CLARK FORKLIFT C20 30 DLG C20 32C LG SERVICE MANUAL – PDF DOWNLOAD
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CLARK FORKLIFT C20 30 DLG C20 32C LG SERVICE MANUAL – PDF DOWNLOAD
- Operation of the truck to check performance must be conducted in an authorized, safe, clear area. 10. Before starting to drive truck: a. Be in operating position. b. Be sure parking brake is engaged. c. Put direction control in neutral. d. Start engine. e. Check functioning of direction and speed controls, steering, brakes, warning devices, and any load handling attachments.
- 11. Before leaving truck a. Stop truck. b. Put directional control in neutral. c. Apply the parking brake. d. Stop the engine by turning off the ignition circuit. e. Put blocks at the wheels if truck is on an incline. 12. Brakes, steering mechanisms, control mechanisms, warning devices, lights, governors, guards, safety devices, and frame members must be carefully and regularly inspected and maintained in a safe operating condition. 13. Special trucks or devices designed and approved for hazardous area operation must receive special attention to ensure that maintenance preserves the original, approved, safe-operating features.
- 14. Fuel systems must be checked for leaks and condition of parts. Extra special consideration must be given in the case of a leak in the fuel system. Action must be taken to prevent the use of the truck until the leak has been corrected. 15. The truck manufacturer’s capacity, operation, and maintenance instruction plates, tags, or decals must be maintained in legible condition.
- 16. Batteries, motors, controllers, limit switches, protective devices, electrical conductors, and connections must be inspected and maintained in conformance with good practice. Special attention must be paid to the condition of electrical insulation. 17. To avoid injury to personnel or damage to the equipment, consult the manufacturer’s procedures in 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.
- 19. Modifications and additions that affect capacity and safe truck operation must not be done without the manufacturer’s prior written approval. Capacity, operation and maintenance instruction plates, tags, or decals must be changed accordingly. This is an OSHA requirement. 20. Care must be taken to assure that all replacement parts, including tires, are interchangeable with the original parts and of a quality at least equal to that provided in the original equipment. Parts, including tires, are to be installed per the manufacturer’s procedures.
- Always use genuine CLARK or CLARKapproved parts. 21. Use special care when removing heavy components from the truck, such as counterweight, seat deck, upright, etc. Be sure that lifting and handling equipment is of the correct capacity and in good condition. Also, this removal may upset the stability of the truck. The frame must always be safely blocked for major component removal.
Table Of Contents:
CLARK FORKLIFT C20 30 DLG C20 32C LG SERVICE MANUAL – PDF DOWNLOAD
SM-661........................................................................................ 1 Truck Models Covered by this Manual....................................................... 2 Arrangement and Use of this Manual........................................................ 2 CONTENTS.................................................................................. 3 GROUP SA SAFE MAINTENANCE................................................................. 4 Section 1 Safety...................................................................... 5 Safety Signs and Messages......................................................... 5 Safe Maintenance Practices........................................................ 5 Section 2 Lifting, Jacking, and Blocking the Truck.................................... 7 Safe Parking...................................................................... 8 Lifting, Blocking, and Jacking Points............................................. 8 Raising Drive Wheels Off Floor.................................................... 8 Raising Truck with A Hoist........................................................ 9 Blocking the Upright In Raised Position........................................... 10 Raising Rear of Truck............................................................. 10 Raising Entire Truck.............................................................. 11 Shipping Tie-Down Instructions.................................................... 12 Section 3 Towing...................................................................... 13 GROUP PS PERIODIC SERVICE................................................................. 15 Section 1 Maintenance Schedules....................................................... 16 “Periodic Service” and “Planned Maintenance"...................................... 16 Determining Maintenance Intervals................................................. 16 Service Chart/Lubrication Points.................................................. 17 Recommended Periodic Service Schedule............................................. 18 Section 2 The Planned Maintenance Program............................................. 21 Introduction to Planned Maintenance............................................... 22 PM Intervals...................................................................... 22 The PM Form....................................................................... 22 The Basic PM Procedures........................................................... 22 The Recommended PM Task Chart..................................................... 23 Visual Inspection................................................................. 24 Functional Tests.................................................................. 25 Air Cleaning the Truck............................................................ 27 Truck Chassis Inspection and Lubrication.......................................... 28 Upright and Tilt Cylinder Lubrication............................................. 28 Lift Chain Lubrication............................................................ 28 Under-the-Hood Inspection......................................................... 28 Fluid Checks...................................................................... 28 Stall Test........................................................................ 29 Cranking Voltage Test............................................................. 29 Critical Fastener Torque Checks................................................... 29 PM Report Form.................................................................... 30 GROUP 00(G) ENGINE........................................................................ 31 Section 1 Engine Specifications (4G64 Gas/LPG Engine)................................. 32 Section 2 Engine Troublshooting (4G64 Gas/LPG Engine)................................. 33 Engine hard to start or won’t start............................................... 33 Irregular idling.................................................................. 33 Engine runs unevenly at high speed................................................ 33 Engine fires erratically.......................................................... 33 Backfiring........................................................................ 33 Lack of power or poor acceleration................................................ 34 Overheating....................................................................... 34 Faulty compression................................................................ 34 Low oil pressure.................................................................. 34 High oil pressure................................................................. 34 High oil consumption.............................................................. 35 Engine knocks and other noises.................................................... 35 Vibration originating at engine................................................... 36 Section 3 Engine Oil and Filter (4G64 Gas/LPG Engine)................................. 37 Engine Oil Requirements........................................................... 37 Engine Oil Level Check........................................................ 37 Engine Oil and Filter Change.................................................. 38 Section 4 Engine Tune-Up (4G64 Gas/LPG Engine)........................................ 39 Tune-Up Specifications............................................................ 39 Procedures........................................................................ 39 Section 5 RPM, Vacuum, and Stall Tests (4G64 Gas/LPG Engine).......................... 40 Introduction...................................................................... 41 Test Procedures................................................................... 41 Engine RPM and Vacuum at Idle..................................................... 42 Engine RPM at Maximum No-Load Governed Speed...................................... 42 Engine Vacuum at Maximum No-Load Governed Speed................................... 42 Engine RPM and Vacuum at Stall.................................................... 43 Analysis of Stall Test............................................................ 43 Section 6 Compression Checks (4G64 Gas/LPG Engine).................................... 44 Test Preparation.................................................................. 44 Compression Test Procedure........................................................ 44 Analysis of Pressure Readings..................................................... 45 Section 7 Engine Removal and Replacement (4G64 Gas/LPG Engine)........................ 46 Engine Removal.................................................................... 47 Engine Replacement................................................................ 49 Section 8 Engine Overhaul (4G64 Gas/LPG Engine)....................................... 51 GENERAL INFORMATION Overhaul Specifications....................................... 52 Cylinder Head................................................................. 52 Camshafts..................................................................... 52 Valves........................................................................ 53 Valve Springs................................................................. 53 Valve Guides.................................................................. 53 Valve Seats................................................................... 53 Silent Shafts................................................................. 54 Pistons....................................................................... 54 Piston Rings.................................................................. 54 Piston Pins................................................................... 54 Connecting Rods............................................................... 54 Crankshafts................................................................... 55 Cylinder Blocks............................................................... 55 Oil Pump...................................................................... 55 Service Precautions............................................................... 56 Match Marks................................................................... 56 Special Tools................................................................. 56 Tightening Torque............................................................. 56 Replacement Parts............................................................. 56 Rubber Parts.................................................................. 56 Oil and Grease................................................................ 56 Sealant Specifications........................................................ 56 Tightening Method for Permanently Yeilding Bolts.................................. 57 Form-In-Place Gasket (FIPG)....................................................... 57 Special Tools..................................................................... 58 OVERHAUL PROCEDURES............................................................... 60 Timing Belt................................................................... 61 Removal Service Points.................................................... 62 Inspection................................................................ 64 Timing Belt “B” Installation.............................................. 65 Intake Manifold and Thermostat................................................ 68 Exhaust Manifold and Water Pump............................................... 69 Rocker Arms and Camshaft...................................................... 70 Removal Service Point..................................................... 71 Inspection................................................................ 71 Installation Service Points............................................... 72 Cylinder Head and Valves...................................................... 73 Removal Service Points.................................................... 74 Inspection................................................................ 74 Installation Service Points............................................... 77 Front Case, Silent Shaft and Oil Pan.......................................... 78 Removal Service Points.................................................... 79 Inspection................................................................ 80 Installation Service Points............................................... 80 Piston and Connecting Rod..................................................... 85 Removal Service Points.................................................... 86 Inspection................................................................ 86 Installation Service Points............................................... 88 Crankshaft, Flywheel, and Drive Plate......................................... 92 Inspection................................................................ 93 Installation Service Points............................................... 94 GROUP 00(D) ENGINE (4TNE94-SFW Diesel).................................................... 96 Fuel system Section 1 Engine (4TNE94-SFW)............................................. 97 Fuel Injection Pump Exploded View................................................. 98 Cooling System........................................................................ 99 Disassembly/Assembly..............................................................100 Service points....................................................................100 Lubrication System....................................................................101 Disassembly/Assembly..............................................................102 Service points....................................................................102 Parts inspection and measurement..................................................102 Inspection............................................................................103 Engine Oil........................................................................103 Coolant...........................................................................103 Leak from Cooling System and Radiator.............................................103 Fan belt tension inspection and adjustment........................................104 Valve Clearance Adjustment........................................................104 Fuel Injection Nozzle.............................................................105 Injection Pressure Measurement....................................................105 Spray Pattern Inspection..........................................................106 Nozzle Valve Sliding Test.........................................................106 Fuel Injection Timing.............................................................107 Sensor............................................................................108 Compression Pressure Check........................................................109 Engine Speed and Compression Pressure.............................................110 Adjusting Operation...................................................................111 Periodic Maintenance Chart............................................................112 Troubleshooting Chart.................................................................113 Maintenance Standard..................................................................115 Tightening Torque.....................................................................119 Special Tools.........................................................................121 Measuring Tools.......................................................................123 Precautions...........................................................................126 Cylinder Head.........................................................................127 Disassembly/Assembly..............................................................127 Service Points....................................................................128 Parts Inspection and Measurement..................................................130 Gear Train And Camshaft...............................................................135 Disassembly/Assembly..............................................................135 Service Points....................................................................136 Parts Inspection and Measurement..................................................137 Cylinder Block........................................................................139 Disassembly/Assembly..............................................................139 Service Points....................................................................140 Parts Inspection and Measurement..................................................142 GROUP 01 ENGINE COOLING SYSTEM............................................................150 Section 1 Engine Cooling System Specifications and Description........................151 Specifications....................................................................151 Description.......................................................................152 Section 2 Engine Cooling System Troubleshooting.......................................153 Section 3 Engine Cooling System Testing and Maintenance...............................154 Engine Coolant Level Check........................................................155 Cooling System Inspection.........................................................156 Cooling System Tests..............................................................157 Engine Coolant Change.............................................................158 Section 4 Engine Cooling System and Alternator Belt Service...........................160 Belt Checks.......................................................................161 Gas/LPG Truck Belt Removal........................................................161 Gas/LPG Truck Belt Replacement....................................................162 Section 5 Radiator Removal and Replacemant............................................164 Radiator Removal..................................................................165 Radiator Replacement..............................................................167 GROUP 02(LP) LPG FUEL SYSTEM (CARBURETED).................................................169 Section 1 Fuel System Specifications and Description..................................170 Specifications....................................................................170 Description.......................................................................171 Carburetor and Throttle Body......................................................173 Vaporizer-Regulator...............................................................174 Governor..........................................................................175 Section 2 Fuel System Troubleshooting (Carnureted LPG Fuel System)....................176 Preliminary Checks................................................................176 LPG System Check..................................................................176 Symptoms and Causes...............................................................177 Section 3 Fuel System Adjustments and Maintenance (Carbureted LPG Fuel System)........178 General LPG Maintenance...........................................................179 Carburetor Adjustment.............................................................181 Governor Inspection and Adjustment................................................182 High-Idle Speed (No-Load Governed Speed) Adjustment...........................183 Hunting Adjustment............................................................183 Linkage Check.....................................................................184 Accelerator Cable Adjustment......................................................184 Section 4 LPG Carburetor and Throttle Body Removal and Overhaul.......................185 Carburetor and Throttle Body Removal..............................................186 Carburetor Overhaul...............................................................187 Section 5 Vaporizer-Regulator Removal and Overhaul (LPG Carbureted Fuel System).......188 Removing the Vaporizer-Regulator..................................................189 Installing the Vaporizer-Regulator................................................189 Overhauling the Vaporizer-Regulator...............................................190 Section 6 Fuel Lock-off & Filter Removal and Overhaul (Carbureted LPG Fuel System)....192 GROUP 03 AIR INDUCTION AND EXHAUST SYSTEM.................................................193 Section 1 Air Induction and Exhaust Systems Specifications and Description............194 Section 2 Air Induction System Troubleshooting........................................195 Section 3 Air Induction System Service................................................196 Section 4 Exhaust Systems.............................................................200 GROUP 06(S) TRANSAXLE.....................................................................204 Section 1 Transaxle Specifications and Description....................................205 Specifications....................................................................206 Locations.........................................................................207 Description.......................................................................208 Operation.........................................................................212 Transaxle Hydraulic Schematic.....................................................214 Sectional View Along Turbine Shaft................................................215 Sectional View Along Drive Axle...................................................216 Section 2 Transaxle Troubleshooting...................................................217 Symptoms and Causes...............................................................218 Checks............................................................................219 Stall RPM Test....................................................................220 Section 3 Transaxle Oil and Filter....................................................222 Section 4 Transaxle Oil Cooler........................................................224 Section 5 Transaxle Removal and Replacement...........................................226 Transaxle Removal.................................................................227 Transaxle Replacement.............................................................229 Section 6 Transaxle Overhaul..........................................................231 General Practices to Follow.......................................................232 Overhaul Procedures...............................................................235 Transaxle Disassembly.........................................................235 Differential Overhaul.........................................................242 Clutch Overhaul...............................................................243 Reassembling the Clutch...................................................244 Clutch Discs Reassembly...................................................245 Clutch Gear Reassembly....................................................246 Clutch Gear Installation..................................................246 Oil Distributor Rings Installation........................................246 Transaxle Control Valve Overhaul..............................................246 Transaxle Reassembly..........................................................247 Installing Oil Distributor Sleeve,............................................247 Installing the Suction Tube...................................................247 Installing the Pinion Bearings, Pinion Shaft, and Output Gear.................248 Installing Pinion Shaft and Setting Preload...................................249 Installing the Differential...................................................250 Setting Ring Gear and Pinion Backlash.........................................251 Checking Ring and Pinion Gear Tooth Contact Pattern...........................251 Installing the Clutch and Idler Gear..........................................252 Installing the Pump Idler Gear and Bearing....................................253 Installing the Stator Oil Seal, Impeller Hub Gear.............................253 Joining Converter, Transmission, and Axle Housings............................254 Installing Axle Shafts and Axle Ends..........................................254 Installing Transaxle Peripherals..............................................255 Filling and Initial Startup...................................................257 Section 7 Drive Axle Ends Overhaul....................................................258 Section 8 Transaxle Control Valve Overhaul............................................262 GROUP 12 IGNITION SYSTEM (STANDARD ELECTRONIC IGNITION)...................................264 Section 1 Ignition System Description and Specifications..............................265 Ignition System Overview..........................................................266 Schematic Drawing of Electronic Ignition Circuitry................................267 Distributor Components and Function...............................................268 Section 2 Ignition System Troubleshooting.............................................269 Troubleshooting Tests.............................................................270 Plug Test.....................................................................270 Troubleshooting Chart.............................................................271 Section 3 Ignition System Inspection, Adjustment, and Timing..........................273 Distributor Inspection and Air Gap Adjustment.....................................274 Spark PlugWire Inspection.........................................................275 Spark Plug Inspection and Replacement.............................................275 Ignition Coil Inspection..........................................................276 Ignition Coil Tests...............................................................277 Pick-Up Coil Tests................................................................277 Ignition Timing Checks and Adjustment.............................................277 Adjusting Ignition Timing.........................................................278 Checking Spark Advance............................................................279 Section 4 Distributor Overhaul........................................................280 GROUP 13 ELECTRICAL SYSTEM................................................................285 Section 1 Cautions for working on the electrical system...............................286 Section 2 Specifications and features of electrical system............................287 Section 3 Electrical Circuit Diagram & Electrical Parts Arrangement...................288 Electrical Circuit Diagram • Diesel...............................................289 Electrical Circuit Diagram • Gasoline & Gasoline/LPG (Dual Fuel)..................290 Electrical Circuit Diagram • LPG..................................................291 Electrical Parts Arrangement - Diesel.............................................292 Electrical Parts Arrangement - Gasoline...........................................293 Electrical Parts Arrangement - LPG................................................294 Electrical Parts Arrangement - Gasoline & LPG (Dual)..............................295 Instrument Pod....................................................................296 Lights............................................................................300 Battery Assembly..................................................................301 Section 4 Instrument Pod..............................................................303 Pod Symbols and Functions.........................................................304 Connector Terminal Arrangement....................................................307 Section 5 Specification and Operation of Electrical Components........................308 Battery...........................................................................309 Engine Accessories................................................................310 Alternator........................................................................310 Starting Motor....................................................................311 Water Temp Sender.................................................................312 Switch-Eng Oil Pressure...........................................................313 Eng Stop Motor (Diesel)...........................................................314 LPG Pressure Switch...............................................................315 Switch-T/M Temp...................................................................316 Fuel Sender.......................................................................317 Start Switch......................................................................318 Switch Fwd. & Rev.................................................................319 Switch - Indicator................................................................320 Brake Stop Switch.................................................................321 Parking Brake Switch..............................................................322 Seat Switch.......................................................................323 Fuse / Relay Box..................................................................324 Engine Stop Relay.................................................................325 Flash Unit........................................................................326 Start and Preheat Relays..........................................................327 Horn..............................................................................328 Backup Alarm......................................................................329 Lamp-Work.........................................................................330 Lamp-Indicator....................................................................331 Combination Lamp..................................................................332 Lamp-Beacon.......................................................................333 Section 6 Troubleshooting of Electrical System........................................334 Fuel Gauge Malfunction............................................................335 Hourmeter Malfunction.............................................................336 Coolant Temp Gage Malfunction.....................................................337 Transaxle Oil Malfunction.........................................................338 Engine Oil Gage Malfunction.......................................................339 Alternator Charge Malfunction.....................................................340 Preheat Plug Malfunction..........................................................341 Parking Brake Malfunction.........................................................342 Work Lamp Switch Malfunction......................................................343 Rear Work Lamp Switch.............................................................344 Beacon Lamp Switch Malfunction....................................................345 All of Instrument Pod Lamps Fails to Turn On......................................346 Failure to Drive..................................................................347 Failure to engine shut down (Diesel)..............................................348 Failure to engine shut down (GAS/LPG).............................................349 Failure to Start (GAS/LPG)........................................................350 Failure to Start (Diesel).........................................................351 GROUP 22 WHEELS AND TIRES.................................................................352 Section 1 Wheels and Tires Specifications and Description.............................353 Section 2 Cushion Wheels and Tires....................................................354 Section 3 Pneumatic Wheels and Tires..................................................357 Pneumatic Tire Maintenance Precaution.............................................358 General Tire Maintenance, Inspection, and Repair..................................359 Wheel Dismounting and Remounting..................................................360 Wheel Disassembly and Tire Removal................................................362 Tire Replacement and Wheel Reassembly.............................................364 Split-Rim Wheel Assemblies........................................................368 GROUP 23(S) BRAKE SYSTEM (TA30 TRANSAXLE).................................................369 Section 1 Braking/Inching System Specifications and Description.......................370 Section 2 Service Brake Troubleshooting...............................................373 Section 3 Brake/Inching Pedals and Linkages Adjustments...............................375 Section 4 Brake System Bleeding.......................................................379 Section 5 Brake Master Cylinder Service...............................................380 Section 6 Service Brake Adjustment and Overhaul.......................................383 Section 7 Parking Brake Service.......................................................389 GROUP 25 STEERING COLUMN AND GEAR.........................................................391 Section 1 Steering System Specifications and Description..............................392 Section 2 Steering System Troubleshooting.............................................394 Section 3 Steering Column and Component Removal and Replacement.......................396 Section 4 Stering System Relief Pressure Check and Adjustment.........................406 Section 5 Steering Gear Overhaul......................................................408 GROUP 26 STEER AXLE.......................................................................415 Section 1 Steer Axle Specifications and Description...................................416 Section 2 Steer Axle Wheel Bearing Maintenance and Adjustment.........................418 Section 3 Steer Axle Removal and Replacement..........................................422 Section 4 Steer Axle Overhaul.........................................................426 Section 5 Steer Cylinder Removal and Replacement......................................429 Section 6 Steer Cylinder Overhaul.....................................................431 GROUP 29 HYDRAULIC SUMP, FILTERS, AND PUMP................................................435 Section 1 Hydraulic Sump, Filters, and Pump Specifications and Description............436 Section 2 Main Hydraulic Pump Troubleshooting.........................................439 Section 3 Hydraulic Filters and Fluid Maintenance and Change..........................441 Section 4 Hydraulic Pump Removal and Replacement......................................445 Section 5 Hydraulic Pump Overhaul.....................................................447 GROUP 30 HYDRAULIC CONTROL VALVE/ LIFT CIRCUIT............................................455 Section 1 Hydraulic Control Valve/Lift Circuit Specifications and Description.........456 Section 2 Hydraulic System Schematics.................................................458 Section 3 Hydraulic System Troubleshooting............................................459 Section 4 Hydraulic System Pressure Checks and Adjustments............................461 Section 5 Hydraulic Control Valve Removal and Replacement.............................463 Section 6 Hydraulic Control Valve Overhaul............................................467 GROUP 32 TILT CYLINDERS...................................................................471 Section 1 Tilt Cylinder Specifications and Description................................472 Section 2 Tilt Cylinder Checks and Adjustments........................................473 Section 3 Tilt Cylinder Removal and Replacement.......................................476 Section 4 Tilt Cylinder Overhaul......................................................480 GROUP 34 UPRIGHTS.........................................................................483 Section 1 Upright Specifications and Description......................................484 Section 2 Troubleshooting.............................................................490 Section 3 Upright Inspection..........................................................494 Section 4 Carriage and Upright Roller Clearance Checks and Shim Adjustments...........504 Section 5 Cylinder Removal, Shimming, Overhaul, and Replacement.......................514 Section 6 Upright Chain Inspection, Adjustment, and Replacement.......................520 Section 7 Fork and Carriage Removal and Replacement...................................528 Section 8 Upright Removal and Replacement.............................................532 GROUP 38 COUNTERWEIGHT AND CHASSIS........................................................536 Section 1 Counterweight Specifications and Description................................537 Section 2 Counterweight Removal and Replacement.......................................538 Section 3 Overhead Guard/Operator’s Cell Removal and Replacement......................540 Section 4 Floorboard, Cowls, Radiator Cover, and Seat Deck Removal and Replacement....542 Section 5 Operator’s Seat Removal and Replacement.....................................546 GROUP 40 SPECIFICATIONS...................................................................548 Section 1 Nameplates and Decals.......................................................549 Section 2 General Specifications......................................................553 Weights and Performance Specifications............................................554 Maximum Gradeability..............................................................554 Parking Brake Test................................................................554 Hydraulic Valve/Lift Circuit Specifications.......................................555 Tilt Cylinders Specifications.....................................................555 Upright Specifications............................................................555 Counterweight and Chassis Specifications..........................................555 Drift, Lift and Tilt Cylinders....................................................556 Lift Speeds, Upright..............................................................556 Critical Fastener Torque Specifications...........................................556 Standard Transaxle Specifications.................................................557 Ignition System Specifications....................................................557 Instrument Pod & Electrical System Specifications.................................557 Cooling System Specifications.....................................................558 LPG Fuel System Specifications....................................................558 4g64 Gas/LPG Engine Specifications................................................559 4TNE94 Diesel Engine Specifications...............................................559 Wheels and Tires Specifications...................................................560 Steer Axle Specifications.........................................................561 Steering Column and Gear Specifications...........................................561 Hydraulic Sump, Filters, and Pump Specifications..................................561 Drawbar Pull......................................................................562 Travel Speeds.....................................................................562 Turning Radius (outside)..........................................................562 Section 3 Hydraulic Fitting Tightening Procedure......................................563
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