PDF Service Manual CLARK GPHDPH 50-75 Forklift - 8 MB
This service manual, SM-591, provides comprehensive repair and maintenance information for the CLARK GPHDPH 50, 60, 70, and 75 series forklifts.
It contains detailed instructions for troubleshooting, disassembly, repair, and reassembly of all major components.
This is the go-to guide for technicians to perform any service task correctly and efficiently.
Keep your Clark forklift fleet running reliably with this essential manual.
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--- Page 1 ---
Service
Manual
SM 591
GPH/DPH 50/60/70/75
--- Page 3 ---
Introduction lx!mu
restartβ fm requims that the key be returned to Oil Pressure Gauge
the βoffβ position before it can again be turned to
Micaks engine oil pressure.
βstartβ If engine does not start on the first attempt,
Oil pressure should be be-
do not reengage the starter until engine comes to a
tween3Opsi(207kPa)and
complete stop (approximately 5 seconds). After the
60 psi (414 kPa) at nor-
engine starts, let it warm up until it runs evenly.
mal engine operating
Gauges, Meters, and Indicators speeds. At idle, pressure
should not fall below 20-
The gauges, hour meter, and indicator light in the 25 psi (138 kPa). If pres-
instrument panel tell you many important things sure is low or erratic, shut
about the performance of your lift truck FamGrizc downtheengineandlocatetheprob
you&f with their location and purpose and make it 1enL
a practice to scan the instrument panel as you start
the engine, after it starts, and periodically as you Ammeter
operate the tmck. Indicatesrateofbatterycharge
or discharge. With the en-
Water Temperature Gauge gine running, the gauge
shouldmadslightlytothe
Indicates t.czqem of en- β+β side of 0. If the am-
gine coolant water in de- meter shows a continu-
grees,lOO-280Β°F ous high rate of charge or
(3%138Β°C). Water tem- discharge, or reads errati-
peranne should be about tally, troubleshoot the bat-
180Β°F (82Β°C) after 10 tery charging system.
minutes of operation. Ifthe
indicator registers in the
βhotβ zone, turn off the en-
Transmission Temperature tight
gine and troubleshoot the cooling sys-
tem. This light comes on when oil temperature in the
torque converter is too high. Shift to a lower range.
Fuel Gauge If light stays on, shut the truck down and trouble-
shoot the transmission.
Indicates quantity of fuel re-
maininginthetanki&ac- Air Restriction Indicator
tions of the whole. Fuel
level should be checked Located on the seat deck of diesel models, this
at the beginning of each indicator shows red when it is time to change the air
shift. The tank should be filter element.
fullatthebeginningof
each shift. (Notused onLPGl NOTICE
CNG.)
The electrically-operated gauges reg-
ister correctly when the key switch is
in the ON position. When the key
switch is OFF, the indicator needle
willnotnecessarilgre~toanygiven
position.
Planned Maintenance-5 SM591, Aug β93
--- Page 4 ---
Group 00, Engines
Section 1.
Engine Troubleshooting
Engine Will Not Start..β..β...β......β..ββ....β....β....β.β.................β......β.....ββ........β.β...--.β..β..2
Engine Does Not Run Evenly ....-..βββ..ββ...m.....ββ~..βββ...ββ....βββ.β..-~.....β-β-.-..β..β ..2
Engine Does Not Run Evenly .~m..~.......β.ββ.~..~.β..ββ~...ββββ..~..β.~~.β.-...~~..~.~. 2
A Loss of Power .βββββ..~.~β.Hββ.β~......βββ.....~..β....~.β..~-................-.β.~β..β.~~.β .β2
Engine Temperatureabove Normal β..m....Wβ..~β......~....~~β..~~..~.......~~β-β~~- - 3
Oil Consumption above Normal ........._............β.ββ..β.β.....β...β..β~.._ββ..β...__.β._β..~ ....3
Black Exhaust Smoke .β.β...β...........β..β.β.....β........β...._..ββ_β....~.β.β.............β_.β..β.β_β β3
β3
White Exhaust Smoke β~ββ....β...β.Uβ..β.β..β._.β.........β.β...β..β....................ββ..β.....β....β..ββ
._
Truck Slow to Accelerate.β.β_..ββ..β.....β..β...β...ββ~β..β............β__.......β. _β..o.....Uβββ.4
Timing Wrong ......................................._.β......β...β......................β..β._β.....ββ......β...β~..β.β.β 4
Engine Causes a Loud Noise ..β..βββ...ββ.......................................β............................-β...β-~. 4
....β4
Engine Noises . General.......β._.._H....β..β.........ββ.β.................~.....β...................β....ββ...β
Other Types of Engine Noises ...β....ββ.m.ββ..........β........-..β...β..β.ββ.....β...-β-β....-β.- β4
Cylinder Head, Valves, and RockerArms ........._ββ....β..β.......β.....ββ..β......β...........β...ββ....β5
Cylinder Block, Liners, Pistons, and Rods .β.--.-.....β.-β..~β.β..........β......β.....-β-ββ.β. 5
Crankshaft,Main Bearings,and Plywheel.........U_......β....β..........ββ.._.β..β..._ββ....β._β - 6
Cooling System .~.ββ...........H........β.......ββ.........~~..-..β..β..........ββ.........~...β.β...β...~β~ .- 6
Fuel System .β.H.U.........β............β.ββ.....β..ββ.....-.........β....β....β....-.β......-β.β-...β....-.- ... 7
Charging the Circuit ......ββ........U..β.β.β.....β......._............~....βββ_.β....β.....ββ....ββ._._.ββ....8
NOTE
This troubleshootingchartlists engine problemsfollowed by causes.Each cause is
followed by a code indicating whether it pertams to w (A) or only to a
gasoline(G),dieSel@),LIX%),ornaturaiOOengine.
Additional troubleshootinginformation may be found in the B
m locatedin Section2,3, or 4 of Group00.
SM 591, Aug β93 EngineTroubleshooting . 00-l -1
--- Page 5 ---
workshop
manual for
4.248,4.236 & 4.212
diesel engines
0
Perkins Engines
Perkins Enginee, Inc. Canada Limited
32500 Van Born Road 7 Meridian Road
P 0 Box 697 l Wayne. Mfchigan 40104 Rexdale. Ontario M9W 426
Tel (3 13) 595-9600 Phone: (416)675-3540
1981
Publication No. 601 SERO1811062
This publication supercedes the previous edition numbered 601 ZERO9791062
This publication is written for world wide use. In territories where legal requirements govern
engine smoke emission, noise, safety factors etc., then all instructions, data and dimensions
given must be applied in such a way that, after servicing (preventive maintenance) or repair-
ing the engine, it does not contravene the local regulations when in use.
--- Page 6 ---
SECTION B
Technical data
Bore (4.248 engine) 3.975 in (100,96 mm)β
Bore (4.236 and 4.212 engines) 3.875 in (98,43 mm)β
Stroke (4.248 and 4.236 engines) 5 in (127 mm)
Stroke (4.212 engine) .. 4.5 in (114,3 mm)
No. of Cylinders . . Four
Cubic Capacity (4.248 engine) .β. 248 in3 (4,06 litres)
Cubic Capacity (4.236 engine) .. 236 in3 (3,86 litres)
Cubic Capacity (4.212 engine) . ... .β. 212 in3 (3.47 litres)
Compression Ratio (4.248 and 4.236 engines) .. 16 : 1
Compression Ratio - 4.212 (HC Piston
with 3 rings) . . .. 17.5 : 1
Compression Ratio - A4.212 (HC Piston
with 3 rings) . . 17.5 : 1
Compression Ratio - A4.212 (LC Piston
with 4 rings) 15.5 : 1
Firing Order 1, 3, 4, 2.
Cycle . Four-Stroke
Combustion System .,. Direct Injection
Lubricating Oil Pressure . 30/60 Ibf/inβ (2.1/4,2 kgf/cmβ) or 207/414 kN/m* at
max engine speed and normal working temperature.
βNominal -for actual bore size, see pages 8.3 and 8.4.
On A4.212 engines, the HC piston with 3 rings was fitted to MF engines from Nos. 212UA87001 to 212UA147672.
Details of Maximum Gross Ratings
4.248 Engines
General Agricultural and Industrial . 62 kW (84 bhpβ) at 2500 rev/min
Maximum Torque ... __. ___ _._ 263 Nm (194 Ibf ft) at 1400 rev/min
Heavy Duty Agricultural and Industrial 58 kW (78.5 bhp) at 2200 rev/min
Maximum Torque _._ _.. .__ . . 279 Nm (206 Ibf ft) at 1400 rev/min
4.238 Engines
Vehicle ... ... ... ... ... 61 kW (82 bhp) at 2800 rev/min
Maximum Torque _. ._. .__ . 256 Nm (194 Ibf ft) at 1400 rev/min
General Agricultural and Industrial 60 kW (81 bhp at 2600 rev/min
Maximum Torque .__ ... ___ ___ 267 Nm (197 Ibf ft) at 1350 rav/min
Heavy Duty Agricultural and Industrial 54 kW (72 bhp) at 2200 rev/min
Maximum Torque _._ _.. 272 Nm (201 Ibf ft) at 1400 rev/min
4.212 Engines
Agricultural ... . . . . . .. 46 kW (62 bhp) at 2200 rev/min
Maximum Torque ._. .. ... 229 Nm (!69 Ibf ft) at 1350 rev/min
All the above ratings are maximum and can vary according to application.
For details of individual ratings, apply to your nearest Perkins Distributor.
I Engine Weights
1 Typical dry weight . . . 590 lb (269 kg)
1 Typical installed weight ... . . ... 750/900 lb (340/409 kg)
De-Rating for Altitude
Where engines operate at high altitudes they should be de-rated. The following table is given as a general guide to be
applied on a percentage basis. where specific figures for a particular engine rating are not available.
Altitude Maximum fuel delivery de-ratingβ
o- 2.000 feet ( 600 metre) No change
2,000 - 4,000 feet (1200 metre) 6%
4,000 - 6.000 feet (1800 metre) 12%
6,000 - 8.000 feet (2400 metre) 18%
8,000 - 10,000 feet (3000 metre) 24%
10,000 - 12.000 feet (3600 metre) 30%
βMeasured at setting speed given on Pump Setting Code.
Any necessary adjustments in this respect to the fuel pump should be carried out by the C.A.V. dealer for the terrttow
concerned.
For any further information apply to Perkins Engines Ltd., Peterborough, or to Overseas Companies listed on Page 2.
--- Page 7 ---
TECHNICAL DATA-B.1 1
Water Pump (continued)
Inside Dia. of Impeller Bore 0.624910.6257 in (15.87/15.89 mm)
Interference Fit of Impeller on Shaft 0.0005/0.0018 in (0.01/0,05 mm)
Outside Dia. of Impeller . . 3.094/3.096 in (78.58/78.63 mm)
Impeller Blade to Body Clearance . 0.012/0.032 in (0,30/0,81 mm)
Water Pump Seal Type . ... Synthetic Rubber. Carbon Faced
Balance Unit
Note : Later units have needle roller bearings and all CUrrent balance units have reversed weights.
Front Dia. of Shafts (Driving and Driven) 1.2484/l .2490 in (31,71/31,73 mm)
Inside Dia. of Front Balance Frame Bushes 1.251 O/l .2526 in (31.78/31,82 mm )
Running Clearance of Shafts in Bushes 0.002/0.0042 in (0,05/0,11 mm)
Rear Dia. of Shafts (Driving and Driven) . .. 0.998710.9992 in (25.37/25.38 mm)
Inside Dia. of Rear Balance Frame Bushes 1.001/1.0022 in (25.4312546 mm)
Running Clearance of Shafts in Bushes 0.0018/0.0035 in (0.05/0.09 mm)
Shaft Dia. for Ba!ance Weights 1.0622/1.0630 in (26,98/27,00 mm 1
Bore Dia. of Balance Weights ... . 1.0625/l .0637 in (26.99/27.02 mm)
Fit of Balance Weights on Shafts -0.0005/+0.0015 in (-0.01/+0,04 mm)
Spigot Dia. of Earlier Balance Weights . 2.49912.500 in (63,47/63,50 mm)
Recess Dia. in Earlier Balance Weights . .. 2.500/2.501 in (63.50163.53 mm)
Spigot Dia. for Reversed Balance Weights . . .. 1.37411.375 in (34,90/34,93 mm)
Recess Dia. in Reversed Balance Weight Gears 1.375/l ,376 in (34,93/34,95 mm)
Fit of Gear on Balance Weight .. . -0.000/+0.002 in (-O,OO/ +0,05 mm)
Dia. of Earlier Shaft for Lub. Oil Pump Gear . . 0.421 zYO.4235 in (10,71/10.76 mm)
Bore Dia. of Earlier Lub. Oil Pump Drive Gear 0.42510.426 in (10,79/10,82 mm)
Clearance Fit of Earlier Gear on Shaft . . 0.0015/0.0045 in (0.04/0,11 mm)
Dia. of Shaft for Later Lub. Oil Pump Gear . 0.6500/0.6508 in (16.51/16,53 mm)
Bore Dia. of Later Lub. Oil Pump Drive Gear 0.6513/0.6533 in (16,54/16,59 mm)
Clearance Fit of Later Gear on Shaft .. . .. 0.0005/0.0033 in (0,01/0,08 mm)
Depth of Earlier Lub. Oil Pump Body .. ... 0.999/l .002 in- (25,38/25,45 mm )
Depth of Later Lub. Oil Pump Body ... . .. 1.002/l .005 in (25,45/25,53 mm)
Width of Lub. Oil Pump Drive Gears . 0.998/l ,000 in (25,35/25.40 mm)
End Float of Earlier Oil Pump Gears (with joint) 0.003/0.008 in (0,08/0,20 mm )
End Float of Later Oil Pump Gears . . . . .. O.OV2/0.007 in (0,05/0,18 mm)
Shaft Dia. for Lub. Oil Pump Driven Gear .. 0.438210.4386 in (11 .13/l 1 ,14 mm )
Bore Dia. of Lub. Oil Pump Driven Gear .. 0.4394/0.4404 in ( 11 ,16/l 1.19 mm )
Running Clearance of Oil Pump Driven Gear 0.0008/0.0022 in (0.02/0,06 mm)
Hub Dia. for Idler Gear .. 1.498411.4990 in (38.06/38,08 mm)
Bore Dia. of Idler Gear Bush 1.500/l .5016 in (38,l O/38.1 4 mm)
Running Clearance of Idler Gear on Hub . . . . 0.001/0.0032 in (O,OS/O,OS mm)
Idler Gear End Float ___ . . .._ 0.008/0.014 in (0,20/0,36 mm)
Approved Fuel Oil Specifications
United Kingdom . ... B.S.2869 : 1967 - Class Al and A2.
United States ... . ... .. . A.S.T.M/D.975 - 66T - Nos. 1-D or 2-D.
W - F - 8OOa : Grades DF-A, DF-1 or DF-2.
Germany . . . . . . .. . DIN-51601 (1967).
France ... ... .. ... (J.O. 1419157) Gas Oil or Fuel Domestique.
Italy ... . . .. . ... .. CUNA - Gas Oil NC-630-01 (1957).
India .. . . .. IS : 146011968 - Grade Special or Grade A.
Sweden ... .. SIS. 15 54 32 (1969).
Switzerland 1:: :I: ... ... Federal Military Specification 9140-335-1404 (1965).
Fuel oils available in territories other than those listed above which are to an equivalent specification may be used.
Fuel Lift Pump
Type of Pump .. . .. A.C. Delco. V.P. Series
Method of Drive . ... Eccentric on Camshaft
Delivery Pressure-Two Bolt Fixing .._ . . 2Q to 4f Ibf/inβ (0.19IO.30 kgf/cmβ) -19 to 29 kN/mβ
Delivery Pressure- Four Bolt Fixing _.. 6 to 10 Ibf/inβ (0,42/0.70 kgf/cmβ) -41 to 69 kN/m:
Spring Colour Code - Two Bolt Fixing ___ Green
Spring Colour Code - Four Bolt Fixing . ___ Red
--- Page 8 ---
CYLINDER HEAD MAINTENANCE-E.4
Valve Seat Inserts
In the majority of applications, valve seat inserts are
not fitted to production engines, but may be fitted in
service.
However, there are some 4.246 applications in which
exhaust valve seat inserts are fitted in production and
where it is thought necessary, they may be replaced by
new ones.
When fitting inserts to the valve seat, ensure that
genuine Perkins Parts are used and proceed as follows :
follows :
a) For cylinder heads having removable valve guides,
press out existing guide and clean the parent bore.
Press in new guide.
b) For guideless cylinder heads.
Using the appropriate oversize piloted reamer-
0.0115 in (0.38 mm) or 0.030 in (0.76 mm) accord-
ing to the condition of the valve bores in the cylin-
der head-ream out the valve stem bores.
NOTE: Appropriate oversize stem replacement valves
will be needed when this operation has been carried
out on guideless cylinder heads.
Proceed as follows for either type cylinder head, with
or without valve guides:-
Using the new valve bore as a pilot, machine the
recess in the cylinder head face to the dimensions
in Fig. E.8.
Remove all machining swarf and clean the insert
recess. Using the valve bore as a pilot, press the
insert home using the inserting tool (Fig. E.9).
Under no circumstances should the insert be
hammered in, neither should lubrication be used E9
during pressing in.
Inspect to ensure that the insert has been pressed Inlet
fully home and is flush with the bottom of the re- A--f, in (1,59 mm) at 45β
cess. B-2 in (19,05 mm)
Using the valve bore as a pilot, machine the βflareβ
C-O.250 in (6,35 mm)
to the dimensions in Fig. E.lO.
D-3 in (76,20 mm)
E-l .582/l .583 in (40,18/40,21 mm)
t- B I
F-2.009/2.01 9 in (51,03/51,28 mm)
G-l/32 in (0,79 mm) radius
H-& in (1,59 mm) radius
J-& in (1,59 mm) at 45β
K-0.372/0.373 in (9,45/9,47 mm)
Exhaust
A-l/16 in (1,59 mm) at 45c
B-3 in (19,05 mm)
C-O.312 in (7,92 mm)
D-3.0 in (76,20 mm)
E-l .248/l .249 in (31,70/31,72 mm)
F-l .670/l .680 in (43,42/43,67 mm)
G-l/32 in (0,79 mm) radius
H-l/l 6 in (1,59 mm) radius
inlet J-l/16 in (1,59 mm) at 45β
Aq.283/0.288 in (7,19/7,31 mm) K-0.372/0.373 in (9,45/9,47 mm)
B-2.01 6W2.0175 in (51,22/W ,24 mm)
C-Radius 0.015 in (0,38 mm) max.
5. Remove all machining swarf and burrs.
Exhaust 6 Re-cut the valve seat at an included angle of 90β.
so that the valve head depth below the cylinder
A-0.375/0.380 in (9,52/9,65 mm)
head face is within the production limits of 0.0421
B-l .678/l .679 in (42,62/42,64 mm) 0.052 in (1,07/1,32 mm) for exhaust valves and
C-Radius 0.015 in (0,38 mm) max. 0.035/0.045 in (0,89/1,14 mm) for inlet valves.
--- Page 9 ---
CYLINDER BLOCK AND LINERS-G.3
I Oversize Cylinder Liners I oversize to the standard parent bore diameter given or.
1 Oversize outside diameter cylinder liners may be fitted to I Page 8.3. The top of the parent bore must be re-chamfered
after machining. The 0.040 in in oversize liner has a larger
4 236 factory rebuilt engines and are availableforfitment
I ..
tn service where the standard parent bore is enlarged to
I fl ange diameter than the standard liner and if reclaiming a
1 remove damage. ) parent bore with this liner, the flange recess diameter will
have to be increased to 4.24514.250 in (107.82/
1 They are available as follows:-
I 107,95 mm).
Oversize Description
1 0.005 in (0.13 mm) Cast Iron Flangless - bore and hone
1 0.010 in (0.25 mm) Cast Iron Flangeless - bore and hone
Where 0.005 in and 0.010 in oversize liners arefitted, the
0.010 in (0.25 mm) Cast Iron Flanged - bore and hone
I 0.040 in (1.02 mm) Cast Iron Flanged - hone I liner oversize is stamped on the cylinder block top face
I betweenthelinerandtheedgeofthecylinderblock. Where
I Where a parent bore is reclaimed in service, it should be 0.040 in oversize liners are used, the number 1849 is
I machined to the dimension by adding the appropriate liner 1 stamped on the rear end of the block.
--- Page 10 ---
SECTION K
Timing Case and Drive
To Remove the Timing Case Cover
1. Slacken the dynamo or alternator mounting bolts,
remove the adjusting arm and drive bett.
2. Where necessary, remove water pump.
3. Remove the crankshaft pulley.
4. Remove the timing case cover taking care not to
damage the crankshaft front oil seal which is
located in the cover.
To Renew the Crankshaft Front Oil Seal
1. Using a press, remove the oil seal from the timing
case cover.
2. Press the new seal into position from the front.
until the front face is & in (3,17 mm) below the
front face of the cover.
With Massey Ferguson applications, the seal
should be pressed in 0.3810.39 in (0,96/0.99 mm)
below the front face of the cover.
The seal is designed to function correctly with the
direction of rotation of the engine and for identification
purposes the seal is marked with an arrow.
Earlier engines where fitted with a black nitrile seal and
a crankshaft oil thrower.
K2
Current engines have a red silicone seal and the oil thrower
is replaced with a distance piece. Under no circumstances I crankshaft pulley can be used to centralise the cover
should the latest red seal be fitted with an oil thrower. but, as this method utilises the inside diameter of the
I seal and the latest seal is soft, the cover may not be
To Refit the Timing Case Cover I truly central ond leaks may occur.
1. Position the timing case cover on the timing case by
2. Refit the crankshaft pulley with the centre punch
means of two opposite setscrews fitted loosely. Cen-
mark on the pulley aligned with_ the line on the
tralise the cover by locating the centralising tool
front face of the crankshaft (Fig. K.2). Fit the
PD.1 62 on the crankshaft and in the seal housing and
retaining setscrew and washer and tighten to the
tightentheassembJy bymeansofthecrankshatipulley
setscrew and washer - do not overtighten. torque given on Page 8.2.
Tighten all thetiming casecoversetscrewsand remove 3. Bolt the dynamo or alternator adjusting arm to the
the tool. If the centralising tool is not available, the timing case and fit the fan belt.
Kl
--- Page 11 ---
SECTION L
Lubricating System
The importance of correct and clean lubrication cannot through a small bleed hole in each rocker lever and
be stressed too highly and all reference to engine oil lubricates the valves and guides by splash.
should be taken to mean lubricating oil which falls The idler gear and hub are pressure lubricated direct
within the specification given in the appendix. Care nom the pressure rail. Oil enters the rear of the hub
should be taken that the oil chosen is that specified and passes through drillings to lubricate the idler gear
for the climatic conditions under which the engine is bush and gear retaining plate. Where hydraulically
operated. governed pumps are fitted the fuel pump hub is also
pressure lubricated from the pressure rail (Fig. N.12).
Timing gear teeth are splash lubricated by surplus oil
from the front camshaft bearing idler gear hub and fuel
Description pump hub
Pistons, cylinder liners and connecting rod small end
The lubrication is of the forced feed type, the oil being bearings are lubricated by splash and oil mist, also
circulated by a lobed rotor type oil pump driven through the cams and tappets of the valve mechanism.
an idler gear by the crankshaft gear or by a gear type
oil pump driven from the rear of the balance unit
(when fitted). The oil is drawn through a sump strainer The Oil Pump
to the pump. Oil is then pumped to the relief valve The following instructions refer to the lobed rotor