. Control Spring
9. Pump Body 21. Charge Pump Ring Seal 35. Spool
10. Drive Shaft and Gear (for lift 22. Pump Mounting Flange 36. Guide Cap
pump) 23. O-Ring 37. Relief Valve Seat
11. Driven Gear (for lift pump) 24. Shaft Seal 38. Pilot Relief Valve
12. Allen Capscrew 25. Woodruff Key 39. O-Ring
13. Washer 26. Tab Washer 40. O-Ring
41. Pilot Relief Valve Seat
42. Core Plug

Steering Priority and Steering Pressure Relief Parts Inspection

Valve Disassembly
General Inspection
NOTE
1. Wash all parts with clean solvent and dry thoroughly.
Before beginning valve disassembly, clean the
Do not use wiping cloth material that leaves lint
exterior of the valve body (3) of all accumu-
when drying parts. If parts must be left for a long
lated grime that could enter the valve on dis-
period or overnight, cover with a clean cover.
assembly.
2. Thoroughly inspect all components to determine
Steering Priority Valve Disassembly suitability for reuse. The following subsections pro-
vide advice on what to look for on the different pump
1. Remove the spool plug and O-ring (30, 29) from the
components.
bottom of the valve body. Discard the O-ring.
3. Look for warping, scoring, bearing burns, grooves,
2. Remove the load sensing spring seat (32) and O-rings
thread damage, and wear steps on all parts. Parts
(31, 33) and discard the O-rings.
showing evidence of these conditions should be
3. Take out the control spring and spool (34, 35). replaced. Parts that are even slightly out of true or
uneven, scratched, or grooved may lead to fluid leak-
4. Remove the guide cap (36) from the top of the spool
age and diminished and shortened pump life.
to check and clean spool ports.
Steering Pressure Relief Valve Disassembly Bodies

NOTE 1. Inspect all body bore cut-ins where gears fit into the
Disassembly of the relief valve seat (42) is not parts. Bodies can only be reused if the cut-ins are
recommended. If steering pressure relief set- bright and polished looking.
tings cannot be set accurately (see Group 25,
2. Bodies should be replaced if :
“Steering System Relief Pressure Check and
a. Inner surfaces are scored (scratched, grooved, or
Adjustment”) replace the valve seat.
notched)
b. The finishes are dull or have a roughened surface
1. Gently pry out the core plug (43) from the relief
c. They show signs that the tips of gears are digging
valve bore.
in the bores.
2. Screw out the threaded pilot relief valve seat (42).
3. Inspect end surfaces for smoothness and flatness; no
3. Remove and discard the two O-rings (41, 40). superficial damage which may adversely effect per-
formance or sealing can be evident.
4. Remove the pilot relief valve (39).
4. Check all threaded ports and O-ring and shaft seal
5. Remove the relief valve spring (38).
recesses for marks, scratches, or evidence of unusual
wear that may cause imprecise fits and leakage.
NOTE
Replacement shaft seals can be installed with
Loctite hydraulic sealant to overcome slight
damage in areas where the seals are fitted.

Bushes Transmission Charge Pump

1. The flat ends of the bushes (bush side-face) which fit 1. Examine the driveshaft and gear of the transmission
against the ends of the gear teeth (gear side-face) charge pump for excessive wear or damage from cou-
should be perfectly flat with no signs of scoring. pling with the drive gear in the transmission. Replace
a. The side faces of both the bushes and the gears the gear if damage is evident.
should bear a bright, polished appearance.
NOTE
b. Often there is a shadow (or witness) where the
tips of the opposing gears have wiped an overlap If the driveshaft and gear are not serviceable,
resembling a half-moon shape. No noticeable replace the gears as a matched set.
wear step must be evident between the bush and
gear side-faces; they must fit completely flat 2. Examine the thrust plate and bushing seal for scoring
together. or uneven wear and replace if damaged or worn. No
c. Replace the bushes and gears if they show scor- wear step should be evident on the plate and it should
ing, have a dull or roughened finish, or show be smooth and completely flat.
signs of wear steps or tearing of the bush or gear NOTE
side-face materials. A somewhat heavier wear pattern is normal
2. Bush bearing liners (inner bore) are reusable if they on the low pressure (inlet) side of the wear
show no signs of damage or scoring. The general out- plate. However, there should be no heavy
side areas of the bushes should not show any promi- scoring in this area.
nent signs of wear.
Steering Priority and Relief Valve
Gears
Valve components should be free of evident damage. All
NOTE parts are reusable except for replacement kit items. All
If the driveshaft and gear are not serviceable, items should be thoroughly cleaned and dried with a lint-
replace the gears as a matched set. free cloth before reassembly.
The load sensing valve spring seat (32) has an orifice in
1. Gear side-faces should be examined for scoring or the base of the spring recess that must be clean and free
other damage. from contaminants. Clean all threads completely.
2. Operation with contaminated fluid will leave scoring
between the driveshaft and the journal (the portion of
the driveshaft that rotates in the bush bearing) which
leaves a wear step.
Check for a wear step by drawing a sharp point
across the surface from the journal to the tip of the
gear. If a wear step is evident, the gear is unservice-
able.
3. Examine all gear teeth for signs of pitting or uneven
or unusual wear.
4. Journal surfaces should be completely free from
scoring or grooving and should be highly polished
and smooth to the touch.
Replace the gear if journal wear exceeds .001 inch
(0.025 mm).
5. Examine the areas where shaft seals run on gear
driveshafts. These areas show up as polished rings.
If a noticeable groove can be felt, or there is scoring
on the shaft, the driveshaft should be replaced.

Pump Reassembly Lift Pump Reassembly

IMPORTANT 1. Lightly clamp the valve body (3) face up into a vise.
The transmission charge pump section of the 2. Fit valve-end bushes (7, 8) into the lift pump body
pump assembly is present only on standard (9).
transaxle trucks.
3. Place the pump body on top of the valve body and fit
NOTE the driveshaft and gear (10) and the driven gear (11)
Make sure all parts are completely clean. into their original positions in the pump body.
Lubricate all bushes and gears with clean 4. Fit the flange-end bushes (7, 8) into their original
hydraulic fluid. O-ring recesses and end faces bores on the pump body.
of the valve body, pump body, charge pump
flange adapter, and charge pump flange must 5. Fit the new bush seal (6) and back-up seal (5) in the
remain dry, however. flange-end bushes. The bush seal is molded so that
the back-up seal is seated partially in it.
Steering Priority and Relief Valve Reassem- NOTE

Make sure the bush seal and back-up seal are
bly
fitted correctly in the seal grooves of the
bushes.
Steering Priority Valve Reassembly
6. Lift the pump body off the valve body and prop it on
1. Set the spool plug (30) with a new O-ring (29) in the the body-end so it is not resting on the driveshaft.
plug bore on the bottom of the valve body. Tighten
the spool plug to 55-59 lbf⋅ft (75-80 N⋅m). 7. Fit another new bush seal (6) and back-up seal (5) in
the valve-body-end bushes. The bush seal is molded
2. Replace guide cap (36) on top of spool (35). so that the back-up seal is seated partially in it.
3. Set the spool (35) and control spring (34) into the Check fit as in step 5.
valve bore. 8. Set a new body O-ring (4) into place on the valve end
4. Thread the spring seat (32) with new O-rings (31, 33) of the pump body.
into the valve body. Tighten the spring seat to 74-78 9. Place the valve body on the pump body and insert the
lbf⋅ft (100-105 N⋅m). four bolts and washers (1 & 2) through the valve and
lift pump bodies.
Pressure Relief Valve Reassembly
NOTE
1. Set the pilot relief valve (39) into the spring (38) and
Component mating surfaces should be clean,
set the two into the valve bore.
completely dry, and free of any hydraulic or
2. Replace the O-rings (40, 41) on the pilot relief valve other fluids for correct fit.
seat (42).
10. Fit a new body O-ring (4) onto the lift pump side of
3. Insert the pilot relief valve seat into the body and the flange adapter or pump mounting flange (22),
tighten the threads enough to take up the spring load. depending on pump configuration.
NOTE 11. Set the valve and pump body assembly onto the
If a new seal kit was necessary for pump flange adapter (14) or pump mounting flange (22),
overhaul, see Group 25, “Steering System depending on pump configuration, and tighten the
Relief Pressure Check and Adjustment” to bolts to 65-75 lbf⋅ft (88-102 N⋅m).
test for correct relief pressure in the valve. NOTE
Set the relief valve at that time and replace
If seal recess is scored, Loctite hydraulic seal-
the core plug (43) after final adjustment of
ant must be applied to the outer diameter of
the valve.
the seal. Apply a coat of high melting grease
to the shaft seal lips. Do not allow Loctite
onto seal lip.

1. Bolt 14. Charge Pump Flange Adapter 27. Lock Nut

2. Washer 15. Shaft Seal 28. Charge Pump Flange O-Ring
3. Valve Body 16. Circlip 29. O-Ring
4. Body O-Ring 17. Driven Gear (for charge pump) 30. Spool Plug
5. Back-up Seal 18. Drive Shaft and Gear (for 31. O-Ring
6. Bush Seal charge pump) 32. Load Sensing Spring Seat
7. Bush 19. Thrust Plate 33. O-Ring
8. Bush 20. Bushing Seal 34. Control Spring
9. Pump Body 21. Charge Pump Ring Seal 35. Spool
10. Drive Shaft and Gear (for lift 22. Pump Mounting Flange 36. Guide Cap
pump) 23. O-Ring 37. Relief Valve Seat
11. Driven Gear (for lift pump) 24. Shaft Seal 38. Pilot Relief Valve
12. Allen Capscrew 25. Woodruff Key 39. O-Ring
13. Washer 26. Tab Washer 40. O-Ring
41. Pilot Relief Valve Seat
42. Core Plug

Transmission Charge Pump Reassembly 11. Press the drive gear onto the drive shaft (18) and set
the woodruff key (25), the tab washer (26), and lock
1. Set the pump and flange adapter assembly so that
nut (27) on the shaft.
adapter surface faces up.
12. Fit new O-rings (23) into the charge pump inlet and
2. Fit a new shaft seal (15) over the drive shaft (10) and
outlet ports on the mounting flange.
down in the adapter recess. Use a press if necessary
to fit the seal. Do not scratch or dent the seal recess. 13. Proceed to “Final Check.”
NOTE
If seal recess is scored, Loctite hydraulic seal- Final Check
ant must be applied to the outer diameter of
Pour a small amount of clean hydraulic fluid into a port
the seal. Apply a coat of high melting grease
and check that the shaft can be rotated without undue
to the shaft seal lips. Do not allow Loctite
force.
onto seal lip.
3. Fit circlip (16) into grooved recess of the flange

adapter. Follow this with another new shaft seal (15)
as in the previous step.
4. Prop the pump mounting flange (22) on a level, flat
surface with the mounting-side down.
5. Set the bushing seal (20) and the thrust plate (19) into
the flange body.
6. Fit driveshaft and gear (18) and driven gear (17) into
their original positions in the charge pump mounting
flange (22).
7. Set the charge pump ring seal (21) on the mounting
flange.
8. With mating surfaces dry and clean, set the lift pump
assembly on the charge pump flange and insert the
four allen capscrews and washers (12, 13) though the
flange adapter (14) into the mounting flange. Tighten
the capscrews in alternating sequence to pull the
assembly down evenly into place. Tighten the cap-
screws to 28-32 lbf⋅ft (38-43 N⋅m).
9. Turn the assembly over and prop it so that the mount-
ing end is level and flat.
10. Fit a new shaft seal (24) over the charge pump drive
shaft and down in the flange recess. Use a press if
necessary to fit the seal. Do not scratch or dent the
seal recess.
NOTE
If seal recess iss scored, Loctite hydraulic
sealant must be applied to the outer diameter
of the seal. Apply a coat of high melting
grease to the shaft seal lips. Do not allow Loc-
tite onto seal lip.

GROUP 30
GROUP 30
HYDRAULIC CONTROL VALVE/

LIFT CIRCUIT
Hydraulic Control Valve/Lift Circuit

Hydraulic System Schematic ................... Section 2
Hydraulic System Troubleshooting ....... Section 3
Hydraulic System Pressure Checks and

Adjustment ........................................... Section 4
Hydraulic Control Valve Removal

Hydraulic Control Valve Overhaul ........ Section 6
IMPORTANT
Control Valve/Lift Circuit,” Group 32, “Tilt Cylinders,” and
Group 34, “Uprights.” Refer to these other groups for
hydraulic components not covered in this group.
SM 661, Aug ’01 Group 30, Hydraulic Control Valve/ Lift Circuit
Group 30, Hydraulic Control Valve/Lift Circuit
Section 1
Hydraulic Control Valve/Lift Circuit
Specifications Flow Control Adjustments : Adjustable from 4 to 38 L/

min (1 to 10 gpm). Before adjusting, turn fully CCW to
Hydraulic Fluid Type : Clark specification MS-68 (Clark stop. Each CW increases flow by.
part #1802155 and #1800236)
Main Relief Valve Setting : 22100 to 22800 kPa (3200 to Service Intervals
3300 psi) at rated flow.
Hydraulic System Relief Pressure Check : Every year or
Auxiliary Relief Valve Setting : 13800 to 14300 kPa every 2000 hours of operation.
(2000 to 2070 psi) at rated flow.
Rated Flow : Fastener Torques
Lift spool (spool #1) : 76 L/min (20 gpm).
Lever to Spool Rod Turnbuckle Adjustment Jam Nuts :
Tilt spool (spool #2) : 38 L/min (10 gpm). 29.5-33 ft⋅lb (40-45 N⋅m).
Auxiliary spool (spool #3) : 38 L/min (10 gpm). Pivot Pin Keeper Bolt : 6-7 ft⋅lb (8-10 N⋅m).
Integral Pressure Compensated Flow Control Settings : Lever Pivot-Bracket Mounting Nuts Bolts : 29.5-33 ft⋅lb
(40-45 N⋅m).
Tilt spool (spool #2) : 26 L/min (7 gpm).
Auxiliary spool (spool #3) : 9.5 L/min (2.5 gpm).
Maximum Pressure Drop at Rated Flow :
Inlet to outlet : 689 kPa (100 psi).
Lift spool (spool #1) :
- Inlet to cylinder port : 689 kPa (100 psi)
- Cylinder port to outlet : 550 kPa (80 psi).
Tilt spool (spool #2) :
Auxiliary spools (spools #3 and #4) :
Tilt Flow Settings :
Upright Usage Flow

Lpm (gpm)
MFH 6370~7315 TSU 9.8 (2.6)
MFH 4165~5170 STD, 14.4 (3.8)
3860~6100TSU
MFH 2100~3860 STD 17.4 (4.6)
SM 661, Aug ’01 Hydraulic Control Valve/Lift Circuit Specifications and Description • 30-1-1
Description moved. Excess oil flow is returned to the sump. A check

valve prevents reverse flow.
The following description focuses primarily on hydraulic
circutry controlled by the main hydraulic control valve, When all the control valve spools are in neutral, fluid
that is, the lift/tilt/aux circuit. Various other hydraulic sys- flows through the open-centers of the valve spools to the
tems come into play, however, and are mentioned. The sump return line. When a spool is partially shifted and the
entire hydraulic system is depicted in the schematics in associated cylinder or other actuator has not reached its
Section 2 (next page). end-of-travel, some of the fluid flows to the cylinder
(actuator) and the rest flows to the sump line. In both
Descriptions of the braking and steering circuits are given cases, the pressure in the system should be less than the
in Groups 23 and 25. amount required to open the relief valves.
The main hydraulic pump (described in Group 29) is The main relief valve vents flow to the sump when one of
mechanically driven by the transmission (transaxle or the following conditions is present :
hydrostatic pump) and draws fluid from the sump through
a particle-blocking suction screen. A priority valve, con- • The operator continues to hold the lift control in
tained in the pump assembly, senses the demand for flow the lift position after the lift mechanism reaches its
to the steering/braking circuit and divides pump flow end-of-travel.
between the lift/tilt/aux circuit and the steering/braking • Too heavy a load is being lifted.
circuit accordingly, with priority given to steering and • The operator continues to hold the tilt control in
braking. the tilt position after the tilt mechanism has
Fluid from the priority valve goes to the main hydraulic reached its end-of-travel (This is called “tilt
control valve. The lift truck operator moves the main bypass.”)
hydraulic control valve spool by hand, directing fluid to • Auxiliary relief fails to operate.
the lift and tilt cylinders and auxiliary actuators as needed The auxiliary relief valve vents flow to the sump when the
for manipulating the load-handling mechanism. operator continues to hold the attachment control in the
The main hydraulic control valve features an open-center, operated position after the attachment reaches its end-of-
parallel-circuit type modular design. It has the main (lift/ travel.
tilt) pressure relief valve (steering pressure relief valve is Main and auxiliary relief pressure settings can be checked
on main hydraulic pump), a secondary pressure relief through a gauge port on the pump.
valve for optional auxiliary components, a lift spool, a tilt
spool with an integral counterbalance valve, optional aux- Flow from the sump return line is filtered before entering
iliary spools, and adjustable pressure-compensated flow the sump. If the filter is clogged, a by-pass valve routes
controls. All spools are low-leakage design. the flow around the filter. On hydrostatic trucks, fluid in
the return line serves as a source for the hydrostatic pump.
The main hydraulic valve has from two to four valve sec- Fluid from the hydrostatic pump is filtered within the
tions. Each section performs a separate function; standard pump assembly and returned through a separate port in the
two spool assemblies have a inlet/lift section (with fluid sump.
inlet port), a tilt section, and an outlet section. A third and
fourth section may be added to control auxiliary compo- A tilt-lock valve built into the main control valve assem-
nents. bly locks the upright into its current tilt position when the
truck is turned off. A load lowering flow valve mounted
When lift attachments are used, an auxiliary section may on the upright limits the speed at which the operator can
be added to the outer (RH) side of the standard (lift/tilt lower a load, decreasing the speed for heavier loads. A
only) main valve. The optional auxiliary sections also velocity fuse built into one of the lift cylinder ports pre-
have an adjustable relief valve and can be assembled with vents the upright from falling rapidly should a hydraulic
optional flow control levels. line rupture or be disconnected.
The valve spools are arranged in standard sequence (from
NOTE
the operator’s position) to first provide lift control, then
tilt, and finally auxiliary control. The control levers are Hydraulic plumbing arrangement is illus-
spring-loaded (by the valve spool centering springs) to trated in Group 29.
return them to neutral when released. Oil flow is con-
trolled by the amount or distance the control handles are
30-1-2 • Hydraulic Control Valve/Lift Circuit Specifications and Description SM 661, Aug ’01
Section 2
Hydraulic System Schematics
Schematic for Standard Transaxle Truck
1 Hydraulic Sump 5 Main Hydraulic Valve : Main Pressure Relief :

2 Suction Strainer Lift Spool : Tilt Spool & Tilt-Lock Valve :
3 Hydraulic Pump : priority valve : steering relief valve Aux Spools with Secondary Pressure Relief Vavle :
4 Power Steering Valve Adjustable Pressure-Compensated Flow Controls
6 Load-Lowering Valve
7 Filter : Bypass
8 Air breather
SM 661, Aug ’01 Hydraulic System Schematics • 30-2-1

Section 3
Hydraulic System Troubleshooting
The following is a list of problems and solutions relating Overheated hydraulic fluid
to the main hydraulic control valve and associated compo-
nents. For other hydraulic system troubleshooting, refer to • Thin fluid ; drain and fill with correct fluid.
Groups 29 and 34. • Fluid contaminated ; drain sump, clean suction
screen, replace filter, and refill.
No lift, tilt, or auxiliary function • Cavitating pump ; check hydraulic plumbing for
airtight hoses and connections.
• Hydraulic fluid very low; check and fill to correct
• Pump driveshaft misaligned ; check mounting and
level.
alignment.
• Hose or fittings broken; replace component.
• Axial loading on drive shaft ; check shaft end
• Defective main lift valve ; check other Trouble- clearance and shaft alignment ; check for worn
shooting items for possible cause, then consider key/spline.
rebuilding or replacing main lift valve.
• Relief valve in bypass ; check relief setting.
• Hydraulic pump defective ; check other Trouble-
shooting items for possible cause, then consider
rebuilding or replacing pump. Load cannot be lifted to maximum height
• Hydraulic fluid low ; check and fill to correct level.
No motion, slow or jerky action of hydraulic • Hydraulic pump defective ; check other Trouble-
system shooting items for possible cause, then consider
rebuilding or replacing pump.
• Spool not moved to full stroke ; check travel and
linkage adjustment.
Oil leaks at top of lift (secondary) cylinder(s)
• Relief valve not properly set, stuck in place, and/or
worn ; check and clean valve, replace if necessary. • Plugged vent line ; check and clear line.
• Dirt or foreign particles lodged between relief • Worn or damaged piston seal ; rebuild cylinder.
valve control poppet and seat ; check valve and • Scored cylinder wall ; replace cylinder.
clean. See Group 34, “Cylinder Removal, Overhaul, and
• Valve body cracked inside ; check and replace Replacement.”
entire valve.
Oil leak at tilt or auxiliary function cylinder
Foaming hydraulic fluid
• Worn or damaged seal; rebuild cylinder.
• Low oil level ; check and fill to correct level. • Scored piston rod; repair or replace rod.
• Wrong fluid ; drain and refill with correct oil. See Group 34, “Cylinder Removal, Overhaul, and
• Oil too heavy ; change to correct viscosity. Replacement.”
• Pump inlet line restriction or line kinked ; clean
line and suction screen or repair kinked hose. Load will not hold
• Hydraulic pump (or hydrostatic pump) cavitating
• Oil bypassing between lift spool and valve body ;
(pumping air with fluid) ; check hydraulic plumb-
overhaul valve and spool.
ing for airtight hoses and connections.
• Spool not centered ; see spool remedies for correct-
ing problems when spools do not return to neutral.
SM 661, Aug ’01 Hydraulic System Troubleshooting • 30-3-1

• Oil bypassing piston in cylinder ; repair or replace No relief valve action (high pressure)
cylinder.
• Small particles of dirt in relief valve subassembly ;
check, clean, and/or replace relief valve, clean
Oil leaks at either end of main hydraulic valve hole.
spool • Relief valve subassembly installed backwards ;
• Defective O-ring seals ; rebuild valve. reinstall correctly.
Spring-centered spools do not return to neu- Load drops when spool is moved from neu-
tral tral to a power position
• Broken springs ; rebuild valve. • Dirt or foreign particles lodged between check
valve ball and seat ; check and clean.
• Entrapped foreign particles ; check and clean sys-
tem and valve. • Sticking or scored check valve ; clean if sticking,
replace if scored, replace poppet.
• Bent spool ; replace with new valve section.
• Misalignment or binding of linkage ; check and
align/adjust linkage.
30-3-2 • Hydraulic System Troubleshooting SM 661, Aug ’01

Section 4
Hydraulic System Pressure Checks and Adjustments
1. Tilt the steering column fully forward and raise the

! CAUTION engine cover.
SAFE PARKING. Before working on truck: 2. Remove the cap from the gauge port on the pump
and connect pressure gauge to the fitting.
gaps or breaks.
wheels.
Relief Pressure Check

Following is the general procedure for checking main Checking Relief Pressure. Gauge port location varies.
hydraulic valve lift and auxiliary relief pressure, (if the
truck is equipped with an auxiliary component). NOTE
Use quick-disconnect adapter fitting, Clark
Hydraulic system relief pressure setting may be checked
Part #913125.
using a Mico Quadrigage (Clark Part No. 1800106) or
with a conventional pressure gauge with suitable pressure
3. Start the engine and let it warm up until it runs
range calibration. To cover all models of the truck, a
smoothly. Continue with step 4.
gauge with capacity range of 0 to 27,580 kPa minimum (0
to 4000 psi) is recommended. 4. Accelerate the engine to no-load governed speed
(full throttle), and hold at this speed. Gauge should
! WARNING read between 897.5 to 1132 kPa (130-164 psi).
HYDRAULIC FLUID SAFETY. Keep all 5. Check main relief pressure : Move the tilt control
hydraulic ports and components clean. Wipe lever to full back (or forward) tilt relief position.
the area on the pump around the diagnostic Hold tilt control in relief position until pressure read-
check port completely clean to prevent any ing is obtained, and then release. Gauge should read
contamination from entering the hydraulic 21,400 to 22,100 kPa (3100 to 3200 psi).
system.
IMPORTANT
When checking the hydraulic system, do not
Do not operate system in relief any longer
use your hands to check for leakage. Use a
than required to read the pressure gauge.
piece of cardboard or paper to search for
leaks. Escaping fluid under pressure can pen-
6. Check auxiliary relief pressure : (Truck must have
etrate the skin causing serious injury. Relieve
auxiliary component and auxiliary section added to
pressure before disconnecting hydraulic or
main hydraulic valve.) Move the auxiliary control
other lines. Tighten all connections before
lever to full back or forward relief position. Hold
applying pressure. Keep hands and body
auxiliary control in relief position until pressure
away from pinholes and nozzles which eject
reading is obtained, and then release. Gauge should
fluids under high pressure.
read 13,000 to 14,300 kPa (1925 to 2075 psi).
SM 661, Aug ’01 Hydraulic System Pressure Checks and Adjustments • 30-4-1
Main and Auxiliary Pressure Relief Flow Control Adjustment

Adjustment
! CAUTION
IMPORTANT
The main relief valve has been set on the The flow control valve has been set on the
plant. Never try to adjust. If the relief pres- plant. Never try to adjust. If adjusted, it will
sure exceeds the set value, contact to Service cause fetal danger, Contact to Service manag-
managers or Clark experts. ers or Clark experts.
The main and auxiliary relief setting only
applies to a hydraulic valve that has auxiliary 1. Remove the nut from the main hydraulic valve tie
sections added. bolt stud.
To adjust the hydraulic system main and auxiliary pres-

sure relief valve :
1. Loosen the jam nut on the relief valve adjustment
screw.
Jam Nut and

Adjustment Screw
Bottom View of Typical Valve (no auxiliary attachments).

2. Remove the stud from the valve.
3. Turn the flow control adjuster fully CCW to the stop.
Turn CW per specifications (in Section 1) to adjust.
4. Reinstall the tie bolt stud in the valve. Torque the
Main
stud to 38-43 N⋅m (28-32 ft⋅lb). Reinstall the nut on
Pressure the tie bolt and torque to 38-43 N⋅m (28-32 ft⋅lb)
Relief
Valve Auxiliary Pressure Relief Valve
Jam Nut and
Adjustment Screw
2. Turn the adjustment screw to set relief setting to the

normal range.
3. Reset the jam nut on the relief valve adjustment
screw.
30-4-2 • Hydraulic System Pressure Checks and Adjustments SM 661, Aug ’01
Section 5
Hydraulic Control Valve Removal and Replacement
! CAUTION
SAFE PARKING. Before working on truck :
1. Park truck on a hard, level, and solid surface, such as a
concrete floor with no gaps or breaks.
2. Put upright in vertical position and fully lower the forks
or attachment.
remove key.
SM 661, Aug ’01 Hydraulic Control Valve Removal and Replacement • 30-5-1
Hydraulic Control Valve Removal Control Valve Linkage Disassembly

IMPORTANT Remove the cotter rings and clevis pins connecting the lift
Keep all hydraulic ports, components, and and tilt (and auxiliary, as applicable) lever rods from the
fittings completely clean during valve hydraulic valve spools. Back off the lower jam nut at the
removal and replacement to prevent any con- turn buckle to allow the valve spool to be rotated before
tamination from entering the hydraulic sys- removing the clevis pins.
tem.
Preparation for Valve Removal

1. Park truck in a safe position and fully lower the
upright.
2. Return all controls to neutral, apply the parking
brake, stop the engine and turn key switch OFF.
3. Move all hydraulic control levers to all working posi- Cotter pin
tions and return them to neutral. Be sure there is no Valve spool
hydraulic pressure applied to the system by attach-
ments.
Clevis pin
4. Open the engine compartment and remove floor-
board.
5. Remove the right cowl cover from under the dash in
the operator’s compartment. See removal and Valve Removal
replacement procedures in Group 38.
1. Remove the three hex capscrews mounting the
6. Air clean the hydraulic valve and fittings. hydraulic valve to the hydraulic assembly bracket
7. Place a drain pan under the truck and loosen and (lower cowl). Two of the capscrews thread into the
remove all hydraulic lines from the valve. Plug the valve itself; the third is secured with a flange nut.
valve ports. Mark or tag each line as removed to
assure correct position of line at assembly. Hydraulic assembly
bracket(lower cowl)
To
Upright
2. Remove valve assembly from truck. See Section 6

Return Line for valve overhaul instructions.
to Sump
Feed Line
from Pump NOTE
Tilt Cylinder
Lines Be sure to clean up any oil spills and dry the
floor to prevent accidents.
8. Cap ends of lines to keep them clean. Tie ends of
lines to truck to prevent loose ends dropping and
leaking oil onto floor.
30-5-2 • Hydraulic Control Valve Removal and Replacement SM 661, Aug ’01
Hydraulic Control Valve Replacement Control Valve Linkage Reassembly

1. Insert the clevis pins through the rod-end clevises
Valve Replacement and valve spools of the lift and tilt spools (and auxil-
iary-lever rods and spools where applicable) and
1. Position the main valve on the hydraulic assembly secure with the cotter rings. Rotation of the valve
bracket (lower cowl). Install valve mounting fasten- spools is required to allow insertion of the clevis
ers and tighten hand tight so that valve mounting can pins. Rotate spools back so all pins are in line.
be adjusted for alignment with the lever connecting
rods.
Hydraulic assembly
bracket(lower cowl)
Cotter pin
Valve spool
Clevis pin
2. Install the hydraulic lines on the proper ports. Make

sure all lines are clean, are routed correctly in the NOTE
truck, and are not kinked. Torque fittings according The illustration above and system specifica-
to “Hydraulic Fitting Tightening Procedure” in tion torques also apply for auxiliary hydrau-
Group 40. lic functions, such as a side-shifter or rotator.
2. When alignment between the lever rods and the

To valve is set and levers are inline and level with one
Upright another, tighten the valve mounting capscrews and
flange nuts to 40-50 N⋅m (30-33 ft⋅lb).
Return Line
to Sump
Feed Line
from Pump Tilt Cylinder
Lines
3. Adjust the valve to align with the lever connecting

rods.
SM 661, Aug ’01 Hydraulic Control Valve Removal and Replacement • 30-5-3
Operational Checks 2. Check the operation of the valve and hydraulic sys-
tem by moving the valve control levers to the various
1. Start and operate the truck and hydraulic system. positions. The levers must operate smoothly with no
Check the system for leaks. binding. When released from any working position,
the levers must return sharply to their neutral posi-
! WARNING tions.
If valve spools do not moved or return to correct
Do not use your hands to check for hydraulic
position for full function of lift, tilt, or auxiliary cyl-
inders :
search for leaks. Escaping fluid under pres-
sure can penetrate the skin causing serious 3. Refer to Section 4, “Hydraulic System Pressure
injury. Relieve pressure before disconnecting Check” if valve was disassembled or overhauled.
4. Replace the cowl cover under the operator’s com-
partment dash. See removal and replacement proce-
dures in Group 38.
which eject fluids under high pressure.
If any fluid is injected into the skin, it must
be surgically removed within a few hours by
a doctor familiar with this type injury or
gangrene may result.
30-5-4 • Hydraulic Control Valve Removal and Replacement SM 661, Aug ’01
Section 6
Hydraulic Control Valve Overhaul
IMPORTANT
The following overhaul instructions describe a two spool • Clean outside of valve with a good grade of solvent
assembly with the inlet/lift section, a tilt (or auxiliary) and dry thoroughly.
section, and outlet section (outlet section contains no • Before starting disassembly, the valve should be
spool). carefully examined to determine if there is any evi-
dence of external damage.
Preparation for Disassembly
Overhaul valve only in a clean, dust-free location, using
clean tools and equipment. Dirt or grit will damage the
highly-machined surfaces and will result in leakage or
premature failure of components. Cleanliness of the
hydraulic circuit is extremely important to the proper
operation and maintenance of the system. Be sure the
work area is clean.
SM 661, Aug ’01 Hydraulic Control Valve Overhaul • 30-6-1

Disassembly 2. Remove and label all parts between the sections for
correct reassembly. These include :
During disassembly, pay particular attention to identifica- a. Retainers and seals which are included in the
tion of parts for reassembly. Spools are selectively fitted replacement seal kit.
to valve bodies and you must return each spool to the b. O-rings, springs, and ball which are replaced sep-
same body from which it was removed. You must also be arately.
sure to reassemble the valve sections in the original order.
NOTE
NOTE Keep parts in order as removed and avoid
Valve sections may or may not require sepa- mixing the sections and parts.
ration for overhaul.
3. Disassemble each valve spool, one at a time, from
If only valve spools are being overhauled, you do not have bottom of valve as shown in the illustration.
to separate the sections. For a complete overhaul, includ-
ing replacement of the seals, retainers, O-rings, springs, 4. Remove the valve spools by tapping lightly on the
and balls used between the sections, follow steps 1 and 2. top end with a soft-faced hammer to drive them out
To overhaul only the valve spools, begin with step 3. of the valve body.
1. Remove the nuts and studs connecting the valve sec- 5. Arrange the parts in the sequence of removal.
tions.
Figure 1. Inlet/Lift Body, Main Pressure Relief Valve, and Auxiliary Pressure Relief Valve.
Contents of spool assembly are shown in Figure 2.
30-6-2 • Hydraulic Control Valve Overhaul SM 661, Aug ’01

NOTE 3. Inspect valve spools and bores for burrs and scoring.
Remove the outlet port section only if there is If scoring is not deep enough to cause leakage, the
need for further inspection and cleaning of surfaces can be stoned or polished with crocus cloth.
contaminants in the valve. To remove, loosen If scoring is excessive, valve body and spool must be
and remove the nuts and studs and separate replaced. Check each valve spool for free movement
the outlet port section from the valve body. in its bore.
Label and keep all parts for correct reassem- 4. Inspect the main pressure relief valve for damage.
bly. Relief valve must be free from contamination, burrs,
and scoring. Plug, spring, and O-ring should be
Cleaning, Inspection, and Repair cleaned and inspected for damage.
1. Discard all old seals. Wash all parts in a clean min- NOTE
eral oil solvent and place them on a clean surface for Entire relief valve assembly must be replaced
inspection. if damaged. Relief valve pressure is con-
trolled by a hydrostat in the valve relief valve
2. Carefully remove any burrs by light stoning or lap- assembly and is set at the factory. No adjust-
ping. Be sure there is no paint or burrs on mating sur- ments are recommended; if pressure relief
faces of valve bodies. setting is not in recommended range,
hydrostat must be replaced.
Figure 2. Valve Spool and Tilt (or Auxiliary) Body. Differences in lift (or tilt) and auxiliary components noted.
SM 661, Aug ’01 Hydraulic Control Valve Overhaul • 30-6-3

5. Inspect the lift and tilt relief valves for damage. Reassembly
Check the relief valve for smooth free movement in
its bore. The valve poppet should move easily from Use the exploded view illustration of the valve section,
only the force of its own weight. spools, and relief valves for reassembly.
6. Inspect the valve body to make sure it has not been 1. Assemble valve in reverse order of disassembly.
physically damaged. Examine all threads to be sure 2. Coat all parts with clean hydraulic oil to facilitate
they are clean and not damaged or burred. Inspect all assembly and provide initial lubrication. Petroleum
bores and poppet seats. Poppet seat must be even all jelly can be used to hold seal rings in place during
around its circumference with no nicks, burrs, or assembly.
indentations in any of the seat face.
3. Use new O-rings and seals for all parts.
7. All springs should be free of corrosion and not bro-
ken or bent. 4. Install seal rings and the seal ring retainer in the
grooves in body of each inlet and center section. Use
8. If parts must be left unassembled for a period of time petroleum jelly to hold the seals in place. Carefully
or overnight, cover with a lint-free clean material. place the sections together in the same order in which
they were removed.
5. Torque dust-cover screws to 10.8-13.5 N⋅m (8-10
ft⋅lb).
6. Reinsert studs between valve sections and torque
nuts to 27-34 N⋅m (20-25 ft⋅lb).
Relief Valve Settings

After overhaul and reisintallation of the main hydraulic
valve, the hydraulic system relief pressure and auxiliary
valve relief pressure settings (if truck and valve are
equipped with an auxiliary component and section) must
be checked. See the hydraulic system checks and adjust-
ments Section of this Group (30) for procedures.
If the truck is not equipped with any auxiliary equipment,
no adjustments are necessary. If an auxiliary scetion has
been added to the hydraulic valve and auxiliary compo-
nents have been installed on the truck, check the relief
pressure. See the hydraulic system checks and adjust-
ments Section of this Group (30) for procedures.
Figure 3. Outlet Body
30-6-4 • Hydraulic Control Valve Overhaul SM 661, Aug ’01

GROUP 32
GROUP 32
TILT CYLINDERS
Tilt Cylinder Specifications and

Tilt Checks and Adjustments .................. Section 2
Tilt Cylinder Removal and

Tilt Cylinder Overhaul ............................ Section 4
IMPORTANT
Sump, Filters, and Pump,” Group 30, Hydraulic Control
Valve/Lift Circuit,” and Group 34, “Uprights.” Refer to
these other groups for hydraulic components not covered in
this group.
SM 661, Aug ’01 Group 32, Tilt Cylinders

Group 32, Tilt Cylinders
Section 1
Tilt Cylinder Specifications and Description
Specifications Base Mount Pin Lock Plate Fasteners : 8-10 N⋅m (10.8-
13.5 ft⋅lb).
See Group 30 for hydraulic system specification.
Tilt Cylinder Type : double-acting Service Intervals
Maximum Operating Pressure : 22,070 kPa (3,200 psi) Tilt Cylinder Drift Test : Every 50-250 hours or each PM.
Tilt Ranges* : Tilt Cylinder Check and Adjustment : Every 50-250 hours
or each PM.
Cushion-Tire Truck Uprights
Tilt Cylinder Rod Seal Condition Check : Every 50-250
STD (through 2120mm MFH) 6°B~10°F hours or each PM.
STD (2680-2980mm MFH) 8°B~10°F Tilt Cylinder Mounting Check and Tightening : Every 50-
STD (3300-3860mm MFH) 10°B~8°F 250 hours or each PM.
STD (4165-4620mm MFH) 5°B~6°F Tilt Cylinder Rod-End Check and Tightening : Every 50-
250 hours or each PM.
STD (above 5170mm MFH) 5°B~3°F
Tilt Cylinder Rod-End Lubrication : Every 50-250 hours
TSU (through 4800mm MFH) 5°B~6°F or each PM.
TSU (5210-6160mm MFH) 5°B~3°F
TSU (above 6370mm MFH) 3°B~3°F Description
The tilt cylinders provide backward and forward tilt of the
Pneumatic -Tire Truck Uprights
upright. The forward and back tilt angles are governed by
STD (through 2120mm MFH) 6°B~10°F the cylinder stroke and by use of spacers. The tilt cylin-
ders are pin-mounted to the truck frame and upright using
STD (2680-2980mm MFH) 8°B~10°F
yokes, clevises, and pins. Pins are held in place by a lock
STD (3300-3860mm MFH) 10°B~8°F plate and fastener to prevent the pins from working their
way out.
STD (4165-4620mm MFH) 5°B~6°F
The tilt cylinders are serviced by removing them from the
STD (above 5170mm MFH) 5°B~3°F
truck and disassembling them for complete overhaul,
TSU (through 4800mm MFH) 5°B~6°F including installation of new seals and or other cylinder
components.
TSU (5210-6160mm MFH) 5°B~3°F
The tilt lock valve is integrated into the tilt section of the
TSU (above 6370mm MFH) 3°B~3°F
main hydraulic control valve. The tilt lock valve prevents
* Abbreviations : Std = Standard, high-visibility upright ; the upright from tilting forward when the truck is not run-
TSU = Triple-stage upright ; MFH = maximum fork ning. The tilt lock valve is not serviceable and must be
height ; B = back tilt ; F = forward tilt. See truck data plate replaced as a valve section if defective.
for upright MFH.
Fastener Torque
Rod-End Yoke Bolts : 166-193 N⋅m (122-142 ft⋅lb)
Rod-End Pin Lock Plate Fasteners : 8-10 N⋅m (10.8-13.5
ft⋅lb).
SM 661, Aug ’01 Tilt Cylinder Specifications and Description • 32-1-1

Section 2
Tilt Cylinder Checks and Adjustments
3. Raise the capacity load 2500mm (98.5 in) off the

! CAUTION ground and tilt the upright vertical, shut off the truck.
SAFE PARKING. Before working on truck :

gaps or breaks.
2500mm(98.5in)
wheels. 4. Measure and write down the distance between the
cylinder-spacer face and the rod-end yoke.
Tilt Cylinder Drift Check

To check tilt cylinder drift, a rated capacity load is placed Measure rod
on the forks, lifted up and held to determine if the tilt cyl- distance here
inder rods moves (drifts) in a specified length of time.
It is recommended that a test load, made up of a full-
capacity load equally distributed on a 1220×1220 mm (48
×48 in) pallet, be used. The material used to make up the
test load must be stacked to provide load stability and
must not extend beyond the pallet. It must be secured on
the pallet. Refer to the truck data plate for capacity rating.
1. Adjust fork width as wide as possible to distribute NOTE
the load. Refer to truck nameplate for capacity rating. An alternate procedure is to measure the
change in the inclined angle of the upright,
! CAUTION using a protractor and level, or inclinometer.
Test load must be stacked stably, not extend 5. Wait five minutes and remeasure and write down the
beyond the pallet, and be secured on the pal- distance between the same two points.
let. Clamp the load on the load backrest or
fork bar to avoid sliping out from fork. 6. The decrease in the measure must not exceed the fol-
lowing measures :
2. Drive the forks into the load pallet until the test load
and pallet rest against the load backrest. Apply the Temperature Drift
parking brake and chock the wheels. 50°C (122°F) 0.5°, 3.1 mm@1min
5°, 31.1 mm@10min
SM 661, Aug ’01 Tilt Cylinder Checks and Adjustments • 32-2-1

Drift Causes and Remedies Forward Adjustment

Tilt cylinder drift indicates the following possible prob- 1. Slowly tilt upright fully forward to the end of the tilt
lems : cylinder stroke.
• Tilt cylinder hydraulic circuit hoses or fittings are 2. As the cylinders approach the end of the stroke,
leaking. Check the circuit components and repair watch both piston rods for equal movement and
as necessary. upright for twisting. Note if upright “racks” (is
• Cylinder piston seals are worn, damaged, or defec- twisted at the end of its movement by unequal stroke
tive allowing fluid past the piston and causing the of tilt cylinders).
rod to drift. Consider rebuilding the cylinders if the NOTE
other remedies in this list are not successful. See
Correct the twisting effect by shortening the
Section 3 for cylinder removal and replacement
cylinder that is the longest length. Forward
and Section 4 for cylinder repair, if necessary.
twisting must be adjusted before backward
• The main hydraulic tilt valve is misadjusted, worn, twisting. If forward adjustment is not
or defective. Fluid is leaking past the valve and needed, continue with backward adjustment.
causing the tilt cylinders to drift. See Group 30 for
hydraulic valve troubleshooting. 3. To adjust, loosen rod-end yoke capscrew on the tilt
cylinder that extends the farthest, and turn piston rod
Tilt Cylinder Racking Check into rod-end yoke to shorten.
Upright racking occurs when tilt cylinder strokes are

unequal. Cylinders should be checked regularly during
operation to determine if cylinder strokes are the same. To
check for racking :
Loosen capscrew
• Make sure truck is parked on level surface with
parking brake applied and wheels chocked.
Turn to adjust.
• Check condition of the tilt cylinder, rod-end yoke,
mounting pins, piston rod, rod wiper, cylinder
gland, etc., for excessive wear or damage. Make
repairs before making twisting adjustment.
• Use a capacity load (see truck nameplate) centered
on the forks.
! CAUTION Forward Adjustment : Pneumatic-tire truck rod-end yoke

Be sure to secure the load to the fork carriage orientation shown.
to keep it from falling off when tilted forward. NOTE
Raise the upright only to the height that will
Use wrench flat on rod under spacer (if
allow the fork tips to clear the floor when
installed). Move spacer for access.
tilted fully forward.
32-2-2 • Tilt Cylinder Checks and Adjustments SM 661, Aug ’01

4. Continue to turn rod into rod end until tilt cylinder 4. Use rod shims to fill in the space between the rod-
strokes are equal. end yoke and spacer. Screw rod back into yoke the
same number of turns needed to remove.
IMPORTANT
The rod must be threaded onto the rod-end
yoke a distance at least as great as the diame-
ter of the rod plus 6.5 mm (0.25 in).
Rod shim
Rod end yoke
Add 6.5mm Cylinder rod

(.25in) to
diameter Spacer
of rod
Wrench Flat
Thread rod into rodend
yoke the rod diameter
plus 6.5mm(0.25in)
5. Tighten capscrew of the rod-end yoke to 166-193

N⋅m (122-142 ft⋅lb), and repeat the racking test.
6. Repeat steps 1-5 for fine corrections if any racking 5. Tighten capscrew of the rod-end yoke to 166-193
remains evident. N⋅m (122-142 ft⋅lb), and repeat the racking test.
7. When no racking occurs, retighten capscrew of the 6. Repeat steps 1-5 for fine corrections if any racking
rod-end yoke to 166-193 N⋅m (122-142 ft⋅lb). remains evident.
8. Check all tilt functions before returning the truck to 7. When no racking occurs, retighten yoke capscrew to
service. 166-193 N⋅m (122-142 ft⋅lb).
8. Check all tilt functions before returning the truck to
Backward Adjustment service.
Perform forward check and adjustment first. Then :

Tilt Flow Control Adjustments
1. Slowly tilt upright fully backwards while watching
piston rods. They should both bottom out at the same See checks and adjustments Section of Group 30,
time. If they don’t, adjust backward tilt using the fol- “Hydraulic Control Valve/Lift Circuit,” for adjustment
lowing steps. procedure.
2. Stop the upright when the first tilt cylinder bottoms
out against its rod spacer.
3. Go to the opposite cylinder and remove the capscrew
on the rod-end yoke and screw rod out of yoke.
Count the number of turns required to remove the rod
from the yoke.
SM 661, Aug ’01 Tilt Cylinder Checks and Adjustments • 32-2-3

Section 3
Tilt Cylinder Removal and Replacement
SM 661, Aug ’01 Tilt Cylinder Removal and Replacement • 32-3-1

! CAUTION ! WARNING
SAFE PARKING. Before working on truck : The upright assembly is heavy. Use only
hoists with enough capacity to lift the entire
1. Park truck on a hard, level, and solid assembly. Keep hands and feet away from the
surface, such as a concrete floor with no assembly. Use prybars to move the assembly
gaps or breaks. into position for tilt cylinder replacement.
3. Remove the floorboard.
NOTE
switch OFF and remove key. Put a drain pan under the truck at each tilt
cylinder position before removing the
4. Apply the parking brake and block the hydraulic lines.
wheels.
4. Disconnect and cap hydraulic lines from the tilt cyl-
Tilt Cylinder Removal inders (see illustration on facing page). Remove the
hose connections on both sides of the tee fittings of
1. Move tilt lever back and forth several times to relieve the right-side cylinder. Keep all fittings and ports
any pressure. clean.
2. Use an adequate chain and hoist to support the
upright so that it cannot fall when tilt cylinder pins
are removed.
Bearing
Rod end pin
Rod end yoke
Grease fitting
Base pin
Bearing
Tilt Cylinder Mounting Components
32-3-2 • Tilt Cylinder Removal and Replacement SM 661, Aug ’01

5. Support cylinder with a sling to prevent the cylinder 4. If parts are to be left exposed, coat all mating sur-
from dropping when pins are removed. faces of parts with a light layer of engine oil.
6. Remove lock-plate from tilt cylinder rod-end yoke.
Use a soft drift and hammer to tap rod-end pin out of Tilt Cylinder Replacement
yoke.
1. Position tilt cylinder base yoke on frame mounting
7. Pop the cover from tilt cylinder base access port on bracket.
the step to the operator’s compartment.
2. Insert base pin in cylinder base yoke and through
8. Remove the lock-plate from cylinder base yoke. Use frame mounting bracket, making sure slot in pin is in
a soft drift and hammer to tap pin out of yoke. line with the lock-plate. Grease fitting must point
9. Remove cylinder assembly. toward center of truck.
IMPORTANT
Parts Inspection Make sure the spherical bearing is aligned so
that pin fits smoothly in yoke.
1. Clean all bearings, pins, and other components in an
approved cleaning fluid. 3. Install base pin lock-plate in slot and fasten to yoke
2. Inspect all parts for scratches, nicks, dents, and wear. with fastener and washer. Tighten fastener to a torque
Check the cylinder rods to be sure they are smooth of 8-10 N⋅m (5.9-7.4 ft⋅lb).
with no scratches. Check all threaded parts for dam- 4. Position rod-end yoke on upright mounting bracket
age. and insert rod-end pin, making sure lock-plate slot is
3. Replace all parts which show damage. in correct position. Grease fitting must be toward
center of truck. Make sure the spherical bearing is
aligned so that pin fits smoothly in yoke.
Tee fitting
Lines to
main valve
Tilt Cylinder Hydraulic Fittings
SM 661, Aug ’01 Tilt Cylinder Removal and Replacement • 32-3-3

NOTE 5. Install rod-end lock-plate in slot and fasten to yoke

If the rod-end yoke has been removed from with fastener and washer. Tighten fastener to a torque
the rod or loosened for adjustment, reinstall of 8-10 N⋅m (5.9-7.4 ft⋅lb).
the clamp bolts to a torque of 166-193 N⋅m 6. Install tilt cylinder hydraulic lines. Check Group 40
(122-142 ft⋅lb). Nuts must be on inside of for hydraulic fitting tightening procedures. O-rings
upright rails. of fittings should be lightly coated with clean
Orientation of the rod-end yoke is different hydraulic fluid or compatible oil.
for the cushion-tire and pneumatic-tire
trucks. As the illustration shows, the bolt 7. Remove hoist chain from upright.
hole of the rod-end yoke is down on the pneu- 8. See Section 2 for tilt cylinder adjustment procedures.
matic-tire truck but is up on the cushion-tire When adjustments are made, check all upright com-
truck. ponents under load before returning the truck to ser-
vice.
32-3-4 • Tilt Cylinder Removal and Replacement SM 661, Aug ’01

Section 4
Tilt Cylinder Overhaul
IMPORTANT
O-ring
Cylinder barrel Hydraulic
Cylinder cap port Grand
(Base mount)
Wrench flat
Rod
Piston Rod u-cup Rod wiper

Piston packing seal
and wear ring
Typical Tilt Cylinder Cross section
SM 661, Aug ’01 Tilt Cylinder Overhaul • 32-4-1

Preparation For Disassembly 2. Carefully pull the rod, piston assembly, and gland
from the cylinder barrel. Remove gland from rod.
IMPORTANT
Overhaul tilt cylinders only in a clean, dust- ! WARNING
free location, using clean tools and equip-
ment. Dirt or grit will damage the highly- The use of compressed air to blow the piston
machined surfaces and will result in leakage out of the barrel is not recommended. High-
or premature failure of components. Cleanli- pressure air can result in piston and rod
ness of the hydraulic circuit is extremely being ejected at high velocity (explosively),
important to the proper operation and main- causing severe injury to personnel and prop-
tenance of the system. Be sure the work area erty damage.
is clean.
3. Remove and discard the piston packing and wear
1. Before disassembly, the exterior of the tilt cylinder rings from the piston.
should be carefully cleaned to remove all dirt and
grease accumulation.
2. Be sure all hydraulic oil has been removed from the
cylinder. Stroking the piston rod will help force the
oil out.
3. Before starting disassembly, the tilt cylinder should
be carefully examined to determine if there is any Piston packing Wear ring
evidence of external damage.
4. Remove and discard the rod U-cup seal, O-ring, and

Disassembly piston rod wiper from the gland.
The tilt cylinder can be held by clamping the base end or
the barrel in a vise while disassembling. O-ring U-cup seal Rod wiper
IMPORTANT
Do not use excessive force when clamping on
the barrel.
1. Remove the gland with a hook wrench. Carefully

pull the gland assembly from the cylinder tube and
slide it off the cylinder rod.
O-ring
32-4-2 • Tilt Cylinder Overhaul SM 661, Aug ’01

Inspection 2. Replace the piston packing and wearing.
1. Carefully clean all parts in an approved solvent and

place on a clean surface.
2. Check the piston and rod for damage. Look for
gouges, scratches, corrosion, or evidence of unusual
wear. Minor surface damage may be repaired by use
of fine abrasion cloth or stoning. Deeper damage will
require replacement of piston rod assembly.
Piston packing Wear ring
3. Be sure the threads on rod are undamaged.
4. Inspect the tilt cylinder barrel internal bore for wear, 3. Install gland on piston rod. Use gentle pressure and
scratches or other damage. Check the outside for careful movements to avoid damage to the U-cup
damage. Inspect all welds for cracks. seal and rod wiper when these parts are moved over
Deep gouges or pitted surfaces require replacement the piston rod end.
of parts.
Check the gland, base end, and ports for cracks or NOTE
damage that could cause failure. Inspect the ports to Reassemble cylinder carefully to prevent
be sure they are free of contamination and that the damage to seal lips and O-rings.
threads are clean and not damaged.
4. Install piston into cylinder barrel. Be careful not to
5. Put a light coating of hydraulic fluid on all parts. If damage the piston seals when installing the piston
parts are to be left disassembled for a period of time, into end of cylinder.
e.g., overnight, they should be covered with a clean
cloth. 5. Install gland into cylinder them screw the gland into
the cylinder barrel with a hook wrench. When tight-
ing, dont damage the seal Tighten torque : 60±6
Reassembly kgf⋅m
Be sure inside of cylinder and all parts are clean before
starting reassembly. Seals may be lubricated with hydrau- O-ring
lic oil to assist assembly into cylinder barrel.
1. Install piston rod wiper, rod U-cup, and O-ring on the
gland. Make sure U-Cup and wiper are installed in
proper orientation as shown in the illustration.
O-ring U-cup seal Rod wiper
6. Check the assembly by making sure the piston slides

freely in and out of the cylinder.
See Section 3 for replacement procedures ; see Section 2
for checks and adjustments before returning the truck to
service.
SM 661, Aug ’01 Tilt Cylinder Overhaul • 32-4-3

GROUP 34
GROUP 34
UPRIGHTS
Upright Specifications and Description ........................ Section 1
Troubleshooting ............................................................... Section 2
Upringht Inspection ......................................................... Section 3
Carriage and Upright Roller Clearance

Checks and Shim Adjustments ...................................... Section 4
Cylinder Removal, Shimming,

Overhaul, and Replacement ........................................... Section 5
Upright Chain Inspection, Adjustment,

and Replacement .............................................................. Section 6
Fork and Carriage Removal and

Replacement ..................................................................... Section 7
Upright Removal and Replacement ............................... Section 8
IMPORTANT
Related service information is covered in Group 29, “Hydrau-
lic Sump, Filters, and Pump,” Group 30, “Hydraulic Control
Valve/Lift Circuit,” and Group 32, “Tilt Cylinder.”
SM 661, Aug ’01 Group 34, Uprights

Group 34, Uprights
Section 1
Upright Specifications and Description
General Specifications
Upright
Upright Weight: Approximately 363 kg (800 lb) to Upright Type Number Cylinder Type
approximately 1000 kg (2200 lb) without carriage. Standard V2302 Piston-Type Lift Cylinder
Carriage Weight: Approximately 109 kg (240 lb) to 122 V2303 Piston-Type Lift Cylinder
kg (270 lb) with a 41 inch carriage. V2304 Piston-Type Lift Cylinder
TSU M2302 Piston-Type Secondary
Fork Weight: Approximately 50-71 kg each (110-156 lbs) Cylinder
IMPORTANT M2303 Piston-Type Secondary
Before hoisting, the weights of upright, car- Cylinder
riage, forks and attachments being lifted M2304 Piston-Type Secondary
must be combined to determine what lifting Cylinder
capacity is required of the hoisting equip-
ment. Drift:
Capacities and Lift Heights: Upright, carriage, and fork With the upright substantially vertical the descent of the
capacity and upright lift heights are listed on the truck’s rated load caused by an internal leakage in the hydraulic
data plate. system shall not exceed 100mm (4in) during the first
10min with the oil in the hydraulic system at normal oper-
Lubricants: ating temperature. If drift over 100 mm (4 in) in ten min-
• All Purpose Grease (MS-9) utes is evident, cylinder should be checked for internal
leakage. See Section 3 for drift test procedures.
• Innerslide Lubricant (Clark P/N 886396)
• Chain and Cable Lube (Clark P/N 886399)
Fastener and Fitting Torque Specifications
Cylinder Types Trunnion Mounting Bolts: 75~80 N⋅m (55~59 ft-lb)
Standard uprights use two lift cylinders. Triple stage Load Back Rest: 170-190 N⋅m (125-140 ft-lb)
uprights use three cylinders, a primary (center-mounted) Chain Anchor Bolt Jam Nut: 100-200 N⋅m (74-148 ft-lb)
cylinder, and two secondary cylinders. All primary cylin-
ders used on triple-stage uprights (TSUs) are piston cylin- Carriage Side-Thrust Roller Bolts(External): 40-50 N⋅m
ders. The lift and secondary cylinders used on standard (29.5-37 ft-lb)
uprights and TSUs can be piston cylinders. Carriage Side-Thrust Roller Bolts(Internal): 70-80 N⋅m
The types of cylinders used on the truck are listed below. (52-59 ft-lb)
Check the first five characters of the upright number Hose Fittings: See Group 40, “Hydraulic Fitting Tighten-
stamped on the upright of the truck to determine the type ing Procedure.”
of cylinder, piston used on the upright.
Rod End Bolts: 170-190 N⋅m (125-140 ft-lb)
IMPORTANT
Before removing any component for over- Tilt Cylinder Rod-End Pin Lock Plate: 8-10 N⋅m (71-89
haul, make sure the correct repair parts, in-lb).
seals, and gasket sets are available.
SM 661, Aug ’01 Upright Specifications and Description • 34-1-1

Group 34, Uprights
Service Intervals Forks use a hanger design for mounting on the carriage.
Auxiliary attachments may be added to the upright for
• All upright components should be visually checked specialized handling operations. The hydraulic circuit is
every day during the Operator’s Daily Inspection. modified with a hose adapter kit and an auxiliary section
• A thorough visual inspection should be performed is added to the main hydraulic valve to operate the attach-
by a trained service professional every 50-250 ment.
hours. The lift and secondary cylinders on standard uprights and
• Lift chains should be inspected and lubricated triple-stage uprights (TSUs) are piston type cylinders. The
every 50-250 hours or monthly. primary cylinder on TSUs is a piston-type cylinder. See
• Lift chain tension should be checked every 50-250 the chart under “Specifications” to determine the type of
hours or monthly. cylinder used on the upright you are servicing.
• Upright and carriage roller checks should be per- Piston-type cylinders contain a by-pass check valve in the
formed every 50-250 hours or monthly. piston that allows air and fluid that have accumulated in
• Roller patterns should be checked every 6 months the rod end of the cylinder to return to the system. The
or after 1000 hours of service. check valve can be removed and cleaned if indicated by
• Racking and drift tests should be performed every troubleshooting. A non-serviceable check-ball-type cush-
50~250 hours or monthly. ioning function is built into ram and piston cylinders for
smooth staging during the lowering cycle. The primary
• The complete extended inspection should be per- cylinder on TSUs incorporates cushioning on the lift
formed at least every year or 2000 hours of opera- cycle. A velocity fuse in the hydraulic port of the lift cyl-
tion. inders (secondary cylinders on TSUs) prevents the mast
from falling rapidly in case of sudden fluid pressure loss
Description due to line breaks or other malfunction of the hydraulic
circuit.
The upright assembly includes the lift chains, lift cylin-
ders, carriage, forks, and mast or rail sets. Each of the As explained in more detail in Group 30, the main pump
components can be serviced using the tests, checks, sends fluid to the main hydraulic control valve, which
adjustments, and removal and replacement procedures in contains spools that route fluid to the lift cylinders and tilt
the following Sections. cylinders. The valve assembly also contains a counter-
balance valve that prevents upright tilt when the truck is
The upright uses the hydraulic cylinders and chain sets to not operating.
lift the carriage and rail sets. On standard, two-stage
uprights, the lift cylinders lift the carriage with chains and Fluid flow rates for lift functions are factory set and not
directly lift the inner rail set. On triple-stage uprights, the adjustable. Flow rates for tilt and auxiliary functions are
primary (free-lift) cylinder lifts the carriage by chains. controlled by adjustments on the main hydraulic valve. A
When the primary cylinder reaches its maximum exten- non-adjustable “load-lowering” flow valve mounted on
sion, fluid is diverted to the secondary lift cylinders, the upright limits upright lowering speed.
which lift the inner rails using a second set of chains and Groups 29 and 30 contain general hydraulic information
lift the intermediate rails by direct lift. including upright hydraulic functions. Other hydraulic
Friction and play between the nesting rails is controlled by checks for the upright appear in “Troubleshooting,” Sec-
roller sets mounted on the rails and carriage. When rails or tion 2.
rollers become worn, the gap between the rollers and rails
becomes larger, creating more play in lifting and lowering
operations. The rail web to roller side clearances can be
reduced by shimming the rollers to close the gap between
the roller and rails. The gap between the rail flange and
roller bearing surface can be reduced by the use of over-
size rollers on a one-time basis.
34-1-2 • Upright Specifications and Description SM 661, Aug ’01

Group 34, Uprights
Outer rail set
Lift cylinder
Chain sheave
Outer rail set
Chain anchor
Chain
Carriage
Load lowering
flow valve
Lower roller Inner rail set
Typical Standard (Two-Stage) Upright Assembly

Group 34, Uprights
Upper roller
Outer rail set
Hose sheave
Upper roller
Chain sheave
Secondary Chain sheave

cylinder
Chain
Carriage
Lower roller
Intermediate rail set

Lower roller
Inner rail set

Primary
cylinder
Typical Triple-Stage Upright Assembly

Group 34, Uprights
Typical Triple Stage Upringht-Overhead View
Adjustment shims Carriage

Roller
Side thrust roller
External thrust roller

(not in 2.0/2.5 ton STD CL2)
Carriages and Roller Sets

Group 34, Uprights
Two-Hose Adaptation for the

Triple-Stage Upright
Two-Hose Adaptation for the

Standard Upright

Group 34, Uprights
Section 2
Troubleshooting
The visual inspection and the operational checks pre- • Dry hose sheave or rollers; check condition of all
sented in Section 3 should be used to determine problems sheaves and rollers and lubricate as necessary.
with the upright. Possible problems, causes, and remedies • Damaged chain sheaves; check condition of chain
are listed below. sheaves and repair or replace.
Other troubleshooting information about the hydraulic cir- • Excessive fork hanger or carriage fork bar wear;
cuit and components appears in the troubleshooting Sec- inspect and replace as necessary.
tions of Groups 29 and 30. Use these other • Seals dry; lubricate rod.
troubleshooting Sections for more detailed problem isola-
• Seals dry - all primary cylinders; remove gland and
tion with Upright hydraulic functions.
add 100 ml (3.4 oz) of hydraulic oil to rod side of
piston, see “Cylinder Removal, Shimming, Over-
! WARNING haul, and Replacement.”
The procedures for troubleshooting uprights,
carriages, and forks involve movement of the No lift, tilt, or auxiliary function
components. Failure to follow these warnings
can result in serious injury. • Hydraulic fluid level low; check level and fill.
Make sure overhead clearances are adequate • Broken hoses or fittings; check and repair.
before raising the upright to full lift height.
• Damaged or blocked sump strainer; check and
Do not walk or stand under raised forks.
clean.
Block carriage and upright whenever mak-
ing checks with the upright elevated. • Hydraulic pump defective; see Group 29 for pump
Keep clear of load and carriage when making troubleshooting.
any check or adjustment. • Defective main hydraulic control valve; see Group
Keep your arms and fingers away from mov- 30 for valve troubleshooting.
ing parts of the upright. • Defective upright load-lowering flow valve; disas-
Do not reach through open areas of the semble valve, check and clean or replace.
upright.
No lift function but tilt operates

Upright noise
• Broken hoses or fittings; check and repair.
• Bent or broken components; inspect upright thor-
• Cylinder is damaged; inspect and repair.
oughly and repair or replace components as
required. • Main hydraulic control valve, lift section defec-
tive; see Group 30 for valve troubleshooting and
• Damaged upright roller; check condition of rollers
service information.
and replace defective rollers.
• Upright load-lowering flow valve damaged; disas-
• Roller scuffing rails; clean and lubricate rails.
semble valve, check and clean or replace.
• Roller (carriage or upright) shimming needs
adjustment; check and adjust as required.
• Fit between roller edge and rail flange excessively
loose in rails; replace with oversized, “Select-Fit”
rollers. See “Upright Roller Clearance Check and
Shim Adjustment.”
• Dry lift chain; lubricate chain.
SM 661, Aug ’01 Troubleshooting • 34-2-1

Group 34, Uprights
Load cannot be lifted to maximum height • Defective priority valve; see Group 30 for valve
troubleshooting information.
• Hydraulic fluid level low, check level and fill. • Defective upright load-lowering flow valve;
• Debris in upright; check and clean. remove valve clean, inspect, and replace if neces-
• Hydraulic hose fittings loose or damaged; check sary.
and torque correctly (see Group 40 for specifica-
tions) or replace. Lowering speed sluggish
• Check cylinder for external leakage; replace cylin-
der if cracked. • Damaged or binding upright roller; check condi-
tion of roller and replace if necessary.
• Cylinder shimming is incorrect; check and adjust
shimming. • Damaged or kinked hydraulic hose or tube; check
condition of hose and tube, repair or replace as
• Internal leakage on lift or secondary piston cylin-
necessary.
ders; remove rod and piston and clean check
valves; also clean and inspect/replace piston seals. • Defective upright load-lowering flow valve; check,
See Section 5. clean and replace valve if necessary.
• Cylinder check valve on lift or secondary piston • Defective velocity fuse; remove fuse from cylinder
cylinders not functioning properly; remove rod and hydraulic port, clean and recheck for proper opera-
piston and clean check valves; also clean and tion.
inspect/replace piston seals. See Section 5.
• Hydraulic pump defective; see Group 29 for pump Load bounces excessively when lowering
troubleshooting information.
• Defective upright load-lowering flow valve; check,
• Upright rails binding:
clean and replace valve if necessary.
a. Perform a visual inspection and check for worn,
or distorted parts, broken or cracked rails or tie- • Defective main lift valve; see Group 30 for valve
bars, correct chain and hosing placement and troubleshooting and service information.
operation • Defective velocity fuse; remove fuse from cylinder
b. Check rollers for contamination and proper oper- hydraulic port, clean and recheck for proper opera-
ation, perform roller clearance check and adjust- tion.
ment
Upright mis-staging (TSU lifting)
Lift speed sluggish
• Debris in upright roller area of carriage; check and
• Hydraulic fluid level low; check level and fill. clean.
• Broken hoses or fittings; check and repair. • Interference between carriage and inner rail or cyl-
• Pump inlet line restricted; remove from pump and inder; check staging alignment and adjust or repair
clean. as necessary.
• Damaged or binding upright roller; check condi- • Bent or broken carriage or inner rail; replace part -
tion of roller and replace if necessary. do not try to repair by welding.
• Internal leakage on piston-type lift and secondary • Damaged or binding carriage roller; check condi-
cylinders (with load); perform cylinder checks tion of roller and replace if necessary.
listed under “Load cannot be lifted to maximum • Carriage roller shimming or thrust roller out of
height.” adjustment; perform roller checks on carriage and
• Hydraulic pump defective; see Group 29 for pump make adjustments as necessary.
troubleshooting information. • Damaged or kinked primary cylinder hose; check
• Defective main lift valve; see Group 30 for valve condition of hose, repair or replace as necessary.
troubleshooting and service information. • Primary cylinder chain or chain sheave binding or
• Defective velocity fuse; remove fuse from cylinder damaged; inspect and repair.
hydraulic port, clean and recheck for proper opera-
tion.
34-2-2 • Troubleshooting SM 661, Aug ’01

Group 34, Uprights
• Internal leakage in primary lift cylinder; perform • Bent or broken carriage or inner rail; replace part -
cylinder checks listed under “Load cannot be lifted do not try to repair by welding.
to maximum height.” • Carriage and upright roller shimming or thrust
• Damaged primary lift cylinder causing binding in roller out of adjustment; perform roller checks on
the cylinder; inspect and repair or replace cylinder. upright and/or carriage and make adjustments as
• Defective velocity fuse; remove fuse from cylinder necessary.
hydraulic port, clean and recheck for proper opera- • Defective velocity fuse; remove fuse from cylinder
tion. hydraulic port, clean and recheck for proper opera-
tion.
Upright mis-staging (TSU lowering)
External leakage on primary cylinder
• Debris in upright roller area or tie bar area; check
and clean. • Gland loose; check and tighten primary cylinder
• Bent or broken carriage or inner rail; replace part - gland to 135 N⋅m (100 ft-lb) and glands on lift
do not try to repair by welding. (secondary) cylinders to 100 N⋅m (73 ft-lb).
• Damaged or binding roller on upright; check con- • Cracked cylinder tube; replace tube.
dition of roller and replace if necessary. • Rod seal damage; replace seals and check for:
• Carriage and upright roller shimming or thrust − Damaged rod seal groove in gland; check for
roller out of adjustment; perform roller checks on damage to groove and replace seal or gland if
upright and/or carriage and make adjustments as necessary
necessary. − Scored cylinder wall; repair or replace cylinder
tube if necessary
• Damaged or kinked lift cylinder hose; check condi-
− Leaking check valve; clean and replace if nec-
tion of hose, repair or replace as necessary.
essary
• Lift cylinder chain or chain sheave binding or dam- − Leaking O-ring seal on check valve; replace
aged; inspect and repair. check valve.
• Bent cylinder rod; inspect and replace rod and/or • Gland static seals (O-rings and back-up ring) dam-
cylinder as necessary. aged; replace back-up ring.
• Internal leakage in piston-type cylinders; perform • Gland static seals sealing surface damaged; check
cylinder checks listed under “Load cannot be lifted groove and bore and repair or replace as necessary.
to maximum height.”
• Damaged lift cylinder causing binding in the cylin-
External leakage on lift (Standard) and sec-
der; inspect and repair or replace cylinder.
• Defective velocity fuse; remove fuse from cylinder
ondary cylinder (TSUs)
hydraulic port, clean and recheck for proper opera- • Gland loose; check and tighten gland on cylinders
tion. to 100 N⋅m (73 ft-lb).
• Cracked cylinder tube; inspect and replace tube.
Upright mis-staging (Standard upright lower- • Seal damage in piston-type cylinders; replace pis-
ing) ton seals and rod seals.
• Damaged seal groove, piston-type cylinders; check
• Damaged or binding roller on upright; check con-
for scratches, nicks, or burrs and repair or replace
dition of roller and replace if necessary.
rod and piston.
• Top carriage roller retaining cap screw loose;
• Scored cylinder wall, TSU piston-type cylinders;
check and replace cap screw.
replace tube and all seals.
• Lift cylinder chain or chain sheave binding or dam-
• Scored or damaged rod; replace rod and all seals.
aged; inspect and repair.
• Damaged gland back-up seal; inspect and replace
• Debris in upright roller area or tie bar area; check
seal.
and clean.
SM 661, Aug ’01 Troubleshooting • 34-2-3

Group 34, Uprights
• Gland static seals sealing surface damaged; check • Cylinder hydraulic fittings loose or worn; check
grooves and bore. fitting O-rings, tighten fittings according to Group
40, “Hydraulic Fitting Tightening Procedure.”
Oil leak at top of lift cylinder • Check valve worn or damaged; remove rod and
• Scored cylinder wall; see Section 5. piston, clean check valve and replace if necessary.
• Worn or damaged gland rod-seal; see procedures • Control valve spool linkage malfunctioning, dam-
for piston-type cylinders under “Cylinder leaking aged, or worn; see Group 30, Section 5 for linkage
internally.” adjustment and/or replacement.
• Counterbalance function in main hydraulic control
Unsatisfactory lift or tilt cylinder drift test results valve malfunctioning, damaged, or worn; inspect
• Cylinder leaking internally; remove cylinder gland and clean or replace if necessary.
and check:
a. Primary cylinder should have only 3.4 ounces
(100 ml) on rod side of the piston
b. Piston-type lift and secondary cylinders should be
dry on rod side of piston.
If fluid is leaking past piston:
On piston-type cylinders, remove rod and piston,
clean check valves and clean and inspect/replace pis-
ton seals
See Section 5.
34-2-4 • Troubleshooting SM 661, Aug ’01

Group 34, Uprights
Section 3
Upright Inspection
! CAUTION
1. Park truck on a hard, level, and solid sur-
face, such as a concrete floor with no gaps or
breaks.
3. Put all controls in neutral. turn key switch
OFF and remove key.
wheels.
Upright
Load baskrest
Carriage
Forks
SM 661, Aug ’01 Upright Inspection • 34-3-1

Group 34, Uprights
Basic Visual Inspection Lift Chains

Use the following steps to conduct an initial visual inspec- Inspect the chains for:
tion of the upright. This is the same type of inspection
• Proper lubrication. The links should have a coat of
operators should be conducting on a daily basis.
oil on all surfaces. Lubrication oil should penetrate
If you note problems with any component during the basic completely into chain joints.
visual inspection, continue with “Extended Inspection” • Good condition of the chain links and pins. No
for checks and service. rust, corrosion, stiffness, or cracking should be evi-
dent. Pins should not be turned or protruding.
! WARNING • Excessive side wear or edge wear on the chain
The procedures for checking, maintaining, plates.
and adjusting uprights, carriages, and forks • Correct, equal tension on chain sets.
involve movement of the components. Failure • Secure anchor bolt, adjustment nut, and jam nut
to follow these warnings can result in serious mounting.
injury. Always use extreme caution.
Do not walk or stand under raised forks. • Correct alignment of the chain anchors to the chain
Keep clear of load and carriage when making and chain sheaves. Adjust turned chain anchors.
any check or adjustment. • Loose, broken, or damaged anchor bolt pins and
Keep your arms and fingers away from mov- cotter pins. Replace defective pins and cotter pins.
ing parts of the upright.
Do not reach through open areas of the Rollers
upright.
Inspect the upright and carriage rollers for:
General • Broken or loose rollers.
• Check to make sure all fasteners are secure. • Loose, broken, or misadjusted thrust roller on the
carriage.
• Check to make sure the upright lifts and lowers
smoothly with and without a capacity load. • Obvious signs of failed bearing seals.
• Check for visible damage to components. NOTE
Some grease will purge from the bearings in
Forks the first 100-200 hours of operation.
• Check function and security of the fork latch. • Excessive looseness in carriage or upright roller
• Inspect the forks for cracks, especially the hanger shimming.
and heel areas.
• Check for wear in the fork heel. If heel wear is evi- Upright and Carriage Weldments
dent, perform the extended inspection.
Inspect the upright and carriage for:
• Inspect the fork hanger and carriage fork bar for
excessive wear. • Debris or foreign objects on the components.
• Inspect for bent forks. • Bent, cracked, or broken components.
• Undesirable wear on or contact between compo-
Load Backrest nents.
• Irregular roller patterns and signs of excessive
• Inspect load backrest for damage such as cracks or wear or scraping on the rails.
bending.
• Check for tight mounting fasteners.
34-3-2 • Upright Inspection SM 661, Aug ’01

Group 34, Uprights
Hydraulic System Overloading, glancing blows against solid objects, or

picking up loads unevenly can bend or twist a fork. Use
Inspect the upright hydraulic system components for: the following procedure to check for fork bending.
• Damage or wear on all hoses and hydraulic tubes. 1. Place a 50 x 100 x 610 mm (2 x 4 x 24 in) wood
• Leaks on hoses, fittings, or valves. block flat on the fork. Make sure the block is not
• Leakage on the cylinders. resting on the heel radius.
• Excessive drift in lift or tilt operations.
Extended Inspection
The extended inspection should be performed whenever
the basic visual inspection indicates upright problems, as
specified for PMs, or at least every 2000 hours.
Forks
Forks have a limited service life because of wear and
fatigue. Forks should be tested every 50-250 hours using a Fork Bending Check
visual inspection, a fork thickness check, a fork bending 2. Set a carpenter’s square on the block against the fork
check, and a fork gap check. If replacement is necessary, shank
always replace the pair to ensure fork integrity.
3. Check the fork 508 mm (20 in) above the blade to
Fork Alignment
make sure it is not bent more than 14.5 mm (0.6 in) at
1. Park the truck on a flat, even surface, tilt upright to the maximum.
vertical position, and set forks 25-50 mm (1-2 in) 4. If blades are bent over the 14.5 mm (0.6 in) allow-
above the ground. ance they should be replaced as a set.
2. Compare fork arms to be sure they are straight, on See Section 7, “Fork and Carriage Removal and Replace-
the same plane (level), and the same length. ment,” for procedures to remove and replace the forks.
3. Measure the distance from the fork tips to the Fork Fatigue
ground. The height difference between the forks tips Fatigue cracks normally start in the heel area or on the
should be no more than 6mm(1/4in). underside of the top hanger. If cracks are found, the fork
should be replaced. Dye penetrants or magnaflux can be
used for a more accurate inspection.
Fork Wear and Heel Wear
Industrial Truck Association (ITA) standards require that
a fork be removed from service when the blade or heel
thickness is reduced by 10% over its original thickness. If
the heel is 10% smaller than the arm, the load capacity
could be reduced by 20%. A 5,000-pound (2272 kg)
6mm(1/4in ) max. capacity fork with 10% wear can only safely handle 4,000
Fork Arm Height pounds (1818 kg).
4. If the fork tips are not aligned within the specified Use of fork wear calipers are recommended (Clark part
6mm (1/4in) difference, the cause of the problem number 1803641) to gauge fork wear as follows:
must be determined and corrected before returning
1. Use the outside jaws of the caliper to measure fork
the truck to service. If replacement is necessary,
thickness in the shank area of the fork.
always replace the forks in a set.
Fork Bending

Group 34, Uprights
NOTE
A small amount of lubricant can be applied
NOTE to the fork latch. Do not over lubricate and
Hold the caliper square and use light pres- allow lubricant to run down on carriage fork
sure to squeeze the outer jaw tips against the bar.
fork shank. Take care not to accidentally
alter the reading of the calipers. 2. Check fork stops for widening of notches or round-
ing of top edge. Replace the carriage if fork stops are
2. Check the fork blade area to the inside jaws of the excessively worn.
caliper.
3. If the inside jaws fit over the fork in the blade area, Lift Chains
wear exceeds allowable 10% wear and a new set of
The following checks should be performed every 50-250
forks should be installed.
hours to ensure correct chain performance See Section 6
Fork Hanger Wear and Carriage Fork Bar Wear for more complete chain inspection and maintenance pro-
Inspect the fork hangers and carriage fork bar. Excessive cedures.
wear can cause the fork to disengage the fork bars or Chain Wear (Stretch) - All Lift Chains
reduce fork hanger life. Lift chain stretch due to wear in the joints can be mea-
sured using a measuring tape or Clark’s chain check ruler.
Chain Check Ruler - Clark Part Number 59-960-9908

• If fork hangers are excessively worn, replace the
forks as a set. When any section of the chain has worn and increased its
• If carriage fork bar is excessively worn, replace the original length by 3% or more, the chain must be replaced.
carriage. When checking chain wear, always measure a segment of
the chain that rolls over a sheave.
IMPORTANT
Welding is not recommended for repairing
forks or carriage. Replace the worn parts
with new parts.
Fork Latch and Carriage Fork Stops
1. Check fork latches for proper operation. Latches

should operate smoothly. The spring should be in
good condition and securely lock the fork into posi-
tion. Replace the fork latch if it does not operate
properly.

Group 34, Uprights
IMPORTANT
Never replace a single chain in a set. Always
! WARNING
replace the two chains in a set for consistent Do not reach through the upright to push
lift operation. Always replace anchor pins chains for tension check.
when replacing chains.
3. If one chains moves more than the other;
1. For example, measure a 305 mm (12 in) segment of a. Lower the forks to ease tension on the chains.
the chain that does not roll over a sheave and count b. Adjust chain adjustment nuts for equal tension on
the number of links in the segment. both chains. See Section 6 for chain adjustment
procedures
2. Find an area of the chain that normally runs over the
sheave. This can usually be identified by wear on the 4. Repeat the tension test and make adjustments until
plate edges that roll over the sheave. the tension is equal on both chains when the carriage
and upright are raised.
3. If the same number of links measures over 315 mm
(12.36 in) the chain must be replaced.
If using a chain check ruler, see instructions on the ruler. Carriage and Upright Weldments
Chain replacement procedures appear in Section 6. The carriage and upright should be checked for fatigue
Chain Length cracks and bent components every 2000 hours or every
year..Fatigue cracks start in areas of stress after a high
IMPORTANT number of load cycles. Stress concentrations typically
Perform a chain length check and adjust- exist in welded joints, in the area around a welded joint, or
ment every 50-250 hours. Checks and adjust- in the corners of parts. Dye penetrant, magnaflux, or other
ments should also be performed to adjust for crack detection methods can be used to find or trace
chain stretch and tire wear. cracks. If cracks are found in any structural weldment, the
component should be replaced before returning the truck
Chain length must be adjusted if: to service.
• The fork-to-ground clearance is less than 5 mm • Bent components indicate excessive loading or
(.20 in) or more than 25 mm (1.0 in) when the high impacts to the weldments. Bent components
upright is vertical. are usually structurally damaged and should be
• The center of the bottom carriage roller comes replaced.
within 20 mm (0.80 in) of the bottom edge of the • Inspect roller contact patterns on the rail sections.
inner rail. Roller contact patterns should be smooth and regu-
• The carriage safety stop hits the inner rail stop at lar.
full lift height. − In some applications, it may take up to 500
hours of operation to develop a roller contact
• On TSUs, the difference between the bottom of the
pattern on the flange of the rail.
inner rail and the outer rail is greater than 10 mm
− In applications where heavy loads are common,
(0.40 in).
a rail lubricant may be required to allow proper
See Section 6 for chain length adjustment procedures.
wear-in on the roller.
Chain Tension • Check rails and carriage for wear due to undesir-
IMPORTANT able contact between components. Such contact
can be an indication of broken rollers, loose com-
Center any auxiliary attachments before
ponents, foreign objects or debris on the upright, or
beginning tension check
a broken weldment.
− If contact or rubbing exists, the condition must
1. Raise the upright enough to put tension on the chains
be corrected immediately.
to be checked.
− Rail and carriage weldments with damage
2. Push the chains forward and pull them backward; the should be replaced.
amount of tension should be equal on both sides.

Group 34, Uprights
• Tie bar areas should be free of foreign objects and NOTE

debris. The roller area of the rail should be cleaned Some grease will purge from the bearings in
every 500-1000 hours in a normal application. the first 100-200 hours of operation. This is
− In applications where excessive amounts of not necessarily a sign of a failed roller bear-
contaminants settle in the rail channels, cleaning seal.
ing may be required on 50-250 hour intervals.
− If excessive contamination exists, the rollers The external thrust rollers on a TSU and STD CL III are
should be exposed and the bearing seal areas not adjustable. The internal thrust roller adjusts using a
cleaned thoroughly. locking cam on the mounting cap screw. See Section 4 for
See Section 4 for carriage roller and upright roller replacement and internal thrust roller adjustment
roller removal and installation. procedures.
Carriage and Upright Main Load Rollers
Carriage and Upright Rollers Inspect the carriage and upright main load rollers for bro-
ken, loose, or rough bearings. Defective rollers should be
Carriage Thrust Rollers
replaced.
The carriage uses two types of thrust rollers.
Shoulder
• The internal thrust roller is found on both standard Roller shaft
and TSUs. The carriage internal thrust rollers are shims
located on the lift bracket and run on the inside Bearing outer race
web of the inner rail. The internal thrust roller is
intended to carry a portion of the carriage lateral
load.
• The second type of carriage thrust roller is an
external thrust roller. The external thrust roller runs Indications of broken or damaged rollers include:
along the outside flange of the inner rail to control
lateral load on the carriage. External thrust rollers • Part of all of roller bearing missing
are found on TSUs and STD CL III only. • Bearing outer race loose
Internal thrust roller • Scraping noise from the upright
• Scraping of carriage fork bar on inner rail (carriage
rollers)
• Upright rail sections scraping together (upright
rollers)
• Upright mis-staging
External thrust roller • Excessive looseness of the rail section or carriage
(not in 2.0/2.5 ton STD CL2)
demonstrated by the following load test.
Both types of thrust rollers should be checked for smooth NOTE

rotation, seal integrity, radial bearing tightness, and a tight Some grease will purge from the bearings in
cap screw. A roller should turn smoothly without sticking the first 100-200 hours of operation. This is
and be grit free. Replace the roller if any defect is found. not necessarily a sign of a failed roller bear-
ing seal.
External thrust roller cap screws have a locking patch to
prevent the cap screw from backing out. Repeated
Load Test
removal will deteriorate the ability of the patch to hold the
A load test helps you to determine the amount of clear-
cap screw. If the cap screw is backing out without holding,
ance between the moving upright parts. The upright
a new cap screw is recommended. The cap screw can also
requires some lateral movement between the interlocking
be cleaned and set using thread locking compound Loctite
rails and the carriage. But, too much or too little clearance
271 (Clark Part 1802302). The internal thrust rollers use a
can be the cause of binding and uneven operation.
jam nut to ensure that the bearing remains secure.

Group 34, Uprights
manufacturing tolerances and wear in the upright rail sec-

! WARNING tions.
An upright or carriage can move unexpect-
edly during service procedures causing
severe injury:
Do not walk or stand under raised forks.
Keep clear of load and carriage when making
any check or adjustment.
Keep your arms and fingers away from mov-
Do not reach through open areas of the
upright.
Failure to follow these warnings can result in
serious injury. Signs of loose shimming include:
1. Excessive lateral (side-to-side) movement in the
1. Place a capacity load on the forks and secure it to the upright rail sections
carriage.
2. Excessive lateral shift in the upright at, or near, full
! maximum fork height (MFH)
CAUTION
Test load must be stacked stably, not extend 3. Irregular roller patterns on the rail.
beyond the pallet, and be secured on the pal- Signs of over shimming include:
let. Operate the truck only from within the
operator’s compartment. 1. Mis-staging or hanging up of the upright
2. Excessive wear in the rail web
2. Tilt the upright back slightly and raise the upright to
its maximum extension several times. Note the 3. Premature bearing failure.
smoothness of operation, the carriage play, and play Perform the following roll pattern check and the load test
between the rails. if the need for roller shimming is suspected. See Section 4
for detailed clearance measurement procedures.
3. Move the load 102 mm (4 in) off center on the forks
and resecure it to the carriage. Roll Patterns
Impressions made by rollers on upright rails are called roll
4. Raise the upright to its maximum extension and patterns. Roll patterns can provide indication of the need
lower the load to the floor several times. for upright or carriage adjustment.
5. Repeat the step, moving the load 102 mm (4 in) off
center to the other side. ! WARNING
6. Raise the upright to its maximum extension and Keep clear of load and carriage when making
lower the load to the floor several times. any checks or adjustments.
Carefully observe the smoothness of operation, particu-
larly in carriage play, and play between the rails. If any 1. Elevate the carriage about 4 feet (1.3 m).
unusual movement, staging, or noise occurs during the 2. Apply a light, thin layer of grease to the roller con-
test, correct the problem before returning the truck to ser- tact area.
vice. Continue with the following roller shimming checks
if too much play is evident in the carriage and rails in the 3. Lower the forks and pick up a capacity load. Raise
load test. The troubleshooting guide may also help to and lower the upright several times.
identify specific problems with upright operation. 4. Back out from the load and raise the carriage.
Roller Side-Clearance Compare the impressions of the rollers on each side of the
The carriage and upright rollers are shimmed between the upright rails. The impressions should look the same on
inner race and the roller shaft shoulder to maintain mini- both sides. Look for signs of metal scoring or gouging
mal clearance between the side of the roller and the web which can indicate excessive pressure caused by damaged
of the adjacent rail. Shim adjustments help accommodate or misadjusted rollers.

Group 34, Uprights
Carriage rollers, including side-thrust rollers, and all NOTE

upright rollers can be checked by examining roll patterns. The seals are installed with lubricant and a
If irregular impressions result from the checks, perform trace amount will be in the gland/tube inter-
the “Lift Cylinder Shimming Check” and the “Load Test” face area.
to further diagnose problems.
See Section 4 for procedures to measure clearances and 4. After cleaning the top of the gland and the barrel,
adjust carriage or upright rollers. cycle the upright 5-10 times. If a ring of oil forms to
run 3 mm (0.125 in) down the rod, the cylinder must
be overhauled or replaced.
Cylinders
Internal Leakage on Primary Cylinder
Use the Drift Test, presented under “Hydraulic Checks” To check for internal leakage on the primary cylinder:
below, for additional diagnosis of cylinder condition. See
Section 5 for cylinder repair. 1. Lift the upright to maximum height then lower forks
completely.
External Leakage (All Cylinders)
To check for external leakage on the primary cylinder: 2. Cycle the upright 5-10 times through the first 2/3
length of the primary stroke and lower forks com-
1. Clean the top of the gland and rod to remove any pletely.
buildup of debris.
3. Slowly lift the carriage 305-610 mm (1-2 ft) into the
2. Check rod surface for defects or unusual wear. secondary lift stage then lift to full extension.
• Nicks, burrs, or other sharp defects can cause dam-
4. If the carriage does not lift to full height, the problem
age to the seal and will lead to leaks. The rod
is likely an internal leak and the cylinder should be
should be repaired or replaced.
overhauled.
• For piston-type cylinders, small blunt defects in
the top and midsection of the rod can be tolerated 5. If the carriage does lift to full height, but you still
in this cylinder design. The high pressure sealing is suspect an internal leak, repeat the procedure with a
over the last several inches of stroke. This type of 40-70% capacity load.
defect is acceptable if leakage is not evident. NOTE
3. Check for external leakage from the cylinder barrel, The primary cylinder normally has approxi-
gland O-rings and backup ring, and the rod seal. mately 100 ml (3.4 oz) of hydraulic fluid on
the rod side of the piston as a pre-charge.
Use the Drift Test, presented under “Hydraulic Checks”

below, for additional diagnosis of cylinder condition. See
Section 5 for cylinder repair.
Internal Leakage on Piston-Type Lift and Secondary
Cylinders
To check for internal leakage in Standard lift and TSU
secondary cylinders:
1. Lift the upright to MFH then lower forks completely.
2. Cycle the upright 5-10 times through the first 2/3
length of the lift cylinder stroke and lower forks
completely.
• The gland O-rings and backup ring are near-zero
3. Lift the upright to full MFH.
leakage seals. If, after cleaning the gland and tube,
oil accumulates to form a run, the O-rings and Watch for the lift cylinder to increase lift speed. If you see
backup ring should be replaced (see Section 5). an increase in lift speed, one or both of the lift cylinders
have an internal leak and requires overhaul.
• External leakage from the barrel requires replace-
ment of the barrel.

Group 34, Uprights
If the upright does not increase lifting speed, but you still a. Hoses or tubes with scrapes or kinks should be
suspect an internal leak, repeat the procedure with a replaced.
capacity load. If the upright does not extend to full MFH, b. Hoses with outer cover wear exposing the rein-
the problem is likely an internal leak and the cylinder forcement braiding should be replaced.
should be overhauled.
Lift Cylinder Shimming Upright Drift
The lift cylinders on both standard uprights and TSUs bot-
tom out at the end of the stroke to limit upright extension. Drift tests check cylinder, main valve, and hydraulic cir-
The upright has dual lift cylinders and the cylinders’ cuit integrity under load pressures. A load is held elevated
extension length must be equal. If not, “racking,” or side- for an extended period to determine how much the upright
to-side shifting, results. Rod extension length is made “drifts” (moves) over a specified time period. A tilt cylin-
equal by using shims under the rod end of the cylinder. To der drift test appears in Group 32, Section 2, “Tilt Cylin-
determine if shimming of the cylinders is required to pre- der Checks and Adjustments.”
vent racking, perform the following operational check:
! WARNING
! CAUTION An upright or carriage can move unexpect-
Make sure truck is parked on level surface edly during service procedures causing
with parking brake applied and wheels severe injury:
chocked; make sure overhead clearance is Do not walk or stand under raised forks.
adequate to extend upright to its full height. Keep clear of load and carriage when making
any check or adjustment.
1. Center the forks or attachments on the upright. Keep your arms and fingers away from mov-
2. Check for equal chain tension. Do not reach through open areas of the
3. Raise the upright from the retracted position to full upright.
lift height. Note the point when the lift cylinders Failure to follow these warnings can result in
reach the end of their stroke. serious injury.
• If the upright shifts right or left noticeably, shim-
1. Raise upright with the rated capacity and carriage to
ming is required.
its full extension and lower to a point halfway down
• Repeat the check three times before adding shims. from full extension with the upright substantially
NOTE vertical.
Offset or unbalanced loads and off-center 2. Shut off the truck. Apply the parking brake and
attachments can cause the upright to shift chock the wheels.
even with proper lift cylinder shimming.
3. With a pencil or chalk, make a mark across the rails
on one side of the upright.
See Section 5 for lift cylinder shimming procedure. Rack-
ing adjustments for tilt cylinders appear in Group 32, Sec-
tion 2, “Tilt Cylinder Checks and Adjustments.”
Hydraulic Plumbing
Use the Lift Cylinder Shimming Check, the Load Test,
and the following Drift Test to check the performance of
the hydraulic system.
1. Check all fittings for leakage. Disassemble fittings
and inspect the seals. Replace seals as required. See
Group 40 for hydraulic fitting tightening procedures.
Mark upright
2. Check all hoses and tubes for wear and damage. rails here

Group 34, Uprights
Consider rebuilding the cylinders if the first two remedies

! WARNING in this list are not successful. See Section 5 for removal,
Keep clear of load and carriage when making overhaul, and replacement procedures for primary and
any checks or adjustments. Do not use the secondary cylinders.
upright to climb; use an approved platform.
Trunnion Bearings
4. Wait ten minutes and recheck the mark. Measure and
write down the distance the marks on the inner and To check the trunnion mounting:
intermediate rails have drifted from the mark on the
1. Check for missing, broken, bent, or loose trunnion
outer rail.
cap fasteners. Replace any damaged parts.
5. If the rated load drift 50 mm (2 in) or more in the ten
2. Lift the upright 305-610 mm (1-2 ft) and tilt the
minutes, read and follow the procedures presented in
upright fully forward.
“Drift Causes and Remedies.”
3. Check for trunnion bearing or cap wear by inserting a
! CAUTION feeler gauge between the trunnion cap and the axle-
mounting bearing surface.
Test load must be stacked stably, not extend
beyond the pallet, and be secured on the pal-
let.
Drift Causes and Remedies

If drift of 50 mm (2 in) or more is evident under the rated
load, consider the following causes and remedies:
• The main hydraulic valve is misadjusted, worn, or
defective. Fluid is leaking past the valve and caus-
ing the upright cylinders to drift. See Group 30 for
hydraulic valve troubleshooting and service.
• Upright hydraulic circuit hoses or fittings are leak-
ing. Check the circuit components and repair as
necessary.
• Cylinder piston seals are worn, damaged, or defec- Trunnion bearing
tive allowing fluid past the piston causing drift.
• Primary cylinder or piston-type lift or secondary
cylinders have a check valve that allows oil to flow
back to the rod side of the cylinder. This check Trunnion cap
valve may be clogged or defective. Inspect the
check valve for proper sealing and operation. • The gap should not exceed 0.75 mm (0.03 in).
• If the gap exceeds 0.75 mm (0.03 in) the bearing or
cap may need replacement.
See Section 8, “Upright Removal and Replacement,” for
procedures to remove and replace the trunnion bearing.

Group 34, Uprights
Section 4
Carriage and Upright Roller Clearance Checks and Shim
Adjustments
IMPORTANT
Before removing any component for over-
! WARNING
haul, make sure the correct repair parts and/ Use an approved safety platform to reach the
or kits are available. upper areas of the upright. Never use the
upright as a ladder.
! WARNING
Introduction
An upright or carriage can move unexpect-
edly: Standard upright assemblies have two lift roller sets
• Do not walk or stand under raised forks mounted on the rails, three lift roller sets mounted on the
• Kee clear of load and carriage when mak- carriage, and two internal and external (except 2.0/2.5 ton
ing any check or adjustment STD) thrust roller set mounted on the carriage.
• Keep your arms and fingers away from
The triple-stage upright assemblies have four lift roller
moving parts of the upright.
sets mounted on the rails, three lift roller sets mounted on
• Block the carriage or upright when work-
the carriage, and two thrust roller sets (“internal” and
ing with the components in a raised posi-
“external”) mounted on the carriage. (see the “Roller Side
tion.
Clearance Chart” on next page.)
• Do not reach through open areas of the
upright. Each carriage and upright lift roller is nested within its
• Never attempt to move or align the rails adjacent rail set. The front “face” of the lift roller handles
by hand. Use a prybar. front-to-back friction and play between the nesting seg-
Failure to follow these warnings can result in ments of the upright assembly, the side “face” of the roller
serious injury. radius handles side-to-side friction and play. The rollers
SM 661, Aug ’01 Carriage and Upright Roller Clearance Checks and Shim Adjustments • 34-4-1
Group 34, Uprights
are canted (tilted) to allow the side face to bear properly tainty that the clearance is excessive, you perform the
on the web. checks given below.
Rail flange wear can cause excess play between the lift To correct excessive lift roller side clearance, you add
rollers and the rail flange. The only way to correct this is shims as described later in this Section. To correct internal
to install oversize rollers-only one size of which is avail- thrust roller clearance, you adjust thrust roller position as
able. If oversize rollers were fitted previously, the only described later in this Section.
remedy for excessive front-to-back play is to replace the
rail set. (carriage middle rollers are always standard-size
rollers; see “Oversize Rollers” later in this Section for
details on roller replacement.)
The gap between the roller “side” and the web of adjacent
rail set affects the side-to-side motion of the upright-
which should be as small as possible without causing the
sliding segments to bind. The same is true of the internal
thrust rollers.
You check the performance effect of the lift roller side
clearance and internal thrust roller clearance by means of
the load test described in Section 3. To evaluate with cer-
Roller Side Clearance Chart
Web Area Gap at Mimimumm Span of Rail Set Gap at Maximum Span of Rail Set
Roller Set# Forming Gap Targeta Allowedb Targeta Allowedb
(mm) (in) (mm) (in) (mm) (in) (mm) (in)
#1 Front, Inner railc 0.5-1.5 0.02-0.06 0.05-1.25 0.02-0.05 d d 2.25 0-0.09
#2 Front, Inner rail 0-0.75 0-0.03 0-1.5e 0-0.06 d d 2.25 0-0.09
#3 Back, Inner rail 0-0.75 0-0.03 0-1.0 0-0.04 d d 2.25 0-0.09
#4 Back, Inner rail 0-0.75 0-0.03 0-1.0 0-0.04 d d 2.25 0-0.09
#5 Back, Intermd rail 0-0.75 0-0.03 0-1.0 0-0.04 d d 2.25 0-0.09
#6 Back, Intermd rail 0-0.75 0-0.03 0-1.0 0-0.04 d d 2.25 0-0.09
#7 Back, Outer rail 0-0.75 0-0.03 0-1.0 0-0.04 d d 2.25 0-0.09
a. Target is the desired gap after reshimming the roller set. d. Ideal is same as final measured gap at minimum width point of rail set.
b. Allowed is the acceptable gap when checking roller set. e. Measured at top of inner rail.
c. Internal side thrust rollers should extend 0.25-0.50mm(0.01-0.02 in)
beyond #1 rollers.
34-4-2 • Carriage and Upright Roller Clearance Checks and Shim Adjustments SM 661, Aug ’01
Group 34, Uprights
Roller Side Clearance Checks 2. Position the carriage or rails so that the roller set you
want to check is at the mark for the narrowest span
The same basic procedure is used for checking all the lift on the adjacent nesting rail set.
rollers. That general procedure is given in the subsection
directly below. Special instructions for specific rollers fol-
low that subsection. Follow those directions (in the sub-
section called “Directions for Checking Specific Rollers”) Narrowest
and you will be directed to general and specific informa- span
tion you need.
General Roller Side Clearance Checking Pro- Widest

span
cedure
For each roller set, you need to measure the gap between
the outside face of a roller and its adjacent nesting rail. In
general, the lift roller side clearance check procedure is as Example of Aligning Roller Set with Widest and
follows: Narrowest Spans Marked on Adjacent Rail Set.
Rail sets are shown separated for clarity.
1. With the spanner tool, find and mark the narrowest
and widest spans in each rail set at the roller-contact 3. Clamp the rails together opposite the roller you
areas in the rail webs: intend to check. Use wooden shim blocks to protect
• Inner Rail Set-Mark narrowest and widest spans the rails. Place clamp as close to roller as possible.
for both the front and back web areas. Torque clamp to 25 N⋅m (20 ft-lb).
• Outer and Intermediate Rail Sets-Mark narrowest
and widest spans for the back web area only.
4. Measure the gap with a feeler gauge. Make sure

roller is tight against its shoulder. Write down the
result.
Web Areas on Typical Rail Set
5. Repeats steps 2 through 4 for the widest span marked

on the rail set.
Spanner Tool. Clark Part #180109
Group 34, Uprights
6. If the clearance at the widest rail set span is more Top Carriage Rollers and Internal Thrust Rollers
than 2.25 mm (0.09 in), the roller set needs shim- The internal thrust rollers are nearly perpendicular to the
ming. top carriage lift rollers and contact the same flange area as
If the clearance at the narrowest rail set span is more the carriage rollers. The top carriage lift rollers and the
than 1.0 mm (0.04 in), the roller set should be internal thrust rollers should be checked together.
shimmed; however, it is OK for the middle carriage
roller gap to be up to 1.5 mm (0.06 in).
7. Repeat entire procedure for each roller set, following
the instructions in “Directions for Checking Specific
Rollers” below.
Directions for Checking Specific Rollers

Use these directions to supplement the general procedures
given above. 1. Move the top carriage lift roller to the narrowest span
Carriage Rollers on the inner rails set.
Bottom Carriage Rollers 2. Clamp rail to one side as in general procedures.
Follow the general procedure above. Check clearance of lift roller on clamped side. Locate
Middle Carriage Rollers the clamp between the thrust roller and the bottom
The middle rollers are difficult to access and require the roller of the carriage.
following special procedures.
1. Raise the carriage until the middle rollers are at the
top of the inner rails.
2. Measure roller side clearance at the top of the inner
rails. Note measurement here:
_____________________.
If gap is less than 1.5 mm (0.06 in), shimming is not
required.
If gap is more than 1.5 mm (0.06 in), check clearance
at narrowest span by comparison with the top of the
rail set as follows:
a. With spanner tool, measure span of inner rail set
at top of the front web area. Note measurement
The internal thrust roller should contact the web and
here: _____________________.
cause the lift roller to stand off from the web by .01
b. With spanner tool, measure span of inner rail set
to 1 mm (0.001-0.03 in). If the gap is outside this
at narrowest span of front web area. Note mea-
range, the internal thrust roller must be adjusted as
surement here: _____________________.
explained later in this Section under “Internal Thrust
c. Subtract measurement in step b from measure-
Roller Adjustment.”
ment in step a, Write result here:
b-a= _____________________. 3. Check clearance on lift roller opposite clamped side
If the calculated gap is less than or equal to the as in the general procedures. If clearance is greater
gap measured in step 2, the roller set does not than 1.25 mm (0.05 in), the roller set should be
require shimming. Otherwise, the roller set shimmed.
should be shimmed.
4. Move clamp to opposite side and check clearance on
clamped side as in step 2 directly above. Gap should
be 0.01-1.0 mm (0.001-0.03 in).
5. Move the top carriage lift roller to the widest span on
the inner rail set and check clearance as in general
procedures.
Group 34, Uprights
Upright Rollers Internal Thrust Roller Adjustment

1. Remove the carriage as described in Section 7 of this The internal thrust rollers should be adjusted to extend 0-
Group. 0.75 mm (0.03 in) into the top carriage roller side clear-
2. Fully extend the upright making sure carriage hoses ance. Carriage roller side clearance should be within toler-
and chains are secured out of the way to prevent ances before you adjust the thrust rollers.
damage. NOTE
! WARNING Carriage must be replaced on upright before
adjusting internal thrust rollers. See Section
An upright or carriage can move unexpect- 8 for carriage replacement procedures.
edly:
• Do not walk or stand under raised forks 1. Lift the carriage to the top of the inner rail.
• Keep clear of load and carriage when
making any check or adjustment 2. Loosen the jam nut on the back of the thrust roller
• Keep your arms and fingers away from cap screw and then loosen the cap screw. Rotate the
moving parts of the upright. bearing to pivot toward the carriage and away from
• Do not reach through open areas of the the rail.
upright.
• Never attempt to move or align the rails
by hand. Use a prybar.
• Use an approved safety platform to reach
the upper areas of the upright. Never use
the upright as a ladder.
serious injury.
3. Follow the “General Roller Side Clearance Checking
Procedure” given earlier in this Section. 3. Lower the carriage to a convenient height to do the
The clamping procedure is as illustrated below. adjustment.
4. Clamp the carriage between the top and middle car-
riage roller.
• Use a shim block under the clamp on the outside of
the channel rail.
• Torque on the clamp should not exceed 25 N⋅m (20
ft-lb).
5. Insert a 0.5 mm (0.02 in) temporary shim between
the top carriage roller and the rail web on the side
opposite the clamp. If a 0.5 mm (0.02 in) shim will
not fit, insert a 0.25 mm (0.01 in) shim.
Group 34, Uprights
6. Move the clamp to the shimmed side and clamp the Oversize Rollers
rollers against the shim and the rail web by position-
ing the clamp between the top and middle carriage At the time of roller shimming, you may
rollers. want to replace the lift rollers with oversize
rollers to counter rail flange wear as
detected by inspection and the load test.
Because there is only one size of oversize
rollers, you can install them only if they
were not installed previously.
Identify oversize rollers as follows: If a
roller is oversize, it has an indented radius
in the outer edge of its mounting side, as
shown below.
7. Cam the thrust roller on the shimmed side against the
rail clockwise and tighten the cap screws firmly. Lift Roller Shimming
NOTE You need to shim lift rollers if the roller side clearance
Make sure the roller does not rotate with the checks indicated that clearance was excessive at either the
cap screw when tightening. narrowest or widest span of the roller set’s adjacent rail
set.
8. Insert a 0.5 mm (0.02 in) shim in the opposite roller. Your objective in shimming is to add only enough shims
If a 0.5 mm (0.02 in) shim will not fit, insert a 0.25 to bring the clearances at both the widest and narrowest
mm (0.01 in) shim. spans into tolerances. In practice, you achieve this by
9. Loosen the clamp and remove the shim. shimming to obtain the smallest possible clearance at the
narrowest span of the rail set.
10. Reposition the clamp on the opposite side and draw
the roller against the shim and rail web.
Carriage Roller Shimming
11. Cam the thrust roller on this shimmed side toward
the rail clockwise and tighten the cap screws firmly. Using the measurement you recorded in previously in the
“Roller Side Clearance Checks,” determine the number of
NOTE
shims required to reduce the carriage roller clearance at
Make sure the roller does not rotate with the the narrowest span on the inner rail to 0-0.75 mm (0-0.03
cap screw when tightening. in):
12. Loosen the clamp and remove the shim. 1. Remove the carriage as described in Section 8, “Fork
and Carriage Removal and Replacement.”
13. Use a crow’s foot to torque the cap screws 70-80
N⋅m (51.5-59.2 ft-lb). 2. Remove the rollers (note the number of shims
already on the roller shafts, if any).
NOTE
If a crow’s foot is not available, the carriage
can be raised to the top of the inner rail and a
socket used to tighten to the correct torque.
14. Position the carriage to access the jam nut on the

back side of the cap screw and torque to 70-80 N⋅m
(51.5-59.2 ft-lb).
• Clean and inspect roller bearings, shims, and
shafts.
• Replace any defective parts.
Group 34, Uprights
3. Add shims to the top and bottom rollers as deter- Upright Roller Removal
mined in the previous steps.
1. After the carriage has been removed, lower the
• Install shims with the same number on each side. upright rails until both of the secondary (final) lift
• When an odd number of shims is required, always cylinders are completely collapsed.
place the odd shim on the same side on all roller
2. Jack the truck and block under the frame so that the
sets.
bottom of the upright is approximately 254 mm (10
4. Use a straight bar to determine the number of shims in) off the floor. See “Lifting, Jacking, and Blocking”
to add to the middle roller shaft as shown in the fol- in Group SA for safe procedures.
lowing illustration. This shimming may be asymmet-
3. Set the parking brake and block the steer wheels.
ric, meaning the numbers of shims do not have to
match those of the top and bottom rollers. 4. Tilt the upright to as near vertical as possible.
5. Using a hoist and lifting strap of adequate capacities,
connect the lifting strap to the inner rail on standard
uprights or intermediate rails on triple-stage uprights.
Lift hoist to remove slack from the strap.
5. Reinstall all bearings; torque top roller fasteners to

40-45 N⋅m (30-33 in-lb).
Carriage internal thrust rollers must be adjusted after the 6. Disconnect the flow control valve manifold from the
carriage is shimmed. Adjust as described previously. upright bracket.
Upright Roller Shimming

Use the following procedures to remove, shim, and
replace rollers. Use the preceding checks to determine the
number of shims required to reduce the roller clearances
to 0.75 mm (0.03 in) or less.
! WARNING
Use an approved safety platform. Never use
7. Disconnect the cylinder guide bolts.
the upright as a ladder.
! CAUTION
The carriage should be removed for shim-
ming or when any service is performed on
the upright. See Section 8, for removal and
replacement procedures.
Group 34, Uprights
8. Secure the cylinder to prevent its falling and discon- Roller Removal, Shimming, and Replacement
nect the cylinder rod retaining bolts. To add shims to, or replace the rollers:
1. Use a puller to remove the rollers from the posts. Or,
gently pry the rollers off the posts. Pry at different
points around the bearing to work it off. Do not dam-
age the bearing seals on the backside of the roller.
2. Inspect all roller components when removed:
NOTE
For 4-hose adapters, you must disconnect the
hose sheave and bracket. This is not neces-
sary for 2-hose adapters.
a. Clean and inspect the rollers, shims, and roller
9. Move the sheave with the hoses and any other con-
shafts.
nected components out of the way.
b. Bearings should be in good condition and allow
10. Disconnect the rail cylinders by raising the rails to the roller to spin smoothly with a true rotation.
free the cylinder rod ends from the tie bar. Tilt the c. Clean rail sections and add lubricant if necessary.
cylinders inward and secure out of the way of the tie d. Replace any worn or damaged component.
bars.
3. If the clearance check indicated an even number of
11. Lower the assembly completely to expose the rollers. shims needed, split the number evenly between the
rollers on either side of the upright.
The lower roller set of the inner rail and upper roller set of
the outer rail on standard and triple-stage uprights are now 4. If the clearance check indicated an odd number of
exposed for shim adjustment. shims needed, keep the odd number to the same side
on all rails of the upright. If three shims are needed,
for example, add one to the rollers on the left side.
Add the other two on the rollers on the right side.
5. Reposition the rollers onto the roller shaft and use a
plastic or hard-rubber mallet to gently tap the roller.
Seat the roller evenly by continuing to tap gently
until it is fully seated and snug against the added
shims.
Group 34, Uprights
Upright Reassembly 3. Reconnect the cylinder guide bolts. Do not tighten

The following steps detail the procedures for reassem- until inner and/or intermediate rails are in the fully
bling the upright. lowered position. Torque guide bolts nuts to 20-25
N⋅m (14.8-18.5 ft-lb).
! WARNING
The upright can move unexpectedly:
upright.
• Never attempt to move or align the rails
by hand. Use a prybar.
4. Reconnect the cylinder rod retaining bolts. Torque
Failure to follow these warnings can result in rod retaining bolts to 20-25 N⋅m (14.8-18.5 ft-lb).
serious injury.
1. Connect the lifting strap to the inner rail on standard
uprights or intermediate rails on triple-stage uprights
and raise the rails just high enough to clear the lift
cylinders. Use a prybar to guide the rails and allow
the rollers to reenter the rail channel.
5. Replace the 4-hose sheave and bracket assembly

onto the upright. Torque nuts to 20-25 N⋅m (14.8-
18.5 ft-lb).
6. Reconnect the load lowering flow valve to the
upright bracket. Torque nuts to 20-25 N⋅m (14.8-18.5
ft-lb).
2. Reposition the rail cylinders and slowly and carefully

lower the rails to seat the rod end into the mounting.
Group 34, Uprights
7. Jack up the truck only enough to remove the block- Overshimming

ing and slowly lower the truck so that its full weight
is on the floor. Use these steps to check for overshimming:
8. Replace the carriage and forks. 1. With the forks removed, lift the upright to maximum
fork height.
9. Test the upright lift and tilt functions; make sure all
upright components work correctly and smoothly. 2. Slowly lower the upright.
Check for overshimming as described in the next • The carriage should not bind or hang up at any
subsection. Repeat the load test to make sure the point along the rails.
upright works correctly under load. When you are • If the carriage binds or hangs up, and the rails are
sure all components are operating correctly, perform not clogged with grease or debris, the carriage
the chain adjustment checks in Section 3 before requires reshimming. See “Troubleshooting” for
returning the truck to service. other mis-staging problems.
Group 34, Uprights
Section 5
Cylinder Removal, Shimming, Overhaul, and Replacement
Cylinder Types • Ignition off
Standard uprights use two lift cylinders. Triple stage • Parking brake applied
uprights use three cylinders, a primary (center-mounted) • Directional lever in neutral
cylinder, and two secondary cylinders. All primary cylin-
ders used on triple-stage uprights (TSUs) are piston cylin- • Forks lowered completely
ders. • Wheels blocked.
IMPORTANT
Before removing any component for over- Lift Cylinder Shimming Procedure
haul, make sure the correct repair parts,
To shim the lift cylinders to correct unequal cylinder
seals, and gasket sets are available. stroke:
Upright Upright 1. Fully lower upright until both lift cylinders are col-
Type Number Cylinder Type lapsed.
Standard V2302 Piston-Type Lift Cylinder 2. Attach a hoisting strap to the tie bar of the inner rail
V2303 Piston-Type Lift Cylinder or intermediate rail tie bar of TSUs.
V2304 Piston-Type Lift Cylinder
TSU M2302 Piston-Type Secondary Cylinder
M2303 Piston-Type Secondary Cylinder
M2304 Piston-Type Secondary Cylinder
! CAUTION
To remove, or partially remove, the cylinders ! CAUTION
from the upright for shimming or overhaul,
start with the truck in a safe position: Make sure hoisting equipment is of adequate
capacity and in good working order.
SM 661, Aug ’01 Cylinder Removal, Shimming, Overhaul, and Replacement • 34-5-1
Group 34, Uprights
3. Remove the cylinder rod retaining bolt. 2. Disconnect and cap the hydraulic line at the base of
the cylinder.
To load lowering
flow valve
4. Slowly lift the inner (or intermediate) rails off the top
of the cylinder to expose the cylinder rod top.
! CAUTION 3. Remove and discard cotter pins from chain anchor

bolt pins on the cylinder.
Block rail in up position.
4. Remove the pins, draw the chain through the sheave,
5. Insert shim(s) over rod end of cylinder with the and drape the chain over the carriage.
shorter stroke to compensate for unequal stroke
length.
6. Slowly lower the inner or intermediate rail back onto
the rod ends.
! WARNING
Do not try to maneuver the cylinder or rails
with your hands. Use a prybar.
7. Replace cylinder rod retaining bolt to secure rod end 5. Remove the snap ring holding the chain sheave (and
into inner or intermediate rail mounting hole. Torque hose bracket, if equipped) on the rod end and move
the cylinder rod retaining bolts to 20-25 N⋅m (14.8- assembly off top of rod.
18.5 ft-lb).
8. Repeat the racking test and adjustment until no rack-
Snap ring
ing is evident during upright lift extension.
9. Check all upright functions before returning the truck
to service.
Primary Cylinder Removal and

Replacement (TSU Only)
Remove the primary cylinder for replacement only. Cylin-
der can be overhauled without removing it from the
upright. See “Cylinder Overhaul” for procedures.
1. Make sure the cylinder is completely collapsed and
pressure is released.
34-5-2 • Cylinder Removal, Shimming, Overhaul, and Replacement SM 661, Aug ’01
Group 34, Uprights
6. Disconnect cylinder mounting bolts and cylinder 4. Disconnect and cap the hydraulic line from the base
base mounting bolts. of each cylinder. Remove the mounting bolts from
the manifold block.
5. Lower the carriage

connect the lifting strap to the inner rail on standard
uprights and inner and intermediate rails on triple-
stage uprights.
Use these steps in reverse to replace the cylinder. Check

Group 40 for hydraulic fitting tightening procedures. If
complete cylinder was torque hydraulic line bracket to 40-
45 N⋅m (30-33 ft-lb).
Lift and Secondary Cylinder Removal

and Replacement
Only piston-type lift and secondary cylinders must be
removed from the upright for overhaul. The cylinder gland
and rod can be removed for overhaul while leaving the
cylinder tube mounted on the truck.
1. Make sure the cylinders are completely collapsed and
pressure is released. 7. Disconnect the cylinder guide bolts.
2. Tilt the upright to as near vertical as possible.
lift the carriage to access the hydraulic lines at the
base of the cylinders.
! CAUTION
Make sure hoisting equipment is of adequate
capacity and in good working order.
Group 34, Uprights
8. Disconnect the cylinder rod retaining bolts. 1. Clean the rod-end and gland thoroughly to prevent
contamination from falling into the cylinder during
disassembly.
2. With a blunt punch or chisel, bend the lock ring out
of the locking grooves of the gland.
3. Use a spanner wrench to remove the gland. Reuse the
lock ring if undamaged.
4. Carefully lift the rod out of the cylinder and place in
a clean area.
9. Remove the cylinders by raising the inner rail (and 5. Inspect the tube and tube end for damage and cover
intermediate rail on the triple stage upright) to free the cylinder tube end to prevent contamination.
the cylinder rod ends from the tie bar.
6. Remove all rings and seals from the piston and the
10. Remove any shims and note number and location. gland.
11. Lift the cylinders off the base mount.
Use these steps in reverse to replace the cylinders. Torque
the cylinder rod retaining bolts to 20-25 N⋅m (14.8-18.5
ft-lb). Torque the cylinder guide bolt nuts to 30-35 N⋅m
(22.2-25.6 ft-lb). Check Group 40 for hydraulic fitting
tightening procedures.
Cylinder Overhaul
Use these steps to overhaul the primary and lift and sec-
ondary (TSU) cylinders.
NOTE
During overhaul, set rod or cylinder on a
work bench with adequate support for safe
and convenient disassembly. Two sets of 4x4 7. For piston-type cylinders:
in (100x100 mm) “V”-notched blocks are a. Remove the check valve from the piston for
helpful; one set for the cylinder barrel and inspection and cleaning by removing the snap
one set for the piston rod. The blocks prevent ring from the piston bore.
nicks and scratches from harming the piston
or rod.
Cylinder Disassembly
• To overhaul the primary cylinder, it is not neces-
sary to remove the cylinder from the upright.
Instead, free the rod end of the cylinder as Check Valve. Arrow shows direction of flow
explained in “Cylinder Removal.”
b. Use a blunt hook to pop the check valve out.
• To overhaul piston-type cylinders, you should
remove the cylinders from the upright as explained IMPORTANT
in “Cylinder Removal.” The cylinders have seals Use extreme care that you do not make nicks
on the piston, and the rods must be removed for and burrs on the interior surface area of the
seal replacement. cap or cylinder or the piston.
Group 34, Uprights
Parts Inspection and Service NOTE

O-rings should be carefully installed to elimi-
1. Clean all parts completely in a suitable solvent. Dry nate cuts or twisting.
all parts with a soft clean cloth.
2. Inspect cylinder barrel and bore for cracks, pining, 3. Replace the piston seals:
scoring, or other irregularities that may require a. Primary cylinder pistons require a piston seal and
replacement of the barrel. wear ring. Install the piston seal from the top of
the rod. Use a ring compressor to compress the
3. Inspect the piston and rod for nicks, scratches, scor- piston seal. This prevents damage to the seal dur-
ing, or other defects that may demand new parts. ing reassembly.
4. Check all gland and piston seal grooves for nicks,
burrs, and scratches that can damage seals during
reinstallation.
5. Inspect and clean the check valves.
6. Inspect all seals, including the check valve O-ring.
NOTE
Minute imperfections inside the cylinder bar-
rel or on the piston or rod may be improved
for acceptable use by careful honing. How- b. Piston-type lift and secondary cylinder require a
ever, removal of material that produces a cylinder seal, a back-up ring, and a wear ring on
notch, groove, or out-of-roundness may cause the piston. Install the cylinder seal from the top of
excessive leakage during operation and a the rod.
shortened life.
7. Use new parts as necessary. Always use the Packing

Kit listed in the parts manual. New kits include all
the seals, wiper rings, wear rings and O-rings neces-
sary for the particular cylinder.
Cylinder Reassembly
Take care when installing these parts to make sure that no 4. For protection against corrosion, lubricate spacers
parts are damaged. (where used) with petroleum-based hydraulic fluid.
1. Coat all packing, seals and rings in clean, hydraulic Slide the spacer onto the rod.
oil (Clark part number 1800236 qt., 1802155 gal.) 5. Insert the piston and rod into the cylinder. Be careful
prior to reassembly. Coat the inside of the gland nut not to scratch or damage the cylinder gland nut
bore with hydraulic oil. threads.
2. Replace the U-cup seal (groove toward bottom of 6. For primary cylinders, add 3.4 oz (100 ml) of hydrau-
cylinder), rod wiper, and O-ring and back-up seals on lic oil into the cylinder on the rod side of the piston.
the gland.
7. Install the lock ring onto the gland. Lubricate cylin-
der threads and screw gland onto cylinder. Be careful
not to damage gland seal. Make sure the gland is
fully seated on the cylinder barrel. Deform the lock
ring into slots in the tube and the gland.
8. Check the assembly by making sure the piston slides
freely in and out of the cylinder.
9. Tighten the gland nut:
Group 34, Uprights
• On primary cylinders, tighten the gland nut to 135 This competes the cylinder repair procedure. Replace the
N⋅m (100 ft-lb). cylinders as described in “Cylinder Removal and Replace-
• On lift and secondary cylinders, tighten the gland ment.” Complete the chain length adjustment in Section 3
nut to 100 N⋅m (75 ft-lb). for correct carriage and rail position. When all adjust-
ments are completed, return the truck to service.
Typical Piston-Type Standard Upright Lift and TSU Triple-Stage Upright Primary Cylinder
Secondary Cylinder
Group 34, Uprights
Section 6
Upright Chain Inspection, Adjustment, and Replacement
Chain Configuration-Standard Uprights
SM 661, Aug ’01 Upright Chain Inspection, Adjustment, and Replacement • 34-6-1
Group 34, Uprights
Chain Configuraions-Triple Stage Uprights
34-6-2 • Upright Chain Inspection, Adjustment, and Replacement SM 661, Aug ’01
Group 34, Uprights
Periodic Inspections resulting in pin rotation. When chain is allowed to operate

in this condition, a pin, or series of pins, can begin to twist
Each 50-250 hours of operation (more frequently in out of a chain resulting in failure. The pin head rivets
severe or extreme environments), chains should be should be examined to determine if the "VEE" flats are
inspected and lubricated. Inspection should focus on the still in correct alignment. Chain with rotated/displaced
following: heads or abnormal pin protrusion should be replaced
immediately. Do not attempt to repair the chain by weld-
Elongation ing or driving the pin(s) back into the chain. Once the
press fit integrity between outside plates and pins has been
When a length of 12.00 inches (305 mm) of new chain has altered, it cannot be restored. Any wear pattern on the pin
elongated to a length of 12.360 inches (315 mm), it should heads or the sides of the link plates indicates misalign-
be discarded and replaced. It is important to measure the ment in the system. This condition damages the chain and
chain in the section that moves over the sheaves because it increases frictional loading, and should be corrected.
receives the most frequent articulation. Measuring the
chain near its clevis terminals could give an erroneous
reading as it would not have flexed as frequently, if indeed
at all, as nearer the middle of the assembly.
Turned pins and abnormal pin protrusion.
Chains should be replaced when wear exceeds 3% or Cracked Plates

when 12 inches (305 mm) of chain is stretched 3/8 inch
(10 mm). The chains should periodically be inspected very care-
fully, front and back as well as side to side, for any evi-
dence of cracked plates. If any one crack is discovered,
Edge Wear the chain(s) should be replaced. It is important, however,
to determine the causes of the crack before installing new
Check the chain for wear on the link plate edges caused by
chain so the condition does not repeat itself.
running back and forth over the sheave. The maximum
reduction of material should not exceed 5%. This can be • Fatigue Cracking - Fatigue cracks are a result of
compared to a normal link plate height by measuring a repeated cyclic loading beyond the chain's endur-
portion of chain that does not run over the sheave. Dis- ance limit. The magnitude of the load and fre-
torted or battered plates on leaf chain can cause tight quency of its occurrence are factors which
joints and prevent flexing. determine when fatigue failure will occur. The
loading can be continuous or intermittent (impulse
load).
Worn contours and worn surfaces on the outside links or

pin heads should not exceed 5% of new link height. Fatigue cracks generally run from the pin hole toward the
edge of the link plate approximately 90o from the line of
Turning or Protruding Pins pull.
Highly loaded chain operating with inadequate lubrication Fatigue cracks almost always start at the link plate
can generate abnormal frictional forces between pin and pin hole (point of highest stress) and are perpendic-
link plates. In extreme instances, the torque could surpass ular to the chain pitch line. They are often micro-
the press fit force between the pins and the outside plates, scopic in their early stage. Unlike a pure tensile
Group 34, Uprights
failure, there is no noticeable yielding (stretch) of Ultimate Strength Failure

the material.
This type of failure is caused by overloads far in excess of
• Stress - Corrosion Cracking - The outside link the design load.
plates, which are heavily press fitted to the pins,
are particularly susceptible to stress corrosion
cracking. Like fatigue cracks, these initiate at the
point of highest stress (pin hole) but tend to extend
in an arc-like path between the holes in the pin
plate.
Broken plate caused by overload.
Tight Joints
All joints in leaf chain should flex freely. Tight joints
Arc-like cracks in plates are a sign of stress corrosion. resist flexure and increase internal friction, thus increas-
More than one crack can often appear on a link ing chain tension required to lift a given load. Increased
plate. In addition to rusting, this condition can be tension accelerates wear and fatigue problems.
caused by exposure to an acidic or caustic medium
or atmosphere.
Stress corrosion is an environmentally assisted
failure. Two conditions must be present: a corro-
sive agent and static stress. In the chain, static
stress is present at the pin hole due to the press fit If lubrication does not loosen a tight joint, the chain may
pin. No cyclic motion is required, and the plates have corrosion and rust problems or bent pins and must
can crack during idle periods. The reactions of be replaced.
many chemical agents (such as battery acid fumes)
See Section 3 for detailed chain stretch, length, and ten-
with hardened steel can liberate hydrogen which
sions checks.
attacks and weakens the steel grain structure.
For this same reason, never attempt to electroplate
a leaf chain or its components. The plating process Chain Length Adjustments
liberates hydrogen, and hydrogen embrittlement
cracks will appear. These are similar in appearance ! WARNING
to stress corrosion cracks. An upright or carriage can move unexpect-
If a plated chain is required, consult Clark. Plated edly:
chains are assembled from modified, individually • Do not walk or stand under raised forks
plated components which may reduce the chain • Keep clear of load and carriage when mak-
rating. ing any check or adjustment
• Corrosion Fatigue - Corrosion fatigue cracks are • Keep your arms and fingers away from
very similar (in many cases identical) to normal moving parts of the upright.
fatigue cracks in appearance. They generally begin • Block the carriage or upright when work-
at the pin hole and move perpendicular (90°) to the ing with the components in a raised posi-
chain pitch line. tion.
Corrosion fatigue is not the same as stress corro-
sion. Corrosion fatigue is the combined action of
upright.
an aggressive environment and a cyclic stress (not
a static stress alone, as in stress corrosion). • Never attempt to move or align the rails by
hand. Use a prybar.
serious injury.
Group 34, Uprights
Standard Upright Chain Length Adjustment 3. Carriage stop-to-upright:

a. Lift upright to its full height and check for clear-
To adjust chain length on the standard upright use the fol- ance on the carriage safety stop.
lowing illustration and procedures: b. If the carriage stop hits the upright stop, adjust
the chain anchor adjustment nuts out until there is
at least 3 mm (0.12 in) clearance between the
stops.
IMPORTANT
The carriage stop must not be allowed to con-
tact the upright stop under any circumstance
Adjust chain during normal operations.
length here
To carriage If all three chain length requirements listed above cannot

be met, the tire diameter may be out of the design range
1. Fork-to-ground clearance: allowance. Also, excessive tire wear will decrease car-
a. Set the upright to vertical position. riage stop clearance.
b. Break the jam nuts loose on the chain anchors.
Oversized tires will reduce the bottom carriage roller
engagement on the inner rail when the carriage is in the
lowered position. The fork-to-ground clearance can devi-
ate from the 10-20 mm (0.40-0.80 in) allowance by a
small amount if necessary to maintain the safe 20 mm
(0.80 in) clearance of the bottom carriage roller to the
lower edge of the inner rail.
Triple-Stage Upright (TSU) Chain Length

c. Turn the chain adjustment nuts until clearance Adjustments
between forks and ground is 10-20 mm (0.40-
Triple-stage uprights use two chain sets; one set for car-
0.80 in).
riage lift and one set for rail lift. Adjustment anchors for
IMPORTANT the lift cylinder stage are located at the back of the outer
For all chain anchor adjustments: rail. Adjustment anchors for the primary lift stage are
behind the primary cylinder. Carriage chain anchors are
• Threaded chain anchors must be left free to not intended for adjustment.
pivot in mounting hole.
• Anchor cotter pin heads must be to the For TSU inner rail lift chains, chain length must be
inside of the upright. adjusted if the difference between the bottom of the inner
rail and the outer rail is greater than 10 mm (0.40 in).
• Torque jam nuts to adjustment nuts to 100-
200 N⋅m (74-148 ft-lb). For the TSU primary cylinder lift chain, the chain length
• Make sure chain anchors are secured so must be adjusted if:
that no twist is evident in the chains. • The fork-to-ground clearance is less than 5 mm
2. Carriage roller position: (0.20 in) or more than 25 mm (1.0 in) when the
a. Raise carriage about 1 m (3.2 ft) and smear a upright is vertical.
bead of grease on the bottom 75 mm (3 in) inner • The center of the bottom carriage roller comes
rail in the area of the roller pattern. within 20 mm (.80 in) of the bottom edge of the
b. Tilt upright fully back and completely lower. inner rail.
c. Raise carriage about 1 m (3.2 ft) and measure the • The carriage safety stop hits the inner rail stop at
distance from where the center of the bottom car- full lift height.
riage roller stopped to the bottom edge of the
inner rail. Distance should not be less than 20 mm
(0.80 in) or chain length adjustment is required.
Group 34, Uprights
To adjust the cylinder lift chains on a TSU use the follow- IMPORTANT
ing illustration and procedures: For all chain anchor adjustments:
• Threaded chain anchors must be left free to
pivot in mounting hole.
• Anchor cotter pin heads must be to the
inside of the upright.
• Torque jam nuts to adjustment nuts to 100-
200 N⋅m (74-148 ft-lb).
• Make sure chain anchors are secured so
that no twist is evident in the chains.
Adjust chain
length here 2. Carriage roller position:
a. Raise carriage about 1 m (3.2 ft) and smear a
To inner rail
bead of grease on the bottom 75 mm (3 in) of the
1. Set the upright in the vertical position. inner rail in the area of the roller pattern.
b. Tilt upright fully back and completely lower.
2. Break the jam nuts loose on the chain anchors. c. Raise carriage again about 1 m (3.2 ft) and mea-
3. Adjust the chain anchor adjustment nuts until the sure the distance from where the center of the
bottom of the inner rail is within 2.5 mm (0.10 in) of bottom carriage roller stopped to the bottom edge
the bottom of the outer rail. of the inner rail. Distance should not be less than
To adjust the primary cylinder lift chain on a TSU use the 20 mm (0.80 in) or chain length adjustment is
following illustration and procedures: required.
3. Carriage stop-to-upright:
a. Lift upright to its full height and check for clear-
ance on the carriage safety stop.
b. If the carriage stop hits the upright stop, adjust
the chain anchor adjustment nuts out until there is
at least 3 mm (0.12 in) clearance between the
stops.
To carriage IMPORTANT
Adjust chain The carriage stop must not be allowed to con-
length here tact the upright stop under any circumstance
during normal operations.
1. Fork-to-ground clearance:
a. Set the upright to vertical position. If all three chain length requirements listed above cannot
b. Break the jam nuts loose on the chain anchors. be met, the tire diameter may be out of the design range
c. Turn the chain adjustment nuts until clearance allowance. Also, excessive tire wear will decrease car-
between forks and ground is 10-20 mm (0.40- riage stop clearance.
0.80 in).
Oversized tires will reduce the bottom carriage roller
engagement on the inner rail when the carriage is in the
lowered position. The fork-to-ground clearance can devi-
ate from the 10-20 mm (0.40-0.80 in) allowance by a
small amount if necessary to maintain the safe 20 mm
(0.80 in) clearance of the bottom carriage roller to the
lower edge of the inner rail.
Group 34, Uprights
Chain Lubrication Failure to follow these warnings can result in

serious injury. See “Lifting, Jacking, and
Like all bearing surfaces, the precision-manufactured, Blocking” for safe blocking procedures.
hardened-steel, joint-wearing surfaces of leaf chain
require a film of oil between all mating parts to prevent
accelerated wear. General Guidelines
Maintaining a lubricant film on all chain surfaces will: • Chain Movement - Make sure that the chain oper-
ating path is clear and that the chain articulates
• Minimize joint wear. freely through its full range of operation.
• Improve corrosion resistance. • Lubrication - Assure that the chain is well lubri-
• Reduce the possibility of pin turning. cated with the heaviest oil that will penetrate the
• Minimize tight joints. void between the link plate apertures and the pins.
• Promote smooth, quiet chain action. • Paint - Make sure the chain does not get painted
over at any time.
• Lower chain tension by reducing internal friction
in the chain system. • Protection - Where necessary, as a protection from
atmosphere or sliding wear, the chain may be cov-
Laboratory wear tests show #40 oil to have greater ability ered with a layer of grease. It should be noted,
to prevent wear than #10 oil. Generally, the heaviest however, that the grease will have to be removed at
(highest viscosity) oil that will penetrate the joint is best. a later date for chain inspection and relubrication.
Whatever method is used, the oil must penetrate the chain • Chain Mountings - Double check to be sure all
joint to prevent wear. Applying oil to external surfaces chain fastening devices are secured and all adjust-
will prevent rust, but oil must flow into the live bearing ments have been made to assure uniform loading
surfaces for maximum wear life. of multiple chain applications. Check chain
anchors and pins for wear, breakage, and misalign-
To prepare the chain for oiling, the leaf chain plates
ment. Damaged anchors and pins should be
should be brushed with a stiff brush or wire brush to clear
replaced.
the space between the plates so that oil may penetrate the
live bearing area. • Sheaves - Sheaves with badly worn flanges and
outside diameter should be replaced. This wear
Oil may be applied with a narrow paint brush or directly may be due to chain misalignment or frozen bear-
poured on. Chain should be well flooded to be sure the oil ings.
penetrates the joint.
In locations difficult to reach, it may be necessary to use a Lift Chains (Standard and TSUs)
good quality oil under pressure such as an aerosol can or
pump pressure spray. To remove and replace the lift cylinder and/or carriage
chain set on standard and triple-stage uprights (TSU):
Chain Removal and Replacement 1. Attach a hoist strap on the carriage of the standard
upright or inner rail of the TSU.
! WARNING 2. Lift the carriage or inner rail slightly to create slack
The procedures for removing and replacing in the chains. Block the carriage or inner rail up for
chain sets involve hoisting and blocking com- safety.
ponents. 3. Remove the chain anchor pins on the outer rail and
• Do not walk or stand under raised forks. pull the chains off of the sheaves on the inner or
intermediate rails.
upright.
Group 34, Uprights
4. Remove the chain anchor pins from the carriage on 2. Remove the chain anchor pins from the back of the
the standard upright or the inner rail on the TSU. On primary cylinder. Pull the chains through the chain
the TSU, the inner rails must be lowered to the floor sheave and lay over the carriage load backrest.
to access the chain anchor pins.
Lift Chain Removal from Carriage (standard upright) 3. Remove the chain anchor pins from the back of the
carriage.
Triple-Stage Upright Lift Chain Removal from Inner Rail

4. Use these steps in reverse to replace the primary cyl-
NOTE inder/carriage chain.
If a hose adapter assembly is used, the chain Perform the chain length adjustment and chain tension
sheaves must be loosened and removed to check before returning the truck to service.
prevent the hoses from stretching when the
inner rails of the TSU are lowered to access
the chain anchor pins. Other Chain Service Notes
• Use lengths of factory assembled chain. Do not
5. Use the steps in reverse order to replace the lift chain
build lengths from individual components.
set.
• Do not attempt to rework damaged chains by
replacing only the components obviously faulty.
Primary Cylinder/Carriage Chains (TSUs) The entire chain may be compromised and should
be discarded.
1. Tilt the upright forward, lower it, and completely col-
lapse the primary cylinder to create slack in the • Never electroplate assembled leaf chain or its com-
chains. The carriage may also be lifted and blocked ponents. Plating will result in failure from hydro-
in position and the primary cylinder completely col- gen embrittlement. Plated chains are assembled
lapsed to create slack in the chains. from modified, individually plated components.
• Welding should not be performed on any chain or
component. Welding spatter should never be
allowed to come in contact with chain or compo-
nents.
• Leaf chains are manufactured exclusively from
heat treated steels and therefore must not be
annealed. If heating a chain with a cutting torch is
absolutely necessary for removal, the chain should
not be reused.
Group 34, Uprights
Section 7
Fork and Carriage Removal and Replacement
3. Lift tip of each fork and put a 100 x 100 mm (4 x 4

! CAUTION in) block under the fork arm near the heel.
1. Park truck on a hard, level, and solid sur-
! CAUTION
face, such as a concrete floor with no gaps Forks weigh 50-68 kg (110-150 lbs) each.
or breaks. Take care when lifting.
wheels.
Fork Removal
NOTE
Blocking the Fork
Forks do not need to be removed to remove
the carriage. 4. Push down on tips of the forks to disengage the fork
hooks from the carriage fork bar.
1. Release the fork latches.
5. Lift fork heel and remove block.
! CAUTION
Forks are not stable sitting free in upright
position. Use care when working around the
forks.
Latch Operation 6. Back the truck away from the forks.

2. Move each fork to the notch on the bottom of the
lower carriage cross bar. Fork Replacement
1. Carefully drive truck up close to forks.
! CAUTION
Forks are not stable sitting free in upright
position. Use care when working around the
forks.
2. Drag forks into position close to carriage and to line

up with the notche on the lower carriage cross bar.
3. Lift fork heel and place block under arm near the
heel.
SM 661, Aug ’01 Fork and Carriage Removal and Replacement • 34-7-1
Group 34, Uprights
4. Lift tips of forks to engage the fork hooks on the

upper carriage fork bar. ! WARNING
5. Remove blocks from under fork. You may need to pull on the hoses/cables and
chains while lowering the primary cylinder
6. Check fork latches when repositioning forks to upper to get it all the way down. This is done to cre-
carriage fork notches. ate slack in hoses/cables and chains and to
displace as much oil as possible, which will
reduce oil loss when disconnecting hydraulic
Carriage Removal lines for auxiliary components.
The carriage should be removed for shimming or when
any service procedure is performed on the upright. You may need a helper to hold the control
handle in the lowering position while you pull
! WARNING on the carriage chains to fully collapse the
primary cylinder (on TSUs). When pulling
The procedures for checking, maintaining, on the chains to lower the primary cylinder
and adjusting uprights, carriages, and forks (on TSUs), the ignition must be off.
involve movement of the components.
4. Once the carriage is fully lowered, clamp the front of
• Do not walk or stand under raised forks. one fork to the pallet to prevent the carriage from
• Keep clear of load and carriage when mak- falling over backwards when removed.
ing any check or adjustment.
upright.
• Always use a prybar to move the upright or
carriage.
serious injury.
1. Set upright tilt to 0 degrees (vertical). Raise the car-
riage about 12 in (305 mm).
2. Place a heavy pallet under the forks. Turn the key off.
3. Lower the carriage onto the pallet and keep lowering
(until the primary cylinder is all the way down on
TSUs). Before proceeding with the next step read the
following warning.
34-7-2 • Fork and Carriage Removal and Replacement SM 661, Aug ’01
Group 34, Uprights
5. Disconnect the carriage chains at the base of the car- 9. Remove steer wheel blocks. Release the parking
riage. Pull chains back off primary cylinder sheave. brake and slowly back the truck away from the car-
riage.
10. Lower the upright rails until both of the secondary
cylinders are completely collapsed.
Carriage Replacement
To replace the carriage:
1. First check to be sure the carriage is securely
clamped to the pallet.
6. For carriage auxiliary components, disconnect hoses 2. Move the truck up to the carriage assembly with the
(2- or 4-hose assemblies) from carriage. Remove the inner rail centered on the carriage.
bolts and strap fixture also.
3. Raise the upright until the inner rail is high enough to
clear the upper carriage rollers.
4. Tilt the upright until it is at the same angle as the car-
riage assembly.
Remove hose 5. Now slowly move the truck forward until the inner
fittings here
rail is centered over the carriage rollers.
• Cap all lines to prevent leaks.

• Label all lines and fittings for correct reassembly.
7. Elevate the primary cylinder to its maximum height.
Be sure all hoses and loose parts are secured out of
the way to prevent damage.
8. Continue elevating the upright until the inner rail
clears the carriage.
SM 661, Aug ’01 Fork and Carriage Removal and Replacement • 34-7-3
Group 34, Uprights
10. Reconnect the hoses and mounting strap to the car-

! WARNING riage auxiliary component if the carriage is so
Never attempt to move or align the carriage equipped.
or bearings by hand. Use a pry bar.
6. Lower the upright until the inner rail clears all of the
carriage rollers.
Remove hose
NOTE fittings here
If the rail or bearings bind, raise the upright,
back away from the carriage and check to be
sure the carriage rollers are installed prop-
erly.
7. When the inner rail has cleared the carriage rollers,

continue to lower the upright until the lift cylinders
are lowered completely. • Lubricate all O-rings with a light coating of system
8. Reset the truck in a safe position: hydraulic fluid or a compatible oil.
• Ignition off • Use two wrenches to tighten hose fittings to pre-
vent hoses from twisting.
• Parking brake applied
• See Group 40 for hydraulic fitting tightening pro-
• Directional lever in neutral
cedures.
• Forks completely lowered
11. Adjust carriage height according to Section 6 and
• Block steer wheels.
chain tension according to Section 3.
9. Reinstall the carriage lift chains to the base of the
12. Remove the “C” clamp from the pallet and check the
carriage.
operation of the carriage and the upright. Carefully
check for oil leaks. Make sure the carriage and
upright work smoothly and correctly before returning
the truck to service.
• Set anchor bolts so that no twist develops in the

chains.
• Anchor pin heads must be pointing to the inside of
the upright.
• Use new cotter pins.
IMPORTANT
Always use new anchor pins when replacing
chain sets.
34-7-4 • Fork and Carriage Removal and Replacement SM 661, Aug ’01
Group 34, Uprights
Section 8
Upright Removal and Replacement
This Section describes how to remove the entire upright

assembly from the truck. The carriage and forks must be ! CAUTION
removed from the upright assembly before the upright is SAFE PARKING. Before working on truck:
removed. (For uprights with an auxiliary component, a
side-shifter for example, the two hydraulic hoses power- 1. Park truck on a hard, level, and solid sur-
ing the auxiliary component must be removed before the face, such as a concrete floor with no gaps
carriage is removed.) See Section 7, “Fork and Carriage or breaks.
Removal and Replacement,” for procedures to remove the 2. Put upright in vertical position and fully
carriage and fork assembly from the upright. lower the forks or attachment.
wheels.
Outer rail set
Load-lowering flow valve and

two-hose hardware mounting
bracket
Trunnion mount
Transaxle
Trunnion cap Tilt cylinder mount
bearing
Keeper
Typical Upright Installation
SM 661, Aug ’01 Upright Removal and Replacement • 34-8-1

Group 34, Uprights
Upright Removal 2. Disconnect and cap hydraulic line at the load-lower-

ing flow valve. Secure the hose out of the way of the
The following procedures are for uprights with carriage upright.
and forks, or auxiliary components removed. See Section
7, “Fork and Carriage Removal and Replacement,” for
instructions on removing the forks and carriage.
! WARNING
The upright assembly is heavy. Use only
hoists with enough capacity to lift the entire
assembly. Keep clear of the assembly as it is
being hoisted and set down. Keep hands and
feet away from the assembly. Use prybars to
move the assembly into position for reattach-
ment.
1. Attach a hoist and strap of adequate capacity to the NOTE

upright as shown below. Tension the hoist so that the
For two-hose adapter assemblies, the
upright cannot fall when upright mounting pins and
hydraulic lines to the upright must also be
tilt cylinder pins are removed.
disconnected and capped.
34-8-2 • Upright Removal and Replacement SM 661, Aug ’01

Group 34, Uprights
3. Remove tilt cylinder rod-end lock plates and rod-end Upright Replacement
pins from upright.
1. Use an overhead chain hoist of adequate capacity and
an approved lift chain to lift upright into position.
Cushion tire and

Pneumatic tire trucks
with bolt down.
4. Remove trunnion ring bolts and lift upright off

frame. See illustration on page 1. ! WARNING
5. Slowly set upright down on the floor, 100 x 100 mm Use prybars to move the assembly into posi-
(4 x 4 in) blocking, or sturdy pallets set end-to-end. tion for reattachment.
2. Secure mounting bearing to inner, load-bearing half

of the trunnion mounting using double-sided tape.
Install trunnion ring mounting bolts and use Loctite
271 (Clark part number 1802302). Torque to 55 ft-lb
(75 N⋅m).
SM 661, Aug ’01 Upright Removal and Replacement • 34-8-3

Group 34, Uprights
3. Install rod end pins, lock plates, and fasteners. NOTE

Tighten lock plate fasteners to a torque of 121-136 Reconnect two-hose adapter assembly
in-lb (19.3-21.5 N⋅m). hydraulic lines to the upright-mounted
bracket.
Cushion tire and

Pneumatic tire trucks
with bolt down.
4. Attach hydraulic lines to the upright flow control

valve:
5. Remove the lift chain between the upright and hoist.
6. Completely check all upright and hydraulic compo-
nents under load before returning the truck to service.
7. See Section 8, “Fork and Carriage Removal and
Replacement,” for steps to replace the carriage and
fork assembly.
• Lubricate all O-rings with a light coating of system

hydraulic fluid or a compatible oil.
• Use two wrenches to tighten hose fittings to pre-
vent twisting lines.
• See Group 40 for hydraulic fitting tightening pro-
cedures.
34-8-4 • Upright Removal and Replacement SM 661, Aug ’01

GROUP 38
GROUP 38
COUNTERWEIGHT AND CHASSIS
Counterweight Specifications and

Counterweight Removal and

Overhaul Guard/Operator’s Cell Removal

Floorboard, Radiator Cover, and Seat Deck

Removal and Replacement .................. Section 4
Operator’s Seat Removal and

SM 661, Aug ’01 Group 38, Counterweight and Chassis

Group 38, Counterweight and Chassis
Section 1
Counterweight Specifications and Description
Counterweight weights : The counterweight is a solid, cast-iron piece mounted to
the back of the lift truck to counter-balance the loads
Cushion Frame Pneumatic Frame placed on the upright at the front of the truck. The weight
1098 Kg (2420 lbs) 1006 Kg (2217 lbs) must be great enough to counteract forward tipping when
1472 Kg (3245 lbs) 1346 Kg (2967 lbs) lifting or stopping with a capacity load. The weight of the
1854 Kg (4087 lbs) 1686 Kg (3717 lbs) counterweight is determined by the lifting capacity of the
2004 Kg (4418 lbs) truck.
The counterweight is cast with mounting niches molded
Fastener Torques in. The niches fit the truck frame mounting and allow the
counterweight to “hang” on the truck frame bracket.
Counterweight Mounting Bolt : 440-490 N⋅m (325-361 Large, hard steel bolts hold the counterweight to the frame
ft⋅lb) and prevent the counterweight from being dismounted
accidentally.
LPG Tank Support Assembly Bracket Mounting Bolt :
340-380 N⋅m (250-280 ft⋅lb)
! WARNING
General Maintenance The counterweight is extremely heavy. Do not
remove the counterweight unless you have
The counterweight must be maintained in good condition training and are familiar with the correct
and securely attached to the lift truck. Because of its procedures. Counterweights can fall if not
heavy weight and bulky mass, the counterweight must be handled correctly and can cause severe
carefully supported and handled. When removed from the injury or death. Keep your hands, feet, and
truck, store at floor level in a stable position to be sure it body clear of the counterweight at all times.
will not fall or tip, causing damage or injury. Hoisting equipment must be capable of han-
dling the weight of the counterweight when
removing or replacing. Make sure your hoist
is of adequate capacity to handle the weight.
SM 661, Aug ’01 Counterweight Specifications and Description • 38-1-1

Section 2
Counterweight Removal and Replacement
! LPG Tank Removal

CAUTION
SAFE PARKING. Before working on truck : Remove the LPG tank from the counterweight if servicing
a LPG-fuel truck. The tank must be removed to install the
1. Park truck on a hard, level, and solid lifting eyebolts on the counterweight. Remove the two
surface, such as a concrete floor with no bolts mounting the tank support assembly bracket to the
gaps or breaks. counterweight.

lower the forks or attachment. Counterweight Removal
3. Put all controls in neutral. Turn key 1. Install eye bolts into the counterweight. Eyebolts
switch OFF and remove key. must be able to lift 1098-2004 kg (2420-4418 lb)
depending on truck model (see illustration next
4. Apply the parking brake and block the page).
wheels.
2. Using an overhead hoist with sufficient lifting capac-
! WARNING
ity, chain the eyebolts to the hoist ; slowly hoist
chains until slack is removed.
Observe proper, safe lifting practices when
lifting counterweight onto or off truck. 3. Remove the tow bar and the counterweight anchor
Counterweight should only be lifted by bolt(s).
appropriately-sized eye bolts installed 4. Slowly lift the counterweight from the truck frame
through both top lifting holes. .
Use only overhead lifting equipment having a
safe lifting capacity in excess of that of the
counterweight.
LPG tank
Torque to 340~380N.M
250~280ft-lb
Tank support
assembly bracket
LPG Tank Removal
SM 661, Aug ’01 Counterweight Removal and Replacement • 38-2-1

3. Make sure that the bolt holes in the counterweight

! WARNING align properly with the mating holes in the frame.
Stand clear of the counterweight as it is being 4. Inspect the counterweight mounting bolts to make
hoisted, moved, or mounted. sure they are in good condition before re-installing.
Use only Clark replacement parts. Torque the mount-
5. Slowly lower the counterweight onto a sturdy pallet. ing bolts to 441.5-490.5 N⋅m (325-361 ft⋅lb).
Set the counterweight on its flat side if possible. If
set on its curved side, use chocks to prevent the 5. Remove the hoist and eyebolts.
counterweight from shifting or rolling.
IMPORTANT
Never allow a truck to be put into service
Counterweight Replacement without the counterweight mounting bolt(s)
in place. Check the bolt(s) and torque regu-
1. Bring counterweight vertically near the rear of the larly.
truck and positioned so that it is within 25-50 mm (1-
2 in) of the frame.
2. Move the counterweight forward and lower it, mak-
LPG Tank Replacement
ing sure that the support hooks on the frame engage Remount the LPG tank support assembly bracket. Torque
with the counterweight. the bracket mounting bolt nuts to 340-380 N⋅m (250-280
ft⋅lb).
! WARNING
During mounting, always use prybars for
location adjustments. Do not place any part
of your body between the counterweight and
truck.
Anchor bolts
Towbar and pin
Counterweight Installation. A standard cushion-tire truck counterweight and frame is shown. Removal and replacement
of pneumatic-tire models is the same.
38-2-2 • Counterweight Removal and Replacement SM 661, Aug ’01

Section 3
Overhead Guard/Operator’s Cell
Removal and Replacement
! Operator’s Cell Removal and

CAUTION
Replacement
1. Park truck on a hard, level, and solid Removal

gaps or breaks. 1. Tilt the steering column fully forward.
2. Put upright in vertical position and fully 2. Raise the seat deck.
lower the forks or attachment. 3. Lift out the operator’s compartment floor plate.
3. Put all controls in neutral. Turn key 4. Remove the operator’s seat deck; see Section 4.
5. Disconnect and label all wiring for cell-mounted
4. Apply the parking brake and block the lights or other electrical devices.
wheels.
6. Disconnect air induction tube from cell leg.
Overhead Guard Removal and

Replacement
Overhead guard
leg
Overhead guard
Operator's cell
Air Induction
Tube
7. Loosen and remove the four mounting nuts securing

the bolts and cell to the truck chassis as shown in the
illustration on page 2.
8. Use an overhead hoist to lift the cell from the truck
chassis.
SM 661, Aug ’01 Overhead Guard/Operator’s Cell Removal and Replacement • 38-3-1
Replacement 3. Reconnect the air induction tubing to the cell leg.
1. Set cell into place on the truck chassis using an over- 4. Reconnect all wiring for cell-mounted lights or other
head hoist. electrical devices according to the labels made dur-
ing removal.
2. Replace the four mounting bolts and nuts. Torque the
nuts to 100-110 N⋅m (74-81 ft⋅lb). 5. Replace the operators seat deck ; see Section 4.
NOTE 6. Replace the operator’s compartment floor plate and

readjust, if necessary, using the procedures in Section
If the cell is a new replacement or has been
4.
repaired, install new cushion mounts
Mounting bolt
Remove this nut

only to remove
cell.
38-3-2 • Overhead Guard/Operator’s Cell Removal and Replacement SM 661, Aug ’01
Section 4
Floorboard, Cowls, Radiator Cover, and Seat Deck
SM 661, Aug ’01 Floorboard, Cowls, Radiator Cover, and Seat Deck Removal and Replacement • 38-4-1
NOTE
! CAUTION Make sure the accelerator pedal has a full
SAFE PARKING. Before working on truck: stroke and does not bind.
1. Park truck on a hard, level, and solid 8. Once centered, torque the retention screws into the
surface, such as a concrete floor with no pins to 8-10 N⋅m (5.9-7.3 ft⋅lb).
gaps or breaks.
9. Lower and latch seat deck.
Cowl Removal and Replacement
switch OFF and remove key. 1. Remove the right, center, and left cowl covers as
shown in the following illustration.
wheels.
Floor Plate Removal and Replacement

1. Tilt the steering column fully forward.
2. Raise the seat deck.
3. Lift out the operator’s compartment floor plate. Rub-
ber mat lifts out with floor plate.
Floorplate
2. To replace the cowl covers top lip of the right and left
cowl covers must be inserted under the dash prior to
fastening covers into position.
3. Disconnect electrical devices and hydraulic hose.
4. Loosen and remove the two mounting nut securing
the bolts and cowl to the chassis as shown in the
illustration.
4. To replace the floorplate, position the floor plate so

that the retention pins mate with holes in the opera-
tor’s cell side plates.
5. Snug the retention screws to the pins but allow
movement of the parts in the floor plate slot.
6. Orient and place pins into mating holes in cell sides.
Allow the floor plate to rest on the cell sides.
7. Adjust floor plate to center by moving the pins in the
slots.
38-4-2 • Floorboard, Cowls, Radiator Cover, and Seat Deck Removal and Replacement SM 661, Aug ’01
Radiator Cover Removal and 5. Remove the wire circle cotter and washers from the
seat deck prop plate.
Replacement
Remove and replace the radiator cover as in the following
illustration.
Radiator cover Seat deck
bracket
Hand screw Hinge
bracket
6. Unbolt the seat deck bracket from the hinge bracket

from left and right sides.
! CAUTION
Support the seat deck in position when
removing bracket nuts to prevent falling and
Operator’s Seat Deck Removal and possible injury.
Replacement
Removal
1. Tilt the steering column fully forward. Seat deck
bracket
2. Raise the seat deck. Hinge
bracket
3. Lift out the operator’s compartment floor plate.
! CAUTION
Seat deck is not supported when gas springs
and prop plate are removed. Support the seat
deck in position when disconnecting to pre-
vent falling and possible injury.
4. Unclip the upper gas spring connections. Clip sepa- 7. Remove the seat deck.
rates allowing gas spring to be pulled off post.
Replacement
Post To replace the operator’s seat deck :
1. Set the seat deck in place.
Clip
! CAUTION
Pry clip
gently Support the seat deck in position when
replacing to prevent falling and possible
injury.
SM 661, Aug ’01 Floorboard, Cowls, Radiator Cover, and Seat Deck Removal and Replacement • 38-4-3
2. Line up the seat deck bracket and the hinge bracket 5. Check the alignment of the seat deck to make sure it
and replace the lockwashers and nuts. Hand tighten latches correctly.
nuts. • Adjust seat deck to center on overhead guard cell
frame.
• Check for an even gap along the bottom edge.
• Torque the lock nuts to 40-45 N⋅m (30-33 ft⋅lb).
Do not overtorque.
Seat deck 6. Check hood release latch to make sure it is catching
bracket
on seat-deck-mounted striker. Loosen and adjust
Hinge
bracket deck striker as necessary.
Desk striker
3. Reset the seat deck prop plate and replace the wire
circle cotter. Hook release latck
Seat deck
bracket
Hinge
bracket 7. Lift and lower the seat deck several times to make
sure the latch is catching and that the seat deck is bal-
anced before returning the truck to service.
4. Replace the two gas springs by clipping back onto

seat deck posts.
Gas spring
38-4-4 • Floorboard, Cowls, Radiator Cover, and Seat Deck Removal and Replacement SM 661, Aug ’01
Section 5
Operator’s Seat
! Seat Removal
CAUTION
SAFE PARKING. Before working on truck : 1. Tilt steering column fully forward and raise the seat
deck.
1. Park truck on a hard, level, and solid 2. Remove the four nuts (with washers) securing the
surface, such as a concrete floor with no seat rails to the seat deck.
gaps or breaks.
2. Put upright in vertical position and fully ! CAUTION
lower the forks or attachment. Make sure to support seat on deck so it does
3. Put all controls in neutral. Turn key not fall when bolts are removed. Seat may be
switch OFF and remove key. damaged or injury can result.

wheels.
Remove nuts and

washers here
SM 661, Aug ’01 Operator’s Seat Removal and Replacement • 38-5-1

Seat Replacement 3. Check seat for correct, smooth adjustment when slid-
ing forward or back. Make sure the seat locks in
1. Set and hold the seat in position on the raised seat place on the rails when adjusted for different posi-
deck. tions.
2. Replace the four bolts securing the seat rails to the
seat deck and torque to 23-25 N⋅m (210-230 in⋅lb).
38-5-2 • Operator’s Seat Removal and Replacement SM 661, Aug ’01

GROUP 40
GROUP 40
SPECIFICATIONS
Nameplates and Decals ............................ Section 1
General Specifications .............................. Section 2
Hydraulic Fitting Tightening

Procedures ............................................ Section 3
SM 661, Aug ’01 Group 40, Specifications

Group 40, Specifications
Section 1
Nameplates and Decals
Nameplates and Decals ating on elevators, elevated floors, etc. to be sure they
are safe.
This Section shows the nameplate (data and capacity
plate) and decals required to be on all operating Clark 5. Capacity rating, load center, and lifting height data
industrial trucks. The nameplate lists the data on the truck — Shows the maximum load capacity of this truck
- type and serial number - and the capacities of the truck. with relation to load centers and fork heights (see
Decals depict or explain the hazards the operator must diagram on plate). Personal injury and damage to the
avoid when operating the truck. The nameplate and decals truck can occur if these capacities are exceeded. Do
are placed in specific locations on the truck and are not exceed the maximum capacity specified.
intended to warn others working around the truck of its
hazards as well. These nameplates and decals MUST BE ! CAUTION
IN PLACE on all trucks. When attachments are added or if the truck
If any decals or the nameplate are missing from the truck, is modified, the capacity of the truck may be
check with your local Clark dealer for replacements. affected. Contact your authorized Clark
dealer for a new nameplate showing the
IMPORTANT revised capacity.
Do not allow a lift truck with damaged or
missing decals or data plates to be placed in From the factory this truck meets ASME B56.1
service. Replace them immediately. They 1 2
3
contain important information as described
on the following pages. The location of all 5
decals is also shown on the following pages.
The truck data and capacity plate provides essential infor-

mation about the truck. This information is important for
both operators and service personnel. Operators can see 4
what the truck’s capacities and load ratings are. Service
personnel must identify the truck model, type, and serial
number when ordering parts. Refer to example data plate
illustration for callout numbers. Truck Data and Capacity Plate
1. Truck model number or registered name.
2. Truck serial number — An identification number
assigned to this particular truck and should be used
1
when requesting information or ordering service 2
parts for this truck from your authorized Clark dealer. 3
The serial number is also stamped on the frame.
5
3. Attachment description (if any installed) — The user
must see that the truck is marked to identify the
attachment(s), including the weight of the truck/
attachment combination and truck capacity with the
attachment. 4
4. Truck weight — The approximate weight of the

truck without a load on the forks. This weight plus
the weight of the load must be considered when oper-
SM 661, Aug ’01 Nameplates and Decals • 40-1-1

Operator Safety Warning Plate General Safety Decal

The Operator Safety Warning Plate describes basic, safe The General Safety Decal
operating procedures that should be used when operating depicts important points
WARNING
the truck. about truck operation and
Read the
warns operators about truck manual
safety hazards. The General

WARNING Safety Decal is meant as a
reminder for operators and is Buckle up!
BEFORE OPERATING lift truck, operator must: placed where operators can
• Be trained and authorized. review the points daily as
• Read and understand operator's
manual. they conduct a visual inspec- Apply brake
tion and prepare the truck for when leaving
• Not operate a faulty lift truck. truck
• Not repair lift truck unless trained and authorized. work.
• Have the overhead guard and load backrest
extension in place. Watch Out
For Other
People
DURING OPERATION, lift truck operator must:
• Wear a seat belt.
• Keep entire body inside truck cab.
• Never carry passengers or lift people.
• Keep truck away from people and obstructions.
Most lift truck
• Travel with lift mechanism as low as possible. INJURIES
and tilted back. are to other
people near
the lift truck.
TO PARK lift truck, operator must:
• Completely lower forks or attachments.
• Shift into neutral.
• Turn off key.
• Set parking brake.
P Prevent
Overturns!
Clark Material Handling Co. Sit Down Rider 2798233
AVOID :
• slippery,
IMPORTANT sloping,
or uneven
Safety and warning decals are placed in con- surfaces
spicuous locations on the truck to remind • loads over
capacity on
operators of essential procedures or to pre- nameplate
vent them from making an error that could • unstable or

high loads
damage the truck or possibly cause personal • low tire
pressure
injury. Safety and warning decals should be
• poorly
replaced immediately if missing or defaced maintained
lift truck
(damaged or illegible). • fast or
sharp turns
In Case of
Tip-Over:
Don't
jump
Hold on
tight
Brace feet
Lean
away
2798235
40-1-2 • Nameplates and Decals SM 661, Aug ’01

Seat Belt/Tip-Over Warning Decal Keep Away from Forks Decal

This decal is located on the seat deck, to the left of the This safety decal is placed on the upright to warn of the
operator. It’s purpose is to remind the operator that staying danger of injury from forks when they are in the raised
in the seat provides the best chance of avoiding injury in position. Operators and others should never ride on or
the event of a truck-tipping mishap. stand under forks or attachments. The forks can fall and
cause injury or death.
2372604
Lift trucks can be tipped over if operated improperly.

Experience with lift truck accidents has shown that the
Fan Warning Decal
driver cannot react quickly enough to jump clear of the
truck and overhead guard as the truck tips. To protect The fan warning decal reminds operators and service per-
operators from severe injury or death in the event of a tip- sonnel not to touch or work around a spinning radiator
over, make sure this decal is in place to remind them to cooling fan. The decal is placed on the radiator fan
always use their seatbelts. shroud.
Hand Safety Warning Decal

This safety decal is placed on the upright to warn of the
danger of injury from movement between rails, chains,
sheaves, fork carriage, and other parts of the upright
assembly. Operators and others should never climb on or
reach into the upright. Personal injury will result if any
part of someone’s body is put between moving parts of the
upright. IMPORTANT
The Engine Coolant Fan, on all internal com-
bustion engines, can cause extensive injury
and bodily harm. Keep hands, arms and
clothing away from a spinning fan. Also,
don’t stand in line with a spinning fan.
SM 661, Aug ’01 Nameplates and Decals • 40-1-3

Nameplate, Decal Locations The Hand Safety Warning Decal is located on the outer
rail upper tie bar.
The following illustrations show decal locations for the
nameplate and safety decal required on all Clark indus-
trial lift trucks.
The Data Plate is located on the seat deck to the right of
the operator seat.
The Operator’s Safety and Warning Plate is located on the

seat deck to the left of the operator seat.
The Keep Away from Forks decal is placed on both sides
of the upright on the outer rail just above the tilt cylinder
yoke mount.
The General Safety Decal is located on the operator’s cell

leg as shown.
The Fan Warning decal is placed on the cooling fan

shroud as shown.
40-1-4 • Nameplates and Decals SM 661, Aug ’01

Section 2
SM 661, Aug ’01 General Specifications • 40-2-1

Weights and Performance Specifications
Capacities
For standard transaxle trucks.
At 600mm At 500 mm (24 in)
Models Load Center Load Center
C20/C20C 1810kg 2000 kg 4000 lbs
C25/C25C 2270kg 2500 kg 5000 lbs
C30/C30C 2720kg 3000 kg 6000 lbs
C32C 2950kg 3200 kg 6500 lbs
Note : Rated capacity applies when using uprights with maximum fork height up to and including : 170 Inches[4320mm]
for pneumatic tire of upright : 189 Inches[4800mm] for cushion/solid tire of upright.
Truck Weights and Axle Weights

Approximate weights for standard transaxle trucks with cutoff height upright.
Loaded Vehile Empty Vehile Loaded Drive Empty Drive Empty Steer
Weight Weight Axle Weight Axle Weight Axle Weight
(kg/lbs) (kg/lbs) (kg/lbs) (kg/lbs) (kg/lbs)
Cushion tire type Gas & LPG
C20 C 5479/11670 3479/7670 4764/10146 1484/3272 1995/4398
C25 C 6352/13492 3852/8492 5475/11624 1375/3031 2477/5461
C30 C 7278/15431 4278/9431 6210/13155 1290/2844 2988/6587
C32 C 7639/16286 4439/9786 6555/14045 1268/2795 3171/6991
Pneumatic tire type Gas & LPG
C20 5465/11639 3465/7639 4876/10371 1697/3742 1768/3898
C25 6305/13388 3805/8388 5599/11869 1625/3582 2180/4806
C30 7235/15336 4235/9336 6386/13509 1701/3750 2534/5586
Diesel
C20 5575/11881 3575/7881 4913/10452 1734/3823 1841/4059
C25 6415/13631 3915/8631 5636/11951 1662/3664 2253/4967
C30 7345/15579 4345/9579 6426/13597 1741/3838 2604/5741
Note : Refer to the truck data plate for exact service and axle weights.
Maximum Gradeability
At stall in forward with standard upright on surface of 0.6 friction coefficient.
Without load (%) With capacity load (%)
Cushion tire type Gas & LPG
C20C 26.2 36.5
C25C 21.7 31.7
C30C 18.4 25.5
C32C 21.9 24.2
Pneumatic tire type Gas & LPG
C20 29.5 30.6
C25 25.5 26.6
C30 22.9 20.5
Diesel
C20 27.1 46.2
C25 23.8 40.4
C30 22.9 29.1
Parking Brake Test

For standard transaxle trucks.
The brake must be capable of holding the truck with a full rated-capacity load on a 15% grade.
40-2-2 • General Specifications SM 661, Aug ’01

Group 30, Hydraulic Valve/Lift Circuit Tilt Ranges

Specifications (Abbreviation — Std = Standard, high-visibility upright ;
TSU = Triplestage upright ; MFH = Maximum fork height
Rated Flow : ; B = back tilt ; F = Forward tilt)
Lift spool (spool #1) : 76 LPM (20 GPM)
Tilt spool (spool #2) : 38 LPM (10 GPM) Cushion & Pneumatic Uprights
Auxiliary spool (spool #3) : 38 LPM (10 GPM). STD (through 2120 mm MFH) 6°B-10°F
Integral Pressure Compensated Flow Control Settings : STD (2680-2980 mm MFH) 8°B-10°F
Tilt spool (spool #2) : 17 LPM (4.5 GPM) STD (3300-3860 mm MFH) 10°B-8°F
Auxiliary spool (spool #3) : 13 LPM (3.5 GPM). STD (4165-4620 mm MFH) 5°B-6°F
STD (above 5170 mm MFH) 5°B-3°F
Maximum Pressure Drop at Rated Flow : TSU (through 4800 mm MFH) 5°B-6°F
Inlet to outlet : 689 kPa (100 psi) TSU (5210-6100 mm MFH) 5°B-3°F
Lift spool (spool #1) : TSU (above 6370 mm MFH) 3°B-3°F
- Cylinder port to outlet : 550 kPa (80 psi) Group 34, Upright Specifications
Tilt spool (spool #2) :
Upright Weight : approximatelly 474kg (1045 lb) to
approximatelly 1135 kg (2502 lb)
- Cylinder port to outlet : 550 kPa (80 psi)
Carriage Weight : approximatelly 103 kg (227 lb) Class II
Auxiliary spools (spools #3 and #4) :
- Inlet to cylinder port : 345 kPa (50 psi) Fork Weight : approximatelly 99kg (218) 42″ C25C
IMPORTANT
Auxiliary Component Flow Control Adjustments : Before hoisting, the weights of upright, car-
Flow Setting Clockwise Turns riage, and forks must be combined to deter-
L/min (gpm) of Adjustment Screw mine what lifting capacity is required of the
7.6 2.0 0.50 hoisting equipment.
9.5 2.5 0.75
15.1 4.0 1.00 Capacities and Lift Heights : Upright, carriage, and fork
20.8 5.5 1.50 capacity and upright lift heights are listed on the truck’s
26.5 7.0 1.75 data plate.
37.9 10.5 2.50 Lubricants :
45.4 12.0 3.00 All Purpose Grease (Clark specification MS-9)
56.8 15.0 4.25 Innerslide Lubricant (Clark part #886396)
Chain and Cable Lube (Clark part #886399)
Group 32, Tilt Cylinders Specifications
Tilt cylinder type : double-acting with shims.
Specifications
Maximum operating pressure : 24000 kPa (3480 psi ; 240
bar) Counterweight weights :
Tilt Flow Control Adjustments : (Based on 3300 MFH) Cushion Truck Pneumatic Truck
factory setting is 17.4 LPM (4.6 GPM) C20C:1098 kg (2420 lbs) C20:1006 kg (2217 lbs)
C25C:1472 kg (3245 lbs) C25:1346 kg (2967 lbs)
CW Turns of C30C:1854 kg (4087 lbs) C30:1686 kg (3717 lbs)
Tilt Speed Adjustmetn C32C:2004 kg (4418 lbs)
Upright Useage LPM(GPM) Screw
MFH 6370-7315TSU 9.8(2.6) 0.50
MFH 4165-5170 STD 14.4(3.8) 0.75
3860-6100 TSU
MFH 2120-3860STD 17.4(4.6) 1

Drift, Lift and Tilt Cylinders

For standard transaxle truck.
Upright Fork Downdrift : Should not exceed 100 mm (4 in) in a 10-minute period.
Tilt Cylinder Drift : Should not exceed 5° in a 10-minute period.
Determined by marking and measuring carriage descent and upright forward tilt from raised, non-tilted position with
hydraulic fluid at operating temperature ; and a capacity load held evenly distributed on lift forks. (If a pallet is used, load
should not extend beyond pallet ; load should be stacked to provide maximum stability.) Fork completely engaging load
and adjusted as wide as possible to provide even distribution of weight.
Lift Speeds, Upright

For the standard two-stage upright, with standard transaxle or hydraulic transmission.
Note : Hydraulic fluid should be at operating temperature when testing these specifications.
Lift Speed Lowering Speed
Gas & LPG
Loaded 0.49m/s (96ft/min) 0.45m/s (89ft/min)
C20, C20C Empty 0.55m/s (108ft/min) 0.45m/s (89ft/min)
C25, C25C Loaded 0.48m/s (94ft/min) 0.45m/s (89ft/min)
Empty 0.55m/s (108ft/min) 0.45m/s (89ft/min)
C30, C30C
C32C Empty 0.55m/s (108ft/min) 0.45m/s (89ft/min)
Pneumatic tire type Diesel

C20
C25 Empty 0.65m/s (128ft/min) 0.45m/s (89ft/min)
C30 Loaded 0.54m/s (106ft/min) 0.45m/s (89ft/min)
Critical Fastener Torque Specifications

Tightening Torque. Dry
N⋅m ft⋅lb
For standard transaxle truck
Engine Mounting Bolts
4G64 (GAS/LPG) 170-190 125-140
4TNE94 (Diesel) 170-190 125-140
Transaxle to Engine Bolts 40-45 30-33
Torque Converter to Drive Plate Bolts 20-25 14.8-18.5
Transaxle/Drive Axle to Frame Mounting Bolts 340-380 250-280
Drive Wheel Lug Nuts 640-720 470-530
Steer Axle Mounting Bolts 170-190 125-140
Steer Wheel Lug Nuts 225-250 165-185
Steering Handwheel Retaining Nut 35-40 25.5-29.5
Tilt Cylinder Yoke Clamp Bolts 170-190 125-140
Tilt Cylinder Pin Retainer Bolts
Front 8-10 5.9-7.4
Rear 8-10 5.9-7.4
Counterweight Mounting Bolts (Bottom) 441-490 325-361
Overhead Guard Mounting Bolts 100-110 74-81
Upright Trunnion Mounting Bolts 75-80 55-59

Group 06(S), Standard Transaxle Firing Order : 1-3-4-2.

Specifications Rotation (viewed from cap) : Clockwise.
Ignition Timing :
Gasoline Engine : 4 °BTDC @ 680 rpm
Model : Clark TA-30 Transaxle.
LPG Engine : 9 °BTDC @ 680 rpm.
No. Ratios : 1-speed, forward and reverse.
Centrifugal Advance : Beginning : 0° at 1000 rpm
Transaxle Ratio Forward : 15.78. (engine) End : 6.5° at 2600 rpm (engine).
Transaxle Ratio Reverse : 16.06. Vacuum Advance : Beginning : 0° at 80 mmHg (3.14
Ring & Pinion Gear Type : Spiral Bevel. inHg) End : 11.5° at 280 mmHg (11.0 inHg).
Ring & Pinion Backlash : 0.20-0.28 mm (0.008-0.011 in). Ignitor Air gap : 0.8 mm (.031 in).
Differential Type : 2-pinion. Primary Coil Resistance : 1.08-1.32Ω between terminals

(+) and (-).
Differential bearing preload : 0.075 mm (0.003 in) deflec-
tion of each carrier ear. Secondary Coil Resistance : 22.1-29.9 Ω between termi-
nals (-) and center.
Service Brake Size : 310 × 60 mm (12.2×2.36 in).
Ignition Coil Resistor Resistance : 1.22-1.49
Torque Converter Size : 310 mm (12.2 in)/280mm(11in).
Spark Plug Type :
Torque Converter Stall Ratio : 3.9/3.3
Gas Engine : NGK BP4ES, Champion NY 16
Hydraulic Pump Drive ratio : 1.029 × engine rpm.
LPG Engine : NGK BP5ES, Champion NY 12.
Dry Weight : 390 kg (858 lb).
Spark Plug Gap : 0.7-0.8 mm (0.028-0.031 in).
Oil Capacity : 18.5 L (19.5 qt).
Spark Plug Tightening Torque : 25 N⋅m (18.4 in⋅lb).
Transaxle Fluid : Clark # 2776236.
Plug Wire Resistance : 8,000 ohms per foot.
Pressure Specifications*
Charge Pump Flow : 37.8 L/min (10 gpm) @ 1800 rpm. Group 13, Instrument Pod & Electrical Sys-
Regulator Valve Pressure : 1310-1690 kPa (190-245 psi) tem Specifications
@ 1800 rpm. Indicator lights : LEDs integral with circuit board.
Clutch Pressure (Forward/Reverse) : 1240 kPa (180 psi) Buzzer : Integral with circuit board.
@ idle rpm.
Fuel gauge : LED.
Cooler Return Pressure : 345-862 kPa (50-125 psi) @
1800 rpm. Engine Coolant Temperature Gauge : :LED.
NOTE Hour Meter : Digital, with running indicator. Integral to

1. All rpm’s noted are engine speed. circuit board.
2. All clutch pressures are engine idle speed Pinout Locations : See Group 13, “Electrical System,” for
with clutch engaged. schematic.
3. Oil at operating temperature (82-93°C)
180-200 °F. Voltage and Ground
System Voltage : 12 volt.
Group 12, Ignition System Specifications
System Ground : Negative.
(4G64 Standard Electronic Ignition)
Ignition Type : Non-contact, electronic.

Alternator Coolant Mixture : 50% water and 50% low-silicate, ethyl-

ene glycol, permanent-type antifreeze with rust and corro-
Type : 12 volt.
sion inhibitors.
Battery Cooling System Coolant Capacity :
Gas/LPG Engine : Cushion-tire truck with 4-row radiator capacity is
10.5L (11.0 qt )
Type : 12 volt 60AH
Pneumatic-tire truck with 4-row radiator capacity is
Cold Crank Current : 550 amps at 0 °F (-18 °C)
8.5L (9 qt)
Reserve Capacity : 100 minutes at 80 °F (27 °C).
Diesel truck with 4-row radiator capacity is 9.6L (10.1
Diesel Engine : qt).
Type : 12 volt 100AH Fan Type : Pusher type
Cold Crank Current : 800 amps at 0 °F (-18 °C) Fan Drive Belt : V-type belt
Reserve Capacity : 180 minutes at 80 °F (27 °C). Water Pump Type : Centrifugal
Starter Hose Clamp Sizes :
Gas/LPG Engine :
Gas/LPG : 47 mm (1.8 in) @ radiator end ; 44 mm
Type : Positive engagement, planetary gear reduction, (1.7 in) @ engine (water pump or thermostat) end
offset. Diesel : 51mm (2 in).
Voltage : 12 volts
Output : 1.2 kW.
Specifications
Diesel Engine :
Type : Positive engagement, offset gear reduction. LPG Tank
Voltage : 12 volts Capacity : 9.1, 15.2, 19.7kg(20, 33.5 or 43.5 lb).
Output : 2.3 kW. Working Pressure : 138-1654 kPa (20-240 psi).
System Protection Safety Relief Valve : Opens when pressure exceeds 2756
Fuse : 10A Direction Control. kPa (400 psi).
Fuse : 15A Ignition. Shut-off Valve : Manual with maximum withdrawal valve.
Fuse : 10A STOP Switch. Maximum Withdrawal Valve : Closes when flow rate
exceeds 5.7 Lpm (1.5 gpm).
Fuse : 10A Horn.
Fuel Gauge Type : Float level.
Group 01, Cooling System Specifications Low Fuel Light : Instrument pod light comes on at 275
kPa (40 psi).
Radiator Type : Crossflow radiator with coolant recovery
system. Carburetor
System Pressure (Radiator cap) : 83-109 kPa (12-16 psi). Type : Diaphragm-operated air-gas valve design with self-
Thermostat : contained air-fuel metering device.
Gas/LPG : open (cracking) at 82°C ± 1.5° (180°F ± 2.7°) Idle Air-Fuel mixture : 0.3-0.7% CO (carbon monoxide)
fully open 95°C (203°F) @ 680 rpm.
Diesel : open (cracking) at 82°C ± 1.5° (180°F ± 2.7°) Power Mixture : 0.6 to 1.5 % CO at stall.
fully open 95°C (203°F). Idle Speed : 650~700 rpm.

Vaporizer-Regulator Oil Pump Type : Involute gear type

Primary Chamber Pressure : tank pressure to 10.3 kPa (1.5 Engine Oil : 10W30, API, SD, SE/SG, SF engine oil
psi).
Sump Capacity : 4.8 L (5.1 qt)
Secondary Chamber Pressure : 10.3 kPa (1.5 psi) to a neg-
Cooling System : Water-cooled circulation
ative pressure to vapor outlet pressure.
Water Pump Type : Centrifugal impeller type
Vapor Outlet Pressure : -38.1 mm (-1.5 in) water column.
Tune-Up Specifications
Lock-Off Valve
Spark Plug Type :
Type : Solenoid-operated valve actuated by external vac-
uum switch. Gas Engine : NGK BP4ES, Champion NY16
Filter Element : Replace every 2000 hours. LPG Engine : NGK BP5ES, Champion NY12
Spark Plug Gap : 0.7-0.8 mm (0.028-0.031 in)
Fuel
Spark Plug Tightening Torque : 25 N⋅m (18.4 in⋅lb)
HD-5 Propane.
Ignitor Air Gap : 0.8 mm (0.31 in)
Group 03, Air Induction and Exhaust Systems Ignition Timing : Gasoline 4 °BTDC @ 680 rpm ; LPG 9°
Specifications BTDC @ 680 rpm
Centrifugal Advance : Beginning ; 0° at 1000 rpm
Air Cleaner Type : Canister style with replaceable paper
(engine). End ; 6.5° at 2600 rpm (engine)
element and air-restriction indicator.
Vacuum Advance : Beginning: 0° at 80 mmHg (3.14
inHg) End ; 11.5° at 280 mmHg (11.0 inHg)
Group Specifications
Engine Speed (rpm) :
Group 00(G), 4g64 Gas/LPG Engine Idle : 650-700 rpm
Specifications Converter Stall : Gasoline Fuel System : 1850-1950
LPG Fuel System : 1790-1890
Maximum No-Load Governed RPM : 2600-2700 (gas
Engine Type : Mitsubishi 4G64 in-line, overhead valve, & LPG)
single overhead camshaft.
Engine Vacuum at No-Load Governed Speed : 330-381
Number of Cylinders : 4 mmHg (13-15 inHg)
Combustion Chamber : Semi-spherical Idle Vacuum : 406-483 mmHg (16-18 inHg)
Total Displacement : 2350 cu⋅cm (143.4 cu⋅in)
Cylinder Bore : 86.5 mm (3.41 in)
Overhaul specifications are listed in the engine overhaul
Piston Stroke : 100.0 mm (3.94 in) Section of this Group.
Compression Ratio : 8.5
Fuel System Specifications
Cylinder Compression : 1880 kPa (163.5 psi) at 300 rpm
See Group 02 for fuel system specifications.
Valve timing :
Camshaft Identification (D)
Intake valve Open 12° BTDC Group 00(D), 4TNE94 Diesel Engine
Close 40° ABDC Specifications
Exhaust valve Open 54° BBDC
Close 6° ATDC
Lubrication System : Pressure feed, full-flow filtration

Engine Type : Yanmar 4TNE94 Vertical, in-line, 4-cycle Pneumatic Truck Wheel and Tires
water-cooled diesel engine.
Tire Sizes and Ratings
Number of Cylinder : 4
Drive Tires :
Combustion Chamber : Direct injection C20/25 Single : 7.00×12, 14-ply rating
Total Displacement : 2776 cu⋅cm (169 cu⋅in) Dual : 7.00×12, 14-ply rating
C30 Single : 28×9×15-14ply rating
Rated Output : 42 kw (57.7ps) @ 2500rpm Dual : 7.00×12,14-14ply rating
Maximum Torque : 18.0±0.5 kgf⋅m(130 lb⋅ft) Steer Tires :

Compression pressure (STD): 35±1kgf/cm2 (497±14.2psi) C20/25 6.00×9,10-ply rating
C30 6.50×10, 12-ply rating
@ 250rpm
Tire Pressures
Engine Speed (rpm) :
Idle : 750±30 rpm Drive Tires :
Converter Stall : 2460±30rpm C20/25 Single : 1000 kPa (145 psi)
Maximum No-Load : 2700±30 rpm Dual : 1000 kPa (145 psi)
C30 Single : 965 kPa (140 psi)
Fuel Consumption (rated) : 170 g/PS-h Dual : 1000 kPa (145 psi)
Fuel Injection Timing (FID, BTDC) : 10°~12° Steer Tires :
2 C20/25/30 862 kPa (125 psi)
Fuel Injection Pressure : 220~230 kgf/cm (3128~3270
psi)
Firing Order : 1-3-4-2 (No.1 cylinder on flywheel side)
Output Shaft : Flywheel
Direction of Rotation : Counterclockwise(viewed from
flywheel)
Fuel Oil : Diesel oil
Engine oil : 15W 40, API CD, CF-4 Engine oil.
Oil Pan Capacity : Max ; 10.2L(2.5gal)
Min ; 4.5L(1.2gal)
Engine Dimension :
Overall Length : 720mm (28.3in)
Overall width : 508mm (20in)
Overall height : 689mm (27.1in)
Engine weight (dry) : About 260 kg (506 lb)
Start Motor : 12V-2.3 kW
Alternator : 12V-40A
Group 22, Wheels and Tires Specifications

Steer Tire Types : Pneumatic Rubber/Cushion Rubber,
non-marking, and urethane.
Drive Tire Type : Pneumatic Rubber/Cushion Rubber,
non-marking, and urethane.

Cushion Truck Wheel and Tires Group 26, Steer Axle Specifications
Drive Tires Steer Tires
C20/25C 21×7×15 16×5×10.5 Cushion-Tire Truck
C30C 21×8×15 16×6×10.5
C32C 21×9×15 16×6×10.5 Steering System Relief Pressure Setting : 8620-9300 kPa
(1250-1350 psi).
Group 23(G) brake/Inching System Steer Cylinder Type : Double-acting, piston-type.
Specifications (Standard Transaxle) Turning Arc : 83° max. inside turning angle
60° max. outside turning angle.
Service Brake
Pneumatic-Tire Truck
Type : Drum and shoe. Step-bore master cylinder.
Self-adjusting.
(1250-1350 psi).
Fluid : Brake Fluid (SAE dot 3) by reservoir.
Steer Cylinder Type : Double-acting, piston-type.
Brake System Residual Pressure : 117 kPa (17 psi).
Turning Arc : 75° max. inside turning angle
Shoe-to-Drum Gap : 0.45-0.60 mm (0.017-0.024 in). 54° max. outside turning angle
Shoe Lining Thickness : 1.0 mm ( 0.039 in) min. The number of handwheel turns required for lock-to-lock
turning differs between the cushion and pneumatic-style
Drum Thickness : 20.6 mm (0.787 inch).
axles.
Maximum Rebore Diameter : 303 mm (11.92 in).
Pedal Freeplay : 4~6mm (0.16~0.24 in). Group 29, Hydraulic Sump, Filters, and Pump
Star Wheel Adjustment Gap : 0.5-0.6 mm (0.020-0.023 Specifications
in).
Hydraulic Pump Type : Transmission-driven, gear-type
with integral load sensing priority flow valve and pressure
Parking Brake
relief valve ; pump is connected to, and works in conjunc-
Type : Ratchet linked to service brake shoe at each wheel. tion with the transmission charging pump.
Holding Test : Rated load on 15% grade. Sump Type and Capacity : Tank is built into truck frame
with capacity of 37L (9.8 gal) for cushion-tire trucks, 40L
Inching (also see transaxle specs) (10.6 gallones) for pneumatic-tire trucks (2.0-2.5ton) and
44L(11.6gallones) for pneunuts-tire truck, (3.0 ton).
Type : Inching pedal mechanically linked to brake pedal
and to inching spool on transaxle. Hydraulic Fluid Type : Clark Hydraulic Fluid specifica-
tion MS-68.
Pedal Freeplay : None.
Tank top Return Filter Type : Disposable, glass micro-
Overrap Adjustment : 1.5-4.5 mm (0.06-0.18 in).
fiber element.
Suction Screen : 100 mesh stainless steel screen.
Specifications Dirty Filter Element Indicator Pressure Switch Setting :
200±40 kPa (29±6 psi).
Steering System Type : Hydrostatic power steering with
load sensing, dynamic signal circuit.
(1250-1350 psi)
Nominal Flow Rating : 23 L/min (6 gal/min)
Inlet Pressure Rating : 12400 kPa (1800 psi)
Return Pressure Rating : 690 kPa (100 psi) maximum

Drawbar Pull Turning Radius (outside)

With standard upright and standard transaxle. For standard transaxle truck.
with load(kg) without load(kg) mm in
Cushion tire type LPG Cushion tire type Gas & LPG
C20 C 1880 963 C20 C 1975 77.8
C25 C 1882 882 C25 C 2035 80.1
C30 C 1810 816 C30 C 2090 82.3
C32 C 1800 798 C32 C 2130 83.9
Cushion tire type GAS Pneumatic tire type Gas & LPG
C20 C 1930 963 C20 2245 88.4
C25 C 1922 882 C25 2300 90.6
C30 C 1867 816 C30 2405 94.7
C32 C 1860 798
Diesel
Pneumatic tire type LPG C20 2245 88.4
C20 1614 1050 C25 2300 90.6
C25 1622 980 C30 2405 94.7
C30 1466 1025
Pneumatic tire type GAS
C20 1654 1008
C25 1624 957
C30 1550 1005
C20 2363 1029
C25 2426 978
C30 2105 1028
Travel Speeds
Maximum speeds with standard upright and standard tran-
saxle.
with load(km/h) without load(km/h)
Cushion tire type LPG
C20 C 17.1 16.6
C25 C 17.2 16.6
C30 C 17.0 16.5
C32 C 16.8 16.6
Cushion tire type GAS
C20 C 17.3 16.6
C25 C 17.2 17.6
C30 C 17.1 16.9
C32 C 16.9 17.7
Pneumatic tire type LPG
C20 20.3 20.9
C25 20.1 20.5
C30 20.2 21.0
Pneumatic tire type GAS
C20 20.3 20.9
C25 20.1 20.5
C30 20.1 21.2
C20 19.3 20.4
C25 19.3 20.4
C30 20.5 21.4

Section 3
Hydraulic Fitting Tightening Procedure
1. Tighten fitting finger tight until it stops turning, 2. Using finger tips only, lightly snug fitting with a
while moving the fitting lightly side to side to pre- wrench until it bottoms out on the seat or port. Do
vent cocking or thread damage. not overwighten.
SM 661, Aug ’01 Hydraulic Fitting Tightening Procedure • 40-3-1

2317 Alumni Park Plaza,
Suite 500 Lexington,
KY 40517
August, 2001

Service Manual: C20-30 D/L/G C20-32C L/G

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Service Manual: C20-30 D/L/G C20-32C L/G

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C20-30 D/L/G

RATED CAPACITY: 2000 – 3200KG

Part No. 8009285

2317 Alumni Park Plaza,

Arrangement and Use of this Manual

Group 34. Upright

Group 06. Transmission

Group 32. Tilt Cylinders

Group 25. Steering Column and

Group 03. Air Induction System

Group 00. Engines Group 14. Electrical System

Group 12. Ignition System

Group 22. Wheels and Tires

SM 661, Aug ’01 CONTENTS-1

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

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

SM661, Aug ’01 Group SA, Safe Maintenance

Safety Signs and Messages Safe Maintenance Practices

SM 661, Aug ’01 Safety • SA-1-1

SA-1-2 • Safety SM 661, Aug ’01

Safe Parking Raising Drive Wheels Off Floor

Lifting, Blocking, and Jacking Points

Under Under Frame Under Upright

7. Check for stable condition of the truck. Be sure that ! WARNING

Blocking the Upright In Raised

access from the front of truck to components on or near

6. Hold the shorter block against the outer rail and

Raising Entire Truck

The reverse is also true. If the counterweight

Put an equal amount of blocks under each side of the truck

8. When maintenance work is completed, lower the

b. Without an Upright and Carriage Installed

Direction of towing for distances of

Disabled truck with Tow truck moving at 8 kilome-

SM661, Aug ’01 Towing • SA-3-1

LIFT TRUCK PARKING

SA-3-2 • Towing SM661, Aug ’01

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

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

SM 661, Aug ’01 Group PS, Periodic Service

“Periodic Service” and “Planned Determining Maintenance Intervals

Since the operating environments of lift

SM 661, Aug ’01 Maintenance Schedules • PS-1-1

Service Chart/Lubrication Points

PS-1-2 • Maintenance Schedules SM 661, Aug ’01

Recommended Periodic Service Schedule

Every 450- Every 900- Every 2000

SM 661, Aug ’01 Maintenance Schedules • PS-1-3

Every 450- Every 900- Every 2000

PS-1-4 • Maintenance Schedules SM 661, Aug ’01

Every 450- Every 900- Every 2000

SM 661, Aug ’01 Maintenance Schedules • PS-1-5

SM 661, Aug ’01 The Planned Maintenance Program • PS-2-1

Introduction to Planned Maintenance The Basic PM Procedures

PS-2-2 • The Planned Maintenance Program SM 661, Aug ’01

The Recommended PM Task Chart

Listed by Service Manual Group

Group PS - The Basic PM Procedures Wiring harness - inspect

SM 661, Aug ’01 The Planned Maintenance Program • PS-2-3

Visual Inspection Carriage, Load Backrest, and Upright

PS-2-4 • The Planned Maintenance Program SM 661, Aug ’01

Engine Shut Down Mode

SM 661, Aug ’01 The Planned Maintenance Program • PS-2-5