CLARK FORKLIFT C500 915 (OH-544) OVERHAUL MANUAL

OH-544 csoo 915 (Perkins Gas)

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CUARK

Copyrighted Matenol

Intended for CLARK dealers only

Do not sell or distribute

Technical Publications Lexington, KY 40508

GROUP

OH

I N D E X ASSEMBLY

GROUP

Engine

Code:

00

SECTION

�

02

1 - 49

10

- 9

Carburetor (IHPCO/LPG)

02

Transmission (Hydr.:itork)

26H206A - 06S206A

Starter (De 1 co-Remy)

11M103A - 11M103F

Distributor

1l

05

1 - 8

Alternator (Delco-Remy) A1ternator (Motorola) Drive Ax le (Clark)

12 12 20

03 04 06

1 - 20 1 - 21 1 - 7

Hydrovac (Bendix)

23HS03P - 23M503T

Master Cylinder (Wagner)

23

02

1 - 6

Brake Assembly (CI ark)

23

1,

- 7

Steer Gear (Saginaw)

25

05

1

Steer Cylinder (Hydrau I ic Prod.)

26

09

1 - 13

Steer Pump (Hydreco)

29

01

1 -

Hydrau 1 i c Pump (Hydreco)

29

13

- 3

Ti It Cy 1 inder (Clark)

32

09

- 4

Lift Cylinder (Clark)

34

01

- 52

OH-544, NOV !36

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15

7

INDEX

GROUP

OH

FOREWO RD OVERHAUL MANUAL This handbook provides the basic step-by-step procedures which should be followed in making a bench overhaul of various assemblies used on the vehicle. Each section includes al 1 relevant illustrative material available, from exploded view through photos and drawings to cross­ section views of assembled parts, when necessary.

Trouble shooting is located at the front of each section, and specifications and other useful information are added at the end of each section. Each section is self­ contained (or modular), with consecutive page numbers and publication date at the bottom of al 1 pages included therein.

Where possible, general instructions are presented as applicable to a family of assemblies. Any necessary variations in specifications are given in column form with a CLARK part number on each 1 ine. Refer to your Product Identification Card to verify applications.

There may be several sections in some parts groups. For example, GROUP 16 may cover a drive motor in Section 1, a hydraulic pump motor in Section 2 and a steering pump motor in Section 3 in an Overhaul Handbook for an electric truck; or, for a gasoline engine truck, Group 12 may have a voltage regulator in one section, a generator in another, or an alternator with a built-in voltage regulator. Refer to your Table of Contents for proper Group and Section numbers.

The basic group in which a section appears bears the same group number as Service Parts Books list for most assem­ blies. In some cases, however, an overhaul procedure will mention a sub-assembly from another parts grouping simply because it would be impractical to attempt to overhaul the sub-assembly. For example, a motor brake must be dis­ assembled to get the drive motor disassembled on several electr1c trucks; and on most trucks with drive axles (GROUP 20), it is usually necessary to deal with certain brake assembly parts (GROUP 23), when overhauling the axle assembly. Any overlapping is intended to be helpful, rather than confusing. Refer to your CLARK dealer's Service Parts Book for correct part numbers when ordering parts or assemblies.

Code: OH-321, REV OCT 77

Copyrighted Ma1erial Intended for CLARK dealers only Do nol sell or dislribut�

Foreword

GROUP

00

GROUP 00 SECTION

02

(3.86 L) GAS/LPG ENGINE OVERHAUL

IMPORTANT

BEFORE REMOVING ANY COMPONENTS FOR OVERHAUL, MAKE SURE THE CORRECT REPAIR PARTS, SEALS ANO GASKET SETS ARE AVAILABLE.

Code: OH-539, NOV 85

Copyrighted Material Intended for CLARK dealers on!)

Do not sell or distribute

GROUP 00, Section 02, Page 1

CL'IRK

GROUP

00

CONTENTS PAGE

DESCRIPTION

Cylinder Head Removal•..•.••.....•.•...•.......•........•...3 Cylinder Head Disassembly•••....••........•..........••..•..3 Cylinder Head Assembly....••..•.•..•....•.••................ 6 Cylinder Head Installation ...•••••........•..........•••.... ?

Gear Cover And Gear Removal.••.••.•..•...................... 9 Gear Cover Parts lnspection.....•....................•.....13 Gear Cover Installation...•....•..••.•..................... 14 Water Pump Removal••.•.•.•.•.............•.............•.•.17 Water Pump Installation..•.•........................•...•..18 Flywheel Housing Removal................................... 19 Flywheel Housing Installation....•...•..................... 20 Camshaft Removal .•.•.•....•...........................•.••. 21 Camshaft Installation•.•......••.•.•................•...•.. 22 Oil Pan And Balancer Removal....••..•............•.....••.. 23 Oil Pan And Balancer Installation..........................25 Crankshaft And Piston Removal .•...•..•...•.......•...•..... 27 Crankshaft And Piston Installation......................... 30 Basic Engine Data

General ...................•.•..................•..... 33 Valves................•..•..••...............•.......33 Camshaft............................................. 34 Connecting Rod.....•••..•.•.....•..•..•.•.•....•..•.•34 Crankcase............•...••.•........................34

Crankshaft...........................................34

Piston And Pin................................•......35 Camshaft Gear...••.•.•.••.•••...•...•.••.•..•..••....35 Distributor Drive Gear.•..•••••.••.••..•••.•••••..••.35 Idler Gear.•••..•.•..••..••••........•.•••••.•••..•.•35 Crankshaft Gear ..........................•...•.•.....35 Hydraulic Pump Drive Gear.•••..••..•.•..••.••••••.•.•35 Backlash....•....•.••.•...•••••••..••...•..•.•.•..•••35 Plates Engine Gasket Sets....•...•••••••.....•.......••...•.36 Engine Subassembly (Cooling) ••••..••.••.•...•••...•.•37 Crankshaft ••...•...•.•..•••••..•••..•.••••...•••..•.•38 Balancer•.•........•••••••••••.••.•••..•.•..••••••••.39 Engine Subassembly (Balancer) ........................40 Flywheel Housing......•••••• .,., •••........••••...•.•..41 Front End Cover.....••..••••••..•....•...•.....•...•• 42 Crankcase Head..•••.•.•••••••..•...•.....•.•.•.•..••.43 Crankcase........•..•.....••••.••.••••..••.•••••••••.44 Camshaft.....•......••..•.•••...••...•..••..•..•..... 45 Oilpan.•...........•.•.••.•••..•.••• r••··············46 Water Pump Assembly.......••••••••.•••••.••••••••••••47 Manifolds•...•....•..•....••••..••.•...••••..••.••...48 Fuel Pump ..•.•...........••••..•••.•..•.•..•.•••....• 49

GROUP 00, Section 02, Page 2

Cop)1ighted Material Intended for CLARK dcak'!'S only Do not sell or distribute

Code� OH-539, NOV 85

GROUP

00

CYLINDER HEAD REMOVAL: 1. Drain water from cylinder block and head.

2. Remove hose connections to water pump.

3. Remove hose assembly between carbur­ tor and air cleaner (air inlet hose).

4. Remove spark plug cables.

5.

11. Remove carburetor.

12. Remove intake manifold and exhaust manifold and gaskets.

13. Remove cylinder head rear end plate and gasket.

14. Remove oil cap.

15. Remove thermostat housing and gas­ ket.

Remove spark plugs.

6. Remove fuel line from fuel pump to carburetor.

16. Remove rocker arm cover and gas­ ket.

7. Remove crankcase ventilation hose.

17. Remove rocker arm assembly.

8. Remove choke connection at the car­ buretor.

18. Remove crankcase head gasket.

9. Remove throttle linkage at the car­ buretor.

19. Remove push rods.

·10. Remove engine oil pressure gauge manifold �racket.

CYLINDER HEAD DISASSEMBLY: 1. Use a valve spring compression tool to compress the valve spring and remove two half-conical collets (seat locks).

2. Remove valve spring seat, valve seal, inner and outer springs, and valve spring pilot.

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3. Remove valves (note that valves are numbered).

IMPORTANT

G

KEEP REMOVED PARTS IN PROPER ORDER TO MAKE SURE SAME ASSEMBLY OF PARTS WILL OCCUR. 4. Inspect springs for fatigue damage, cor­ rosion, cracks or pitted surfaces. Make sure ends are square.

Code: OH-539, NOV 85

Copyrighted Material Intended for CLARK dealers onl)' Do not sell or distribute

@ � .:@�

� 0 (1,\Jr!m!!D =J==O f)

25766

GROUP 00, Section 02, Page 3

GROUP

00

5. Clean all parts to remove dirt, oil and carbon. Blow out all oil passages to remove foreign material.

NOTE: Before cleaning cylinder head check it for cracks, water leaks, or any other evidence of damage. If damaged, it must be repaired or replaced.

6. Inspect cylinder head mounting surface for flatness using a straight-edge and feeler gauge.

Measure length-wise and cross-wise. Surface must be flat within (0,15 nm) 0.006 in. length-wise and within (0,08 mm) 0.003 in. cross-wise.

If surface is outside this limit, it must be corrected.

7. Inspect rocker arm cover for cracks, dents or other damage.

85M095

8. Examine hoses for damage by abrasion, cuts, excessive heat, cracking, plugged with debris or other damage that would impair the operation. Replace all dam­ aged hoses.

9. Insect manifolds for cracks, corrosion or other damage. Inspect flatness of mounting surface with straight-edge and feeler gauge.

If it measures more than (0,15 nm) 0.006 in. it must be corrected.

25818

85M064

GROUP 00, Section 02, Page 4

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Code: OH-539, NOV 85

GKOUP

00

10. Check the fit of valve stems in bore. if worn, replace with new valves having oversized stems available as (0,08, 0,38, and 0,76 mm) 0.003, 0.015, and 0.030 in. oversize.

NOTE:

NOTE:

If oversized stems are used, be sure to also use correct size oversized seals.

If oversize stems are used, pilot bores in head must be reamed with piloted reamer to give (0,10 rrrn) 0.004 in. clearance.

11. Inspect valve seats for damage (burnt or eroded areas) or for corrosion or carbon build-up on surfaces.

If damaged, valve seat faces must be refaced.

Reface seat to dimensions and limits shown in tables.

!-

44'

0•081 HI 12.0&....) MAX.

"

' 0-04S,n

.,.JMU. (1.14 • 4e• I

25765 12. The exhaust valve has a removable seat.

The preferred method of seat removal is by use of a valve seat insert puller. If one is not available, seat can be removed by following method: a). Grind a scrap valve to fit inside of seat. b). Weld a scrap valve to seat in three places. Use old head gasket to protect head surface when welding.

Be careful not to weld on head. c). Use a soft-faced.hammer to strike valve stem end, driving valve and seat out of head. d). Remove all burrs and foreign matter from counterbore.

85Ml71

j

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85Ml73

Code: OH-539, NOV 85

Copynsh1cd l\fa1cnal lnlcndcd for CLARK de�lers only Do nol sell or di,,tribulc

GROUP 00, Section 02, Page 5

GROUP

00

13. Inspect counterbore to measurements shown. If not to size, use valve bore as pilot and machine to correct dimensions.

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b.l'lallSI � 375/0 310 in (9 S219 U mmJ 8-1 671/1 679 tn !•2.f.2/412 &4 mm, C-R•o1uso01s1n tO31mm1 m11.

A.....02&3/0.291,n (7,1tfl.31 mml 8-2 016S/2.011'S � (51.22/51,24 mmt C-flaOKit O01 S 1n 10,311 rnml ma.1

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14. Press insert in place using an insertion tool as shown.

NOTE:

25828

A.-r't 11'1 11,H ftWII Mu• ...... 11'1111,Gll'MII C,-4ZXI � Cl.»-1 D--3 "' (71.a -· E-1 ,a/1 Y3 _,. (A0.11/40.11 _, ,-1oa1,ao1t .. 1s1.w11,2t '"'"'' 0-11» • 10..n-1

'"°'""

Do not "hammer" insert into position.

Do not use lubricant on bore or on insert.

,,._n •� ".,. _, ,.-w �•,111(1,M-1 .. .e.s·

lt-0 SWO l1l 11'1 ftUlt•1 -1

.,_, "-"''"" ,,.s-......

1 .. -s• 9-f Ill Clt,05 ,.,., C-0.)12 tt'1 (1.ft _, o-JO 11'1 Ht,0-1 (-1 h1JU4 .,_ flt,1'0/1',72 �""l 111--1 f701f -.,. IU.W4l.t1 _, 0-11».., to..n-1,.,..,.._ ,._,,,,'" 11.se-, �-... ,;.....1/IIMIIM-J•US" IC-0 J1V0 11'),. 11,tVI 47 11¥11

L.

25826 16. Inspect rocker arm assembly for damaged parts. Inspect rocker arms for excessive wear or distortion. Check rocker arm springs for damage. Examine wear surface of rocker arm tips for damage.

Replace all damaged parts. If necessary to disassemble rocker arm assembly, be sure to keep removed parts in proper order of re­ moval for correct assembly.

Inspect oil passages making sure they are free of foreign matter.

25819

CYLINDER HEAD ASSEMBLY: 1. Clean all parts thoroughly and apply a light layer of engine oil to all parts.

2. Use a valve spring compression tool to compress valve springs when installing valve spring retainer and locks (ha1f­ conical collets).

GROUP 00, Section 02, Page 6

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25767

Code: OH-539� NOV 85