CLARK FORKLIFT C300 356 (OH-381) OVERHAUL MANUAL

Overhaul Manual

OH 381 C300 356

333 West Vine Street Lexington, KY 40507-1640

INDUSTRIAL TRUCK DIVISION CUSTOMER SERVICES GROUP

T A B L E

GROUP 00 00 00 00 00 00 02 02 02 02 02 02 06 11 11 11 12 12 12 20 23 23 25 26 29 30 31 32 34 40

SECTION

C O N T E N T S

PAGE

OOTS152A-Z OOM552AF, SUPP. A-H OOS152A-B oos152c SUPP. A-L OOS1520 OOS152E-N 02M160A-F 1-5 01 1-16 02 1-11 05, 1-12 06' 1-13 11 03 1-47 11M103A-F 11M6o1A-H 1-20 03 1-9 01 1-20 03 1-9 05 1-10 05 1-6 02 1-9 09 02 1-17 1-13 09 1-16 07 1-15 01 1-4 02 1-9 06 1-52 01 1-7 12

Code: OH-381, SEP 79

0 F

OH-373 PMA-274 OH-373 OH-373 OH-367 OH-381 OH-367 OH-301 OH-372 OH-369 OH-369 OH-224 OH-337 OH-336 OH-372 OH-369 OH-321 OH-224 OH-334 OH-336 OH-377

Engine Overhaul Engine Reassembly Engine Specifications Engine Specifications Engine Specifications Limits And Clearances PCl Carburetor Overhaul IMPCO Carburetor Overhaul IMPCO LPG Fuel System IMPCO LPG Lock-Off Valve IMPCO LPG Vaporizer-Regulator Marvel-Schebler Carburetor Overhaul Hydratork Transmission Overhaul Delco-Remy Cranking Motor Overhaul Delco-Remy Distributor Overhaul Prestolite Distributor CNerhaul Delco-Remy Generator Overhaul Delco-Remy Generator Overhaul Electrical Checks Axle End Overhaul Brake Master Cylinder Overhaul Service Brake Overhaul Char-Lynn Power Steering Gear CNerhaul Power Steering Cylinder Overhaul Vickers Hydraulic Pump CNerhaul Hydraulic Valve CNerhaul Tilt Lock Valve CNerhaul Tilt Cylinder Overhaul Upright Lift Cylinder Overhaul Safety Instructions, General Info.

Copyrighted Material lnt�nded for CLARK dealers only Do not sell or distnbutc

Contents

Brmttl �

MASTER MAINTENANCE MANUAL

Instructions

L-HEAD ENGINES FOUR CYLINDER N56-N62

Y69 - Y91 - Yl 12

F124-F135-F140-F162-F163

SIX CYLINDER F186-F209-F226-F227-F244-F245 M271 -M290-M330-M363 B371 -B427

COURTESY OF:

�'°'TELEDYNE CONTINENTAL MOTORS

TELEDYNE CONTINENTAL MOTORS

Printed in U. S. A.

Form No. X-27053A-Revised 9-71

Copyright 1971

REV SEP 72

QW,;SJhii�mcn3t ln1ended for CLARK deJJers onl, Do nol sell or distnbu1e

mmml �

MASTER· MAINTENANCE MANUAL

TROUBLE SHOOTING A preventive maintenance system including in­ spection. lubrication and adjustment as recom­ mended in our l\Iaintenance Section will prevent the greater portion of gasoline engine troubles.

Failure of a gasoline engine to start is mainly due to two things: ignition trouble or failure in the fuel system.

Operators handling the same engine every day, soon develop a sense of impending trouble when abnormal operation occurs. Immediate attention to these danger signals can prevent major failures, insure dependable operation and increase the life of the engine.

Operators should depend on their well-developed !ienses of feeling. hearing, seeing and smeliing and replace their sense of taste in this type of work with a generous amount of "Common-Sense".

A good rule to follow in locating trouble is to never make more than one adjustment at a time thE'n locate the trouble by a process of elimination.

Remember the cause is usually Simple - rather than mysterious and complicated.

Following are listed some of the normal com­ plaints encountered in routine operation of all gas­ oline engines and the probable causes.

A - STARTING MO T O R - WILL NOT CRANK ENGINE:

1- Weak or dead battery.

2 - Poor grc!!nd connection.

3- Faulty starting switch or relay.

4 - Defective starting motor.

5 - Internal engine seizure - tum engine man­ ually to determine cause.

B - ENGINE CRANKS - BUT DOES NOT START:

Disconnect one spark plug wire, turn ignition on with starter cranking engine and free end of wire •iii '' from cylinder head - note spark.

1-NO SPARK:

(A) - If Ammeter Shows No Discharge - it indicates an open primary circuit due to: 1 - Points not closing.

2 - Open primary wires.

3 - Defrctive ignition switch.

4- Faulty coil.

(B) - Normal Ammeter Reading (2-5 Amps) - this indicates that prima1·y circuit is OK trouble may be in secondary circuit due to:

1 - Broken or grounded high tension wfre from coil to distributor.

2 - Wet high tension wires.

3 - Faulty distributor cap or rotor. .1 - Broken secondary winding of coil.

(C) - Excessive Ammeter Reading (over 5 Amps) - indicates a "short" in the primary winding which may be due to: 1 - Shorted or grounded primary winding.

2 - Distributor or magneto points not opening.

3 - Grounded breaker point arm.

4 - Defective condenser.

2-WEAK SPA'.K-may

(A)

(B) (C) (D) (E) (F)

be caused by: Loose ignition wiring connections.

Burned or pitted distributor points.

Wet spark plug wires.

Defective condenser.

Cracked distributor cap.

Weak ignition coil.

3 - GOOD SPARK AT EACH PLUG-indica le>.::

that ignition system is OK and trouble is in fnE>I system - which may be due to:

(A) No Gas in Carburetor - which may he due to: 1- No gas in tank.

2 - Clogged filter or lines.

3 - Faulty fuel pump.

4 - Leaky fuel line from tank.

5 - Plugged vent in fuel tank cap.

(B) Gas in Carburetor - which m a r be flooded due to: 1 - Too much choking - plugs are wet.

2 - Wrong float level.

3 - Choke not operating conectlr.

4 - Water in Gas. Copyristit-.V "'Sf:fl'1 72

Fl 00TS 152 rntendcd for CL-ARK dealers only Do nol sell or disuibut�

MASTER MAINTENANCE MANUAL C - ENGINE RUNS WITH CONTINUOUS MIS-FIR• ING: Due to: 1- Uneven compression.

2 - Wet or deteriorated high tension wires.

3 - Cracked distributor cap.

4 - Faulty spark plugs-if spark plug por­ celain is white when removed, use Colder plug - if light brown OK - if Black or oily use Hotter plug.

6- Defective Spark Plugs.

F - LACK OF POWER - which may be due to: 1- Poor Compression.

2 - Wrong Timing.

3- Throttle contrnl not opening fully.

4 - Air leak in fuel system.

5 - Restriction in air cleaner - should have vacuum less than 10" water.

6- Exhaust line obstructed - should have back pressure of not more than 20" water.

7 - Poor fuel.

8 - Piston rings sticking or worn.

D - ENGINE RUNS UNEVENLY 1- At Idling Speed-which may be due to: (A) Too wide spark plug gaps.

(B) Poor Carburetor idle adjustment.

(C) Wrong float level.

(D) Carburetor or intake manifold air leaks.

(E) Leaky cylinder head gasket.

2 - At High Speed - which may be due to:

G - POOR COMPRESSION-eheck with compres­ sion gauge - if irregular, seal the piston with a teaspoonful of engine oil poured through the spark plug hole, and take a second reading; if pressure does not increase this will indicate that poor seating of valves are at fault.

Poor compression may be due to:

(A) Wide breaker points.

(B) Weak distributor breaker arm spring (C) Weak valve springs.

(D) Spark plug of wrong type or incor­ rect gap.

1- Valves holding open - no tappet clearance.

2 - Leaky cylinder head gasket.

3- Broken or weak valve springs.

4 - Burned or sticking valves.

5 - Badly worn, broken or stuck piston rings.

6- Wrong valve timing.

E - ENGINE RUNS IMPROPERLY 1 - Back-Firing into Manifold - indicates Too Rich a fuel mixture; into carburetor in­ dicates Too Lean a mixture-may be due to: (A) Late Ignition Timing.

(B) Clogged Air Cleaner.

(C) Fuel line restrictions.

(D) Clogged carburetor jets.

(E) Sticking Valves.

(F) Weak or broken valve springs.

2 - Excessive Ping (Detonation)-Results in damaged pistons and bearings and is caused by pre-ignition o r using inferior grade of gas.

3- Engine Idles Too Fast - indicates imp proper throttle adjustment or weak throttle return springs.

4 - Engine Dies When Idling - which in­ dicates incorrect speed or mixture adjust­ ment; clogged idling circuit in carburetor or wrohg choke adjustment, or air leaks in intake manifold.

5 - Engine "Stumbles" on Acceleration which may be due to defective accelerator pump or air in fuel lines.

H -OVERHEATING 1- Lack of watei: in radiator.

2 - Fan belts slipping.

3 - Thermostat sticking or inoperative.

4 - Radiator clogged or leaky.

5 - Late ignition timing.

6- Back pressure in exhaust line.

7 - Defective water pump.

8 - Overloading of engine.

I - LOW OIL PRESSURE

lntend��:;��tJ},?eirrs only a

Do nol sell or disuibut�

1- Low Oil level.

2 - Oil pressure gauge or line faulty.

3- Oil too light- diluted.

4 - Suction screen plugged.

5 - Dirt in relief valve or broken spring.

6- Worn bearings.

7 - Worn or damaged oil pump gears.

8 - Worn Cam Bushings.

REV SE p ?2

rmmm.D �

INDUSTRIAL TRUCK DIVISION SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK

r:rrmT!1 �

WORK SAFELY DRIVE SAFELY BE CAREFUL

ALWAYS GIVE MACHINE SERIAL NUMBER WHEN ORDERING PARTS

Cop�nahted MilteQal

Rev OCT �nd.!d forCL.\1lVJe51ersonl} Do not sell or distribute

MASTER MAINTENANCE MANUAL

More thon conventional number of studs to rc;.·w;;t ;•>��t f.ih.;r·c;, dinO.f.oii of c,1ir.dsi born and valv• Mtals

,.

Lubri<.tion to piston pins

Cylinder head gasket Chroma top ri�s

v.Jv. seat N'ls.rts

. �.

Full length water jackets - Exhaust Ylfves Piston Valve guides r:uU p,essure lubncetion to all main, conne(l. ing rod and cam bearings, as well os uppen and timing gears

+---------Valve ip!ings

Spurt hole for lubrication of thrusl side of cyGnder walls, piston pins, and cooling of piston head

Camshaft

Moin and connecting rod bearings

Dipstick Submerged gtlT type oil pump dnven off camshofl

figure / - Cross Section of a Typical Continental ••L i; Head Engine OOM�ted Materi�EV SEP lntcnd�d for CLARK dcJlcrs onh Do n<>1 ,di or di-tnbuk

72

MASTER MAINTENANCE MANUAL

GENERAL INFORMATION L-Head engines have inherent design advan­ tagei; which result in a more simple engine of lower height. weight and cost. All valves, cams, valve lifters and all other moving parts are a part of the cylinder block assembly.

The cross-section of an L-Head engine resem­ bles the letter "L" written upside down and en­ gines with this type of combustion chamber are also called side-valve engines.

Intake and exhaust valves are located in the side pocket and both are directly operated through tap­ pets from a single camshaft. This provides a sim­ ple and heavy duty valve gear, since there is no deflection.

Figure

2 - L-head design

CONTINENTAL L-HEAD ENGINES Continental has eight basic four-cylinder and ten six-cylinder L-Head type engines, ranging in size from 56 to 427 cubic inch displacement.

The combustion chamber design has been tai­ lored for the required turbulence, charge flow and burning characteristics to provide dependable and economical heavy duty service.

Some of the principal design features are: 1. Individual Porting - of the intake manifold whereby each cylinder is fed with the fuel-air mixture individually and not influenced by other cylinders of the engine.

This is accomplished by casting the cylinder block with individual intake valve passages for each cylinder and connecting these passages to an intake manifold which also has individualized pas­ sages for each cylinder.

Figure 3 This equal d i stribution results in maximum power, smooth operation, easy starting and longer engine life. qi/ ��le�p 2 OOM 1 l"ntended c; 2 B Copyrighl for CLARl<.'de3ic'rs onY7 Do not sell or disuibul�

y

- Individual

Porting

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MASTER MAI NTENANCE MANUAL

2. Directional Cooling - is accomplished by regu­ lating the course of the cool water from the water pump so it first comes in contact with exhaust valve seats and then to other points as indicated by their relative temperatures.

This feature promotes uniform cooling through­ out the system, prevents hot-spots and prolongs valve life.

This coupled with the by-pass and thermostat included in the engine assembly, insures rapid warm-up and even temperature distribution.

Figure

4 - Directional

Cooling in Block

3. Full Length Water Jackets - completely sur­ round all cylinder bores the ful l length of the piston travel.

This insures uniform cooling with minimum bore distortion - which results in lower oil consump­ tion ; less b low-by and minimum tendency to sludge.

4. Removable Tappets -The larg�, barrel shaped, pressure lubricated tappets are so designed that by removing the adjusting screw - the main body can be lifted out and replaced from above through the valve chamber. This e liminates the costly serv­ ice operation of dropping the oil pan and pulling the camshaft. Locking of the adj ustment is both simple and effective.

5, Choice of Fuels - Gasoline - LPG - Natural Gas - Fuel Oil - Continental L-Head engines have been tailored for heavy-duty operation using gasoline LPG - natural gas - fuel oil fuels.

Copyrigh(yf!IM1t9'2't 0 Intended for CLA'l!. 1< dealers only Do nol sell or distnbute

Figure

5 - Full Length Water Jackets

Figure

REV SEP 72

6 - Removable

Tappets

MASTER MAI NTENANCE MANUAL

INFORMATION FOR ORDERING P•RTS When ordering parts, refer to the engine name plate attached to side of the cylinder block, which lists the model and serial number. In most cases a specification number is listed. This data is of vital impor­ tance in obtaining the correct parts : always include this information on your parts order.

NEW STYLE NAMEP LATE

Serial No.

s

p E c.

Tappet Clearance- Exhaust Oil C rade-\\'inter

OL D STYLE NAMEPLATE

\ )ii \ ; r:Hle-. um mer

F i gu r e 7 -- Namep l a te (New S ty l e and O l d Sty l e )

OOM 1 52 D

Copy,ilMi,\4 t-5.&Pat 72

Intended for CLARK dealers onl� Do nol sell or distribute