CLARK FORKLIFT C500 (OH-370) OVERHAUL MANUAL

OH-370 CSOO SERIES

CUARK

Copyn�ht.oo M.1.1,'TUJ lntcnd�-d forCLI\RK dealer. only Uo not ,el I or distnbul�

Technical Pu�Hcations Lexington, KY 40508

INDUSTRIAL TRUCK DIVISION SERVICE ENGINEERING DEPARTMENT, 8.ATTLE CREEK

OVERHAUL HANDBOOK for CLARKLIFT CSOO SERIES [3,000 THRU 5,000 Kg. RATED CAPACITY] 6,000 THRU 10,000 LB RATED CAPACITY

Book No. OH-370 (T) 3rd REVISION

CLARK EQUIPMENT COMPANY PUBLISHED BY CUSTOMER SERVICES ENGINEERING DEPARTMENT BATTlE CREEK, MICHIGAN, U.S.A. C"1',n1,1htcJ MJl•'rul lntcnJeJ t« tL\R"- dc:ilcn onh U<1 not 1ell or d111nbwc

INDUSTRIAL TRUCK DIVISION NOTES

1146-Z

REV OCT 72

(op}nih100 /11.11cnal lnt<ndcJ h,.- CL.\ RK lkal�n- onh 1 i., fk11 :,ell 01 dwnhut�

CIARK

INDUSlRIAL ll�UCK DIVISION

MARKETING TRAINING DEPT

OWNER SAFE MAINTENANCE PRACTICES Powered industrial trucks may become hazardous if adequate maintenance is not done. Therefore, maintenance facilities, personnel and procedures must be provided.

Maintenance and inspection of all powered industrial trucks should be done in agreement with the recOOllllenda­ tion in this manual and the following practices.

1.

Only qualified and authorized personnel should be permitted to maintain, repair, adjust, and inspect industrial trucks.

3.

Before Leaving The Truck:

4.

A.

Stop Truck.

B.

Fully lower the load engaging means.

C.

Put directional controls in neutral.

Use blocks or other positive truck positioning devices.

C.

Put blocks under the load engaging means, innermast(s), or chassis before working under them.

Before working on engine fuel system of gasoline powered trucks with gravity feed fuel systems, make sure fuel shutoff valve is closed.

A scheduled preventive maintenance, lubrication, and inspection system must be followed.

2.

B.

Before working on engine fuel system of LP gas powered trucks, close LP gas cylinder valve and run engine until there is no more fuel in the system and engine stops running .

Operation to check performance of the truck or attachments must be done in a clear, authorized, safe area.

5.

Before Starting To Operate The Truck A.

Be in operating position.

B.

Push clutch (or brake pedal on automatic transmission and electric trucks) .

D.

Apply the parking bralee •

E.

Stop the engine or turn off power.

C.

F.

Lock the control or ignition circuit.

Put. the directional controls in neutral.

D.

Start engine or turn on power.

G.

Put blocks at the wheels if truck is on a ramp, or being worked on.

E.

Before operating truck, check functioning of lift and tilt systems, directional and speed controls, steering, warning devices, brakes, and any attachment. (If used)

F.

Release parking brake.

Before Working A.

On

Truck:

Raise wheels free of floor or disconnect power source.

- continued 1023-Z C�\!ht.SERk� (FRONT) Intended for CLARK d;:alcnonly Do not sell or d1>tnbuti,

INDUSTRIAL TRUCK DIVISION

MARKETING TRAINING DEPT.

OWNER SAFE MAINTENANCE PRACTICES (CONT.) 6.

Avoid fire hazards and have fire protect ion equipment available.

Do not use an open flame to check level, or for leakage, of fuel, electrolyte or coolant. Do not use open pans of fuel or flaunnable cleaning fluids for cleaning parts.

7.

Provide ventilation to the work area, vent exhaust fumes, and keep shop clean and floor dry.

8.

Handle LP gas cylinders with care.

Do not drop, dent, or damage in any way.

9.

Brakes, steering mechanisms, con­ trol mechanisms, warning devices, lights, governors, lift overload devices, guards and safety devices must be inspected regularly and maintained in a safe operating condition.

10. All parts of lift and tilt mechan­ isms and frame members must be carefully and regularly inspected and maintained in a safe operating condition.

11. Special trucks or devices designed and approved for hazardous area operation must receive special attention to make sure that maint­ enance keeps the original, approved safe operating features.

12. Fuel systems must be checked for leaks and condition of parts.

Extra special consideration must be given in the case of a leak in the fuel system. Action must be taken to prevent the use of the truck until the leak has been corrected.

13. All hydraulic systems must be regularly inspected and maintained in conformance with good practice.

Tilt cylinders, valves, and other like parts must be checked to make sure that "drift" has not devel­ oped to the extent that it would create a hazard.

14. Capacity, operation and maintenance instruct ions plates, tags , or decals must be maintained in legible condition.

15. Batteries, motors, controllers, limit switches, prot ective devices, electrical conductors and connect ions must be inspected and maintained in conformance with good practice. Special attention must be paid to the condition of elec­ trical insulation.

16. Industrial trucks must be kept in a clean condition t o minimize fire hazards and help in the detection of loose or defective parts.

17. Modifications and additions which affect capacity and safe truck operation must not be done by the customer or user without manufacturers prior written ap­ proval. Capacity, operation and maintenance instruction plates, tags or decals must be changed accordingly.

18. Care must be taken to make sure that all replacement parts are interchangeable with the original parts and of a quality equal to that provided in the original equipment .

1023-7.

R�''"d� �\f11na�BACK) "1ntc&ti:'ct YNebfR.lt1Jc'..tlc� oiily Do not MJll or dutnbute

INDUSTRIAL TRUCK DIVISION MARKETING TRAINING DEPT.

C500-60/70/80/S90/S100 SERIES OVERHAUL CONTENTS Section/Page No's

Description

GROUP 00

OOMOOO OOTS152 OOM152 00S152

A-C A-D A-AF A-K

Engine Engine Engine Engine

GROUP 01

OlMOOl

A-H

Water Pump

GROUP 02

02M100 02M100 02M160 02M166 02TS200 02M200 02M252 02M253 02M254 02M257 02M500 02S500 02M551 02S551 02M553 02S553 02M554 02S554 02M999 05 06 08 11

A-CU CV-DA A-F A-F A-K A-BX A A-B A-B A-B A-C A A-D A A-D A A-C A A-D 1-11 1-12 1-10 1-13

Carburetor - Standard Gas Type; Bendix 67 Series Carburetor - Standard Gas Type; Bendix 68 Series Carburetor - LP Gas; PCl Pressure Carburetor Carbu retor - LP Gas; PC2 Pressure Carburetor Exhaust Emission System - Troubleshooting Exhaust Emission System - Bendix/Teledyne Fuel Pump - AC Fuel Pump - Ai rtex Fuel Pump - AC Fuel Pump - Airtex LP Gas Systems - Bendix - Fundamentals LP Gas Systerns - Specifications LP Gas Systems - Bendix - Vaporizer/Regulators A965 LP Gas Systems - Specifications LP Gas Systems - Bendix - Vaporizer/Regulators A962 LP Gas Systems - Specifications LP Gas Systems - J & S Vaporizer LP Gas Systems - Specifications Oxy-Catalyst Exhaust System Impco LPG Lock-Off Va 1 ve Impco LPG Vaporizer - Regulator Impco LPG Carburetor Marvel-Schebler GLE Carburetor

GROUP 06

06TS205 06M205 06S205 06M206 06S206

A-D A-P A A-AW A

Troubleshooting - l Speed Hydratork Transmission 1 Speed Hydratork Overhaul Procedures Specifications 2 Speed Hydratork Troubleshooting & Overhaul Specifications

GROUP 08

08TS106 08M106 08S106

A A-X A

Troubleshooting - Power Assist Clutch R211T Standard Shift Transmission Overhaul Specifications

GROUP 11

llTSOOO 11M103 11S199 11M602 11S052

A-BK A-F A-C A-D A-C

SUN 11 Troubleshooting Starting Motor Specifications Distributor Specifications

Code: OH-370 {T), REV JUN 83

-- Continental -- Troubleshooting - Overhaul Procedures -- Specifications; Limits & Clearance Data

11

C.opyri�hloo Mn<Yi;il Intended for CLARK tlc:ilc« only Oo not sell or tltstnbute

Contents, Page 1

INDUSTRIAL TRUCK DIVISION

MARl<ETING TRAINING DEPT.

Section/Page No 1 s 1-9 1-10 1-19

Description Alternator/Generator Voltage Regulator Alternator

GROUP 12

01 02 03

GROUP 20

06 19 20

1- 7 1-7 1-8

Axle Ends - Cla rkl ift Differential Overhaul-2 Piece Case and Four Pinion Differential Overhaul-! Piece Case and Two Pinion

GROUP 22

01

1-14

Wheels & Tires (Drive)

GROUP 23

02 03 23M503 23M800 11

1-6 1-7 A-AA AA 1-7

Inching Master Cylinder Brake Master Cylinder Overhaul Power Brakes - Hydrovac Parking Brake Disc Type Wheel Brakes

GROUP 25

25M503

A-B

Steering Gear

GROUP 26

26TS053 26M053 26TS201 26M201 26Ml01 26S101

A A-B A A-C A-K A

Troubleshooting - Steer Cylinder {Vickers) Steer Cylinder Overhaul Troubleshooting - Steer Cylinder Valve (Vickers) Steer Cylinder Valve Overhaul Power Steering Cylinder (HPD) Specifications

GROUP 29

01

1-12

t-'ain Hydraulic & Steering Pumps

GROUP 30

01

1-3

GROUP 31

02

1-4

Tilt Lock Valve

GROUP 32

01 06

1-6 1-11

Accumulator Charging Procedures Tilt Cylinder Overhau.l Procedures

GROUP 34

01

1-52

Lift Cylinder Overhaul Procedures

GROUP 40

01 04

1-3 1-15

Machine Seria 1 & Deck tiirnber � ta Lubrication Specifications

1125-Z 1139-Z.1 1139-Z.2

Elevating Drive Wheels Retractable Overhead Guard Retractable Overhead Guard

Contents, Page 2

Lift & Tilt Control Valve

C.op)righicJ M::itcri.il

I ntcrukd for CLARK denim ,,nl� Do not M:11 or dulnbulc

Code: OH-370(T), REV JUN 83

INDUSTRIAL TRUCK DIVISION

MARKETING TRAINING DEPT.

F O R E W 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. MAR 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.

C.op)righicJ M::itcri.il

I ntcrukd for CLARK denim ,,nl� Do not M:11 or dulnbulc

Page 1

INDUSTRIAL TRUCK DIVISION

MARKETING TRAINING DEPT.

m

F O R E W O R D

m

WAR_!i!__!iG

DO NOT WELD IN THE VICINITY OF

�AR_!i!_N.!i_

WEAR SAFETY GLASSES WHEN

THE FUEL TANK TO PREVENT INJURY.

REMOVING OR INSTALLING SNAP RINGS TO PREVENT INJURY.

m

�ARN!__!i.!i_

W A R N I N G

WHEN LIFTING ANY ASSEMBLIES WITH

NEVER ALLOW A FLAME OR SPARKS

OVERHEAD CRANES, MAKE SURE YOU

NEAR A BATTERY TO PREVENT AN

KNOW THE WEIGHT OF THE ASSEMBLY

EXPLOSION WRICH COULD RESULT

YOU ARE GOING TO LIFT AND THE

IN PERSONAL INJURY.

CAPACITY AND CONDITION OF THE CRANE AND CHAINS.

m

W A R N I N G ------MAKE SURE ALL ASSEMBLIES AND HARDWARE OF ANY L.P.G. SYSTEM

WARN!_NG

DO NOT USE AIR PRESSURE GREATER

IS FREE OF LEAKS.

THAN 30 PSI WHEN CLEANING TRUCKS

HIGHLY EXPLOSIVE WHEN IN DIRECT

OR ASSEMBLIES.

CONTACT WITH OXYGEN, FLAME OR

ALWAYS WEAR

L.P.G. IS

SAFETY GLASSES WHEN CLEANING

SPARKS.

WITH AIR PRESSURE.

COULD RESULT FROM ANY EXPLOSION.

Page 2

Cop) nghtcJ Malcrtal Intended for CLARK de�lcrs onlv Do notMJll or dutnbute

SEVERE PERSONAL INJURY

Code: OH-339, MAR 81 P.S.L.