CLARK FORKLIFT C500 (OH-339) OVERHAUL MANUAL

OH-339

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OVERHAUL MANUAL

CUARK 11'1')-,W,U,,S\l.d<T•I llll<rulcd fs(L\l.l.:Jc.>lff, o■h llulk>l,cll•ldialil-■o.

Technical

Publications ��;�ton, KY

INDUSTRIAL TRUCK DIVISION

MARKETING TAAIN"NG DEPT

T A B L E

OF

C O N T E N T S

GROUP

SUBJECT ENGINE OVERHAUL (GAS) • •

ENGINE OVERHAUL (DIESEL) • • • • •

ENGINE OVERHAUL (PERKINS DIESEL).

EXHAUST EMISSION SYSTEM • • • • • CARBURETOR OVERHAUL (BENDIX-ZENITH) LPG SYSTEM MAINTENAM:E

TRANSMISSION OVERHAUL (HYDRATORK) TRANSMISSION OVERHAUL (MANUAL) ENGH£ TEST PROCEDURES STARTER OVERHAUL . • • DISTRIBUTOR MAINTENANCE ALTERNATOR MAINTENA�E ALTERNATOR OVERALL • AXLE END MAINTENANCE • BRAKE MAIITTENANCE • • • NEUTRAL STARTING SWITCH STEER CYLINDER MAINTENANCE HYDRAULIC PUMP OVERHAUL (GEAR) HYDRAULIC PUMP OVERHAUL (VANE} HYDRAULIC VALVE OVERHAUL TILT LOCK VALVE • • • TILT CYLINDER • • • • • • ACCUMULATOR OVERHAUL • • UPRIGHT LIFT CYLINDER OVERHAUL. UPRIGH ROLLER CHECK AND ADJUSTMENT PROCEDURES.

Code: ()-1-339, REV MAY 83

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SECT ION

03 00 04 00 00 12 02TS200A-K 02M200A-02S553A 02 05 02 06 02 08 06TS205A-06M406E 08'1104A-08TS106A 11TSOOOA-11TS0008K 11M103A-11S199C l1M602A-11M6020 12TS100A-12Sl02A 12 03 20M801A-20S801B 23M500HB-23M867G 23M900A-26TS101A 26TS101A-26Sl01A 29 01 29M007 A-30S2028 3CJ,1203A-30TS203A 3OTS3O1A-3OM301D 32 06 32 01 34 01 02 34

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INDUSTRIAL TRUCK DIVISION MARKETING TRAINING DEPT.

F O R EW O R D This overhaul manual has been written to aid the mechanic in the disassembly and assembly of the main components of the specific truck that this manual includes. Every improvement has been made to help the mechanic to discharge his duties in a safe and practical procedure.

This manual has been written in groups and sections with a table of contents for easy reference.

Each section includes many photographs and drawings to directly show how to do these operations.

The mechanic is told to always use Genuine Clark Parts when replacements are needed. "Look alike" parts from other supplies never work as well as the original parts.

Specifications and notes on safety have been included as needed for each step to be done. The mechanic is told to use safety and accuracy in his work because we cannot control his work and procedures.

Code: OH-339, MA R 81 P.S.L.

If the mechanic does not understand the right procedure in the maintenance of this truck, he is told to see his immediate supervisor instead of risking injury of personnel.

Approved methods of service and correct procedures of repair are important for the safe operation of all trucks as well as the safety of personnel and the mechanic doing the work. This manual gives directions for service and repairs with procedures that are tested.

There are many different procedures, tools, and parts for servicing vehicles, as well as in the ability of the mechanic doing the work. This manual cannot be written for all such variations. Any mechanic who works differently from this manual must first make sure that he works safely and accurately.

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INDUSTRIAL TRUCK DIVISION

MARKEllNG TAAlNlNG DEPT.

m

SA F E TY M E S SAG E S

WARNING

WARNING

WARNING

CARBON MONOXIDE

BATTERY SERVICE

INTERNAL C(),18USTION ENGINES GENERATE TOXIC GASES �ICH CAN CAUSE SERIOUS INJURY OR DEATH WHEN !�ALEO. BE SURE THERE IS ENOUGi VENTILATION.

BATTERY SERVICE MUST BE DONE

BY TRAINED PERSONNEL. BATTERY ACID CAN CAUSE SEVERE BURNS AND INJURY.

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WARNING

HYDRAULIC FLUD PRESSURE

WARNING AR PRESSURE

WEAR EYE PROTECTION & PROTECTIVE CLOTHING �EN CLEANING OR DRYING WITH AIR PRESSURE. REDUCE PRESSURE TO [207 kPa] 30 PS I. ll:BR rs REMOVED WITH AIR PRESSURE CAN CAUSE INJURY.

DO NOT USE YOUR HANDS TO CHECK FOR HYORAULIC LEAKAGE. FLUID UNDER PRESSURE CAN PENETRATE YOUR SKIN AND CAUSE SERIOUS INJURY.

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WARNING STEAM

WARNING

FALLING FORKS

DO NOT WALK OR STAND UNDER RAISED FORKS. THE FORKS CAN FALL AND CAUSE INJURY OR DEATH.

DO NOT REMOVE THE RADIATOR CAP vMEN THE RADIATOR IS HOT. STEAM FROM THE RADIATOR WILL CAUSE SEVERE BURNS.

Code: OH-339. MAY 83

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WEAR EYE GLASSES, SAFETY SHOES AND CORRECT FITTING CLOTHING \..HEN WORKING ON LIFT TRUCKS. INJURY CAN RESULT IF YOU DO NOT WEAR PROTECTION.

DO NOT WORK ON THIS TRUCK UNLESS YOU ARE TRAINED AND AUTHORIZED AND KNOW THE CORRECT MAINTENANCE PROCEDURES.

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WARNING

PERSONAL INJURY

LIFT TRUCK MAINTENANCE

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GROUP 00

GROUP 00 SECTION

3 C L A R R

( W A U K E S H A )

D l 5 5 G,

E � G I N E

D l 5 5 GA,

Code: OH-369, MAR 80

D l 7 6 G

O V E R H A U L

(GAS)

Section 3, Pagel ( Cf'7'1.,tlW I.Ila■! l,imJ,,HorCI\RI.: 1b1m ••�I Oo 1a1r1 ,11 o, d�h:.

INDUSTRIAL TRUCK DIVISION

CUSTOMER SERVICES GROUP

TROUBLE SHOOTING ENGINE WILL NOT CRANK

The cause of the trouble is usually in the starting system.

If the trouble is not in the starting system, check for hydrostatic lock or a seized engine, as follows: Remove the spark plugs, and attempt to crank the engine with the starter. If coolant is ejected from the openings it indicates that water is leaking into the cylinders.

Remove the cylinder head and inspect the gasket and head for cracks. Examine the cylinder block for cracks.

ENGINE CRANKS NOR.HALLY, BUT WILL NOT START

Check the fuel supply. If there is sufficient fuel in the tank, the cause of the trouble probably lies in either the ignition or the fuel system.

To determine which system is at fault, perform the following test: Disconnect a spark plug wire, check the spark intensity at the end of the wire by installing a terminal adaptor in end of the wire. Then, hold adaptor approximately 3/16 inch from the cylinder block and crank the engine.

IF THERE IS NO SPARK OR A WEAK SPARK AT THE SPARK PLUGS

The cause of the trouble is in the ignition system.

Disconnect starter relay leads install an auxiliary starter switch between the battery and the starter relay.

To determine if the cause of the trouble is in the primary or the secondary circuit, remove coil high tension lead from the top of the distributor, and hold it approximately 3/16 inch from the cylinder head. With the ignition on, crank the engine and check for a spark.

If the spark at the high tension lead is good, the cause of the trouble is probably in the distributor cap, rotor or spark plug wires.

If there is no spark or a weak spark at the coil high tension lead, the cause of the trouble is probably in the primary circuit, coil to high tension lead, or the coil.

IF THERE IS A GOOD SPARK AT THE SPARK PLUGS

Check the spark plugs. If the spark plugs are not at fault, check the following items:

Section 3, Page 2

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Code: OH-369, MAR 80

0 0

CIARK

GROUP

00

TROUBLE SHOOTING CHOKE Check the choke linkage for binding or damage. Make certain the choke plate closes when the choke knob is pulled out and that the plate opens when the knob is pushed in.

FUEL SUPPLY AT CARBURETOR Disconnect carburetor fuel inlet line .<it the carburetor.

Use a suitable container to catch the fuel. Crank the engine to see if fuel is reaching the carburetor.

If fuel is not reaching the carburetor, check: The fuel pump, the fuel filter, the carburetor fuel inlet line for obstructions; the fuel pump inlet line for a collapsed condition; the fuel tank line for obstructions; the fuel tank vent.

If fuel is reaching the carburetor, check: The fuel inlet system including fuel inlet screen, fuel inlet needle and seat assembly and the float assembly.

ENGINE Mechanical failure in the camshaft drive.

ENGINE STARTS BUT FAILS TO KEEP RUNNING

FUEL SYSTEM Idle fuel needle not properly adjusted, engine idle speed set too low; float setting incorrect; float inlet system not operating properly: dirt or water in the carburetor fuel lines or in the fuel filter; defective fuel pump.

Check for dirt in the carburetor, not allowing fuel to enter or to be discharged from the idle system.

IGNITION SYSTEM Defective spark plugs, breaker points not properly adjusted.

ENGINE RUNS, BUT MISSES

Code: OH-369, MAR 80

Determine if the miss is steady or erratic and at what RPM the miss occurs by operating the engine at various RPM(s) under load.

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Section 3, Page 3

INDUSTRIAL TRUCK DIVISION

CUSTOMER SERVICES GROUP

TROUBLE SHOOT ING M ISS&S STEADILY AI ALL SPEEDS Isolate the miss by operating the engine with one cylinder not firing. This is done by operating the engine with the ignition wire removed from one spark plug at a time until all cylinders have been checked. Ground the spark plug wire removed.

If the engine R?.-1 changes �men a particular cylinder is shorted out, that cylinder was delivering power before being shorted out. If no change in the engine operation is evident, the !Iliss was caused by that cylinder not delivering power before being shorted out. In this case check the: IGNITION SYSTEM If the miss is isolated in a particular cylinder, perform a spark test on the ignition lead of the cylinder. If a good spark does not occur, the trouble is in the secondary circuit of the system. Check the spark plug wire, and the distributor cap. If a good spark occurs, check the spark plug. If the spark plug is not at fault, a mechanical component of the engine is probably at fault.

ENGINE Intake manifold leak (vacuum). Perform a manifold vacuum or a compression test to determine which mechanical component of the engine is at fault.

M ISSES ERRAT ICALLY AT ALL SPEEDS G) !:1::1 0 C 'ti

EXHAUST SYSTE:l Exhaust system restricted.

0 0

IGNIT ION SYSTEM Breaker points not properly adjusted.

Defective breaker points, condenser, secondary wiring, coil or spark plug.

High tension leakage across the coil, rotor or distributor cap.

Defective ignition switch.

Code: OH-369, MAR 80

Section 3, Page 4 l'4")rl�l,1,J \l......i hanokd lor ( L'-llK ,blcn only Do n,11 '-l It ,11 dh,Uha:

CIARK

GROUP 00 TROUBLE SHOOTING FUEL SYSTEM float setting incorrect.

Fuel inlet system not operating properly.

Dirt or water in the fuel lines or carburetor.

Restricted fuel filter.

COOLING SYSTEM Check the cooling system for internal leakage and/or for a condition that prevents the engine from reaching normal operating temperature.

ENGINE Damaged cylinder head gasket.

Perform a compression or manifold vacuum test to determine which mechanical component of the engine is at fault.

MISSES AT IDLE Ot-n.Y FUEL SYSTEM Idle fuel mixture needle not properly adjusted.

Restriction in idle fuel system.

IGNITION SYSTEM Excessive play in distributor shaft.

Worn distributor cam.

Defective coil, rotor, condensor, breaker points, ignition wiring or spark plugs.

E�GINE

Valve clearance (engines with mechanical lifters) or valve adjustment (engines with hydraulic valve lifters) set too tight. Worn camshaft lobe.

Perform a compression test to determine which mechanical component of the engine is at fault.

Code: OH-369, MAR 80

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Section 3, Page 5

INDUSTRIAL TRUCK DIVISION

CUSTOMER SERVICES GROUP

TROUBLE SHOOTING MISSES AT HIGH SPEED ONLY FUEL SYSTEM

Low or erratic fuel pump pressure.

Fuel inlet system not operating properly.

Restricted fuel filter.

Restricted main fuel system.

ENGINE

Perform a compression test to determine which mechanical component of the engine is at fault.

COOLING SYSTEM

Engine overheating.

IGNITION SYSTE.J.f Defective spark plugs.

ROUGH ENGINE IDLE

FUEL SYSTEM Engine idle RP�t set too low.

Idle fuel mixture needle not properly adjusted.

Float setting incorrect.

Air leaks between the carburetor and the manifold, or the manifold and cylinder head, and/or fittings.

Fuel leakage at the carburetor fuel bowl.

Idle fuel system air bleeds or fuel passages restricted.

Leaking fuel pump, lines or fittings.

Section 3, Page 6

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Code: OH-369, MAR 80

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