🏷️ Basic Information Identification Make: Clark Product Type: Forklift Truck Model Series: GP138I Covered Models: DCS17I, DCS20I, DCS22I, DCS25I, DCS27I, DCS30I, DPS17I, DPS20I, DPS22I, DPS25I, DPS27I, DPS30I Codes Model Nomenclature Description: Details on how the model designations (DCS/DPS, followed by capacity in hundreds of lbs) are structured. Serial Number Code Description: Information on how to interpret the serial number to identify specific manufacturing dates, options, and configurations. 👋 Introduction Market Position Product Category: Industrial Material Handling Equipment Target User: Forklift Technicians, Maintenance Departments, Equipment Owners Competitive Analysis Competitor Manuals: Equivalent to or exceeding the detail provided in service manuals from competitors like Hyster, Yale, Toyota, and Komatsu for similar capacity forklifts. Key Features Content Scope: Comprehensive coverage of operation, maintenance, and repair, offering a complete resource for technicians. Visual Aids: Inclusion of high-quality images and circuit diagrams enhances understanding and facilitates accurate repairs. Searchability: Searchable PDF format allows for rapid access to specific information, saving valuable diagnostic and repair time. 📋 Manual Details Coverage Areas Primary Focus: Workshop Service and Repair Operational Guidance: Operation, Maintenance, and Repair Page Count Total Pages: 895 Manual Type Type: Factory Workshop Service Manual Language Language: English Format Format: PDF Download File Format File Type: PDF Print Quality Printability: Printable Binding Type Binding: N/A (Digital PDF Download) Paper Type Paper Type: N/A (Digital PDF Download) Searchability Text Search: Searchable Text Illustration Quality Image Quality: High Quality Images 📖 Manual Coverage Systems Covered Engine: Detailed coverage of engine applications and specifications, including maintenance, troubleshooting, and component repair for Mitsubishi 4G54 (2.6L), Continental TM27/TMD27 (2.7L), and Waukesha D176GA (2.9L) diesel engines. Transmission: Comprehensive information on Clark TA18, HR500, and HR600 transaxles, including maintenance, repair, and specifications. Brakes: In-depth coverage of the brake system, including brake and inching control, component repair, and troubleshooting. Steering: Detailed information on the steering system, steer axle, and steering cylinder, including maintenance and repair procedures. Hydraulics: Coverage of the main hydraulic system, including lift speeds, fork drift, tilt cylinders, and component maintenance. Electrical: Extensive coverage of the electrical system, including wiring diagrams, ignition system maintenance and troubleshooting (for all engine types), alternator maintenance (Delco 1 OSI, Motorola 9DM), and starter motor troubleshooting and repair. Chassis And Frame: Information on frame/chassis specifications, truck weights, counterweight weights, and general truck chassis maintenance. Uprights: Specific section dedicated to uprights, covering their construction, maintenance, and potential repair needs. Fuel System: Detailed maintenance and troubleshooting for the fuel system are covered. Procedures Included Maintenance: Planned maintenance schedules, general maintenance procedures, and specific maintenance tasks for engine, fuel system, electrical system, transaxle, brakes, steering, hydraulics, and wheels/tires. Troubleshooting: Detailed troubleshooting guides for key systems, including the electrical system (ignition, starting) and potentially other areas based on the comprehensive nature of a workshop manual. Repair: Step-by-step repair instructions for a wide range of components within the engine, transmission, hydraulics, braking, steering, and electrical systems. This includes rebuild procedures where applicable. Diagnostics: Diagnostic procedures, especially for electrical and hydraulic systems, likely involving checking specifications and component functionality. Safety Protocols: Essential safety information, including safe maintenance practices, safety signs and messages, general precautions, and procedures for machine jacking and blocking. Engine Ignition Conversion: Specific procedure for 'Electronic Ignition Conversion - D176GA Engine' indicates a focus on modernization or repair options. Technical Depth Level Of Detail: High, typical of an original factory workshop manual, with illustrated instructions and circuit diagrams for comprehensive repair and maintenance. Diagnostic Capability: Advanced, with detailed troubleshooting sections for electrical and potentially other complex systems. Component Rebuild: Expected to cover complete rebuild procedures for major components like engines, transmissions, and hydraulic pumps/cylinders. Special Tools: Likely to specify any special tools required for specific maintenance or repair tasks. Wiring Diagrams: Inclusion of electrical system wiring diagrams is a key feature for accurate diagnostics and repair of the electrical system. ⚙️ Engine Specifications Primary Engine Engine Options: Mitsubishi 4G54 [2.6L], Continental TM27/TMD27 [2.7L], Waukesha D176GA [2.9L] Diesel Performance Power Output: Specific horsepower and torque figures are detailed within the manual for each engine variant, crucial for diagnostics and component selection. Fuel System Fuel Type: Diesel Components: Coverage includes fuel injection systems, fuel pumps, filters, and related troubleshooting for each engine. Cooling System System Type: Engine Cooling System Details: Specifications and maintenance for the radiator, coolant, water pump, and thermostat are covered. Ignition System System Type: Diesel Ignition (Glow Plugs) & Electronic Ignition for specific gasoline variants if applicable (though the description focuses on diesel models). Troubleshooting: Specific sections dedicated to ignition system troubleshooting and maintenance for each engine type (4G54, TM27, D176GA). 🔧 Transmission Standard Type: Automatic Transaxle Optional Models Covered: Clark TA18, Clark HR500, Clark HR600 Features Service Procedures: Maintenance, repair, and troubleshooting for these transaxle models are thoroughly detailed. 📐 Dimensions Weights Truck Weights: Detailed specifications for truck weights are provided in the manual. Counterweight Weights: Information on counterweight...