GCS GPS Standard Forklift Service Repair Workshop Manual

SM-520R GCS/GCS

Foreword This service publication provides information covering normal service, maintenance and repair of the Clark lift trucks noted on the cover. It has been specifically prepared to help owners and service personnel maintain these lift trucks in efficient and safe operating condition. Regular, correct maintenance and care of lift trucks is not only important for long and efficient truck life; it is essential for safe operation. The importance of proper maintenance through planned service, inspection and qualified repairs cannot be emphasized too strongly. To assist in keeping lift trucks in good operating condition, this manual includes preventive maintenance procedures to be performed at regular intervals. These are essential to the service life and safe operation of all fork lift trucks. Instructions for safety inspections, operational checks, cleaning, and lubrication are provided for reference in setting-up and conducting a recommended periodic Planned Maintenance (PM) program. Refer to the Operator’s Manual, located on the truck, for additional information on the operation, care and maintenance of your truck. Genuine Clark replacement parts should be used for all service and repair requirements. Substitute parts from other sources may be different than original parts and may not meet OSHA or other safety requirements. Any reference to brand names other than Clark in this manual is made simply as an example of the type of tools and materials recommended for use and, as such, should not be considered as an endorsement. Equivalents, if available, may be used. For more information on maintenance and repair of these trucks, contact your authorized Clark dealer. NOTICE - The descriptions and specifications included in this manual were in effect at the time of printing. C/ark Equipment Company reserves the right to discontinue models at any time, or make improvements and changes in specifications or design without notice and without incurring obligation. Specifications, torques, pressures, measurements, adjustments, illustrations and other items may change at any time. Contact your authorized CLARK dealer for information on possible updates or revisions. 0 1989 Clark Equipment Company 1211 I89 SM520 ii

Contents Subject Part General Information ........................................................................... 1 Specifications........................................................................................ 2 Planned Maintenance ....................................................................... 3 Engine (Group 00) .................................................................................... 4 Fuel System (GROUPS 02,03) ................................................................. 5 Electrical System (Groups 11-15) ........................................................ 6 Transaxle (stops 06,07,20) ................................................................. 7 Brakes and Inching System (GIOUPS 22,23) ................................... 8 Steering System (Groups 25,26) ......................................................... 9 Hydraulic System (Groups28-33) ..................................................... IO Wheels and Tires (Groups 22,23) .................................................... 11 Counterweight and Chassis (Group 38) ...................................... 12 Uprights (Group 34). ............................................................................. 1 3 Index.. .................................................................................................... 14 SM520 212719 1 . . . III

About This Manual This manual is intended for use by persons who are trained and authorized to do lift truck maintenance. It is designed to provide essential information about the correct and safe service maintenance and repair of the lift truck by trained mechanics of service technicians. The information is organized into 14 major Parts of related components or topics as outlined by the Table of Contents at the front of the manual: . 1 General information including precautions and safe maintenance practices. l 2 Service specifications and reference information including lubricants, capacities, pressures, etc. l 3 Planned Maintenance (PM) service procedures. l 4-13 Adjustment, service and repair procedures for truck components. In Parts 4-13, the detailed service and repair procedures are arranged in Sections for each procedure, component or subsystem. Some Sections include explanations that cover service procedures common to several components or subsystems. In general, each Section is written to show and describe the general arrangement, adjustment, removal, disassembly, inspection, repair, and assembly steps that are normally required to service the component. Component specifications (as applicable), information notes and safety messages are included within those procedures. In most cases, specifications are shown in Section 2, Service Specifications, for convenience of reference. Each Section includes Parts GROUP number(s) at the bottom of each page for cross reference. The Parts GROUP numbers are the same as the component group in the Master Parts Book and Service Parts Book. They are parts system reference numbers; use only the appropriate Parts Manual for ordering parts. Do not order parts from numbers shown in this manual. The Table of Contents lists major headings of Parts of the manual. Additional content listings are placed at the beginning of each Section of the manual, subsection or component heading to simplify reference to multiple topics or procedures covering optional equipment, such as engines and transaxles. If you cannot find a topic in the respective Table of Contents, check the Alphabetical Subject Index at the back of the manual. This manual has been made easier to use by providing only specific steps and instructions necessary to explain the activity, component, assembly, or process being worked on. The technician is expected to include obvious additional steps of standard procedure for removal, disassembly, cleaning, inspection, reassembly, installation, etc., as needed. To be better prepared to do the necessary service work, take time to completely read the entire procedure, including any special instructions, before doing any work. The technician is cautioned and expected to always work in a safe manner by using the correct procedure. Do not take chances which may result in injuries. 12/l/89 SM520 -v

1 General Information Safe Maintenance Practices.. ................................................ 1.O-2 Safety Signs and Messages.. ................................................. 1.O-4 General Precautions ............................................................. 1.o-5 Product identification.. .......................................................... 1.O-6 Model Nomenclature ......................................................... 1.O-6 Model Designations.. ......................................................... 1 .O-7 Model Serial Number Code.. .............................................. 1.O-7 Vehicle and Upright Identification.. ..................................... .l .O-8 Product Visual Identification .............................................. .I .O-9 SM520 12/l/89 l.O- 1

1.O General Information Safe Maintenance Practices The following instructions have been prepared from current industry and government safety standards applicable to industrial truck operation and maintenance. These recommended procedures specify conditions, methods, and accepted practices that aid in the safe maintenance of industrial trucks. They are listed here for the reference and safety of all workers during maintenance operations. Carefully read and understand these instructions and the specific maintenance procedures before attempting to do any repair work. When in doubt of any maintenance procedure, please contact your local CLARK dealer. 1. Powered industrial trucks can become hazardous if maintenance is neglected. Therefore, suitable maintenance facilities, trained personnel, and procedures must be provided. 2. Maintenance and inspection of all powered industrial trucks shall be done in conformance with the manufacturer’s recommendations. 3. A scheduled planned maintenance, lubrication, and inspection program shall be followed. 4. Only trained and authorized personnel should be permitted to maintain, repair, adjust, and inspect industrial trucks, and in accordance with the manufacturer’s specifications. 5. Properly ventilate work area, vent exhaust fumes, and keep shop dean and floor dry. 6. Avoid fire hazards and have fire protection equipment present in the work area. Do not use an open flame to check for level, or leakage of fuel, electrolyte, or coolant. Do not use open pans of fuel or flammable cleaning fluids for cleaning parts. 7. Before Starting Work On Truck: a) Raise drive wheels off of floor or disconnect power source and use blocks or other positive truck- positioning devices. b) Put blocks under the upright rails and carriage, innermast( or chassis before working on them. c) Disconnect battery before working on the electrical system. 8. Before working on engine fuel system of gasoline powered trucks with gravity-feed fuel systems, be sure fuel shutoff valve is closed. 9. Before working on engine fuel system of LP-gas powered trucks, close LP-gas cylinder valve and run engine until there is no more fuel in the system and engine stops running. If engine will not run, close LP- tank valve and vent fuel slowly in a safe area. 10. Operation of the truck to check performance must be conducted in an authorized, safe, clear area. 11. Before Starting To Drive Truck: a) Be in operating position. b) Disengage clutch on manual transmissions, or apply brake on trucks with powershift transmission and electric trucks. c) Put directional control in neutral. d) Start engine or turn on power. e) Check functioning of lift and tilt systems, directional and speed controls, steering, brakes, warning devices, and any load handling attachments. 12. Before Leaving The Truck: a) Stop truck. b) Fully lower the load engaging means: upright, carriage, forks, or attachments. c) Put directional control in neutral. d) Apply the parking brake. e) Stop the engine or turn off power. f) Turn off the control or ignition circuit. g) Put blocks at the wheels, if truck is on an incline. h) Remove the ignition key (OSHA regulation) 13. Handle LP-gas cylinders with care. Damage such as dents, scrapes, or gouges may dangerously weaken the tank and make it unsafe for use. 14. Brakes, steering mechanisms, control mechanisms, warning devices, lights, governors, lift overload devices, guards and safety devices, lift and tilt mechanisms, articulating axle stops, and frame members must be carefully and regularly inspected and maintained in a safe operating condition. 12/l/89 SM520 1.0-2

1.O General Information 15. 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. 16. 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. 17. All hydraulic sytems must be regularly inspected and maintained in conformance with good practice. Tilt and lift cylinders, valves, and other similar parts must be checked to assure that “drift” or leakage has not developed to the extent that it would create a hazard. 18. When working on hydraulic system, be sure the engine is turned off or battery disconnected on electric trucks, upright is in its fully-lowered position, and hydraulic pressure relieved in hoses and tubing. WARNING - Always put blocks under the carriage and upright rails when necessary to work with upright in an elevated position. 19. 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. 20. To avoid injury to personnel or damage to the equipment, consult the manufacturer’s procedures in replacing contacts on any battery connection. 21. Industrial trucks must he kept in a clean condition to minimize fire hazards and help to detect loose or defective parts. 22. The truck manufacturers capacity, operation and maintenance instruction plates, tags, or decals must be maintained in legible condition. 23. Modifications and additions that affect capacity and safe truck operation must not be done without the manufacturers prior written approval. Capacity, operation and maintenance instruction plates, tags or decals must be changed accordingly. Note - Using other than Clark parts may nullify the truck rating. 24. 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 CLARK-approved parts. 25. When removing tires, follow industry safety practices. Most important, deflate pneumatic tires completely prior to removal. Following assembly of tires on multi-piece rims, use a safety cage or restraining device while inflating. 26. Use special care when removing heavy components from the truck, such as counterweight, upright, engine, transaxle, etc. WARNlNG - If not properly blocked, truck may become unstable. Be sure that lifting and handling equipment is of the correct capacity and in good condition. 27. Before any truck is returned to service it must be safety checked to insure safe operation. NOTICE - Additional operating and maintenance safety instructions are contained in the following publications: ANSVASME B56.1 - 1983: Safety Standard for Low Lift and High Lift Trucks (Safety Code For Powered Industrial Trucks). Published by: Sociei of Mechanical Engineers, United Engineering Center, 345 E. 47th Street, New York, N.Y. 10017. NFPA 5051982: Fire Safety Standard for Powered Industrial Trucks: Type Designations, Areas of Use, Maintenance and Operation. Available from: National Fire Protection Assoc., Inc., Batterymarch Park, Quincy, MA 02269. General Industry Standards, OSHA 2206: OSHA Safety and Health Standards (29 CFR 1910), Subpart N-Materials Handling and Storage, Section 1910.178 Powered Industrial Trucks. For sale by: Superintendent of Documents, U.S. Government Printing Office, Washington, D.C 20402. SM520 12/l/89 1.0 - 3

1.O General Information Safety Signs and Messages SAFETY SIGNS and MESSAGES are placed in conspicuous places throughout this manual and also on the lift truck to provide instructions and to call attention to specific areas where potential hazards exist and special precautions should be taken. Be sure to know and understand the meaning of these instructions, signs and messages. Each one is there for a specific purpose. Damage to the truck or death or serious injury to personnel may result if these messages are not followed. NOTICE This message is used when special information, instructions or identification is required relating to procedures, equipment, tools, pressures, capacities and other special data. IMPORTANT This message is used when special precautions should be taken to ensure a correct action or to avoid damage to or malfunction of the truck or a component. CAUTION This message is used as a reminder of safety hazards which can result in personal injury if proper precautions are not taken. WARNING This message is used when a hazard exists which can result in injury or death if proper precautions are not taken. DANGER This message is used when an extreme hazard exists which will result in death or serious injury if proper precautions are not taken. These labels identify hazards which may not otherwise be apparent to a trained mechanic. There are many potential hazards for an untrained mechanic and there is no way to label the truck or service manual against all such hazards. Clark Equipment Company cannot anticipate every possible circumstance that might involve a potential hazard. The safety signs and warning messages in this manual are therefore not all inclusive. If a procedure, tool, device or work method not specifically noted or recommended by Clark is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the lift truck or its components will not be damaged or made unsafe by the procedures you choose. 12/l I89 SM520 1.0 - 4

1.O General Information I IMPORTANT SAFETY NOTICE --1 Read and understand all safety precautions and warnings before performing repairs on lift trucks. Appropriate service methods and proper repair procedures are essential to the safe, reliable operation of industrial trucks as well as the personal safety of the individual doing the work. This Service Manual provides general directions for accomplishing service and repair work with tested, effective techniques. Following them will help assure successful repair and reliable truck operation. There are numerous variations in procedures, techniques, tools, and parts for servicing industrial trucks, as well as in the skill of the individual doing the work. This manual cannot possibly anticipate all such variations and provide advice or precautions as to each. Accordingly, anyone departing from the instructions provided in this manual through procedures used or choice of tools, materials, and parts may jeopardize his or her personal safety and/or the safety of the vehicle user. Improper or careless techniques cause accidents. Don’t take chances with incorrect or damaged equipment. Read and understand the procedures for safe operation and maintenance outlined in this manual. STAY ALERT! Follow safety rules, regulations and procedures. Accidents can be avoided by recognizing dangerous procedures or situations before they occur. DRIVE AND WORK SAFELY and follow the safety signs and their messages displayed on the truck and in this manual. General Precautions The following list contains general precautions that should be followed when working on a lift truck: . Always wear safety glasses for eye protection. l Remove rings, watches, loose jewelry and open clothing before working on a vehicle, to avoid serious injury. l Do not smoke while working on a vehicle. l Put ignition switch in the OFF position, unless otherwise required by the procedure. l Set the parking brake. Place wheel chocks or wood blocks of 4” x 4” size or larger to the front and rear surfaces of the tires to provide further restraint from inadvertent vehicle movement. l Use safety stands whenever a procedure requires you to be under the vehicle. l Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide. l Keep hands and other objects clear of the fan belt and fan blades if it is necessary to work in the engine compartment. l Keep yourself and your clothing away from all moving parts, especially the fan and belts, when the engine is running. l Avoid contact with hot metal parts such as the radiator, exhaust manifold, exhaust pipe and muffler to prevent serious burns. SM520 1211189 l.O- 5

1.O General Information Product Identification Model Nomenclature Cushion fire Models GCX 20/22/25/27/30 -,C GCS 20/22/25/27/30 MB GCS 17/20/22/25/27/30 MC,WC,I DCS 17/20/22/25/27/30 I Pneumatic Tire Models G PX 20/22/25/27/30 -, C G PS 20/22/25/27/30 M B GPS 20/22/25/27/30 MC,WC,I DPS 20/22/25/27/30 I Rated Load Capacity* @ 24 inch [500 mm] Load Center Model 17 Basic Capacity Ibs 3500 t&Is1 ww 20 22 25 27 30 4000 4500 5000 5500 6000 [2000] [2250] [2500] [ 27501 [3000] *This is the basic capacity of the truck chassis. The actual capacity of the truck may be less due to the use of high lift uprights and/or attachments. 2/27/g 1 SM520 1.0 - 6

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GCS GPS Standard Forklift Service Repair Workshop Manual

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