CLARK FORKLIFT C500 (OH-428) OVERHAUL MANUAL

ln.dustrial Truck Division

OVERHAUL INSTRUCTIONS

·cLARKLIFT •

csoo

ALL GAS/LPG POWERED 11,000 THAU 15,500 tB. RATED CAPACITY MACHINES

BOOK NO. OH-428

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

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

INDUSTRIAL TRUCK DIVISION CUSTOMER SERVICES GROUP

T A B L E

0 F

C 0 N T E N T S

ASSEMBLY

GROUP

SECTION

Engine Ford

00

0

IMPCO (LPG) Carburetor

02

10

- 9

HR18000 Series Transmission

06

01

1 - 69

Starter (De I co-Remy)

11M103A - 11 M 103F

A 1 ternator (Delcotron)

12

03

- 20

Ax le End

20

09

- 42

Brake Master Cy! inder

23

02

- 5

Brake Assembly (Perrot)

23

16

- 9

Hydrovac (Bendix)

23M503AB - 23M503 AH

Steering Gear (Ross)

25

06

1 - 12

Power Steering Cylinder

26

10

1 - 6

Hydrau 1 i c P:.imp (Parker) (thru.65th machine of Lot 3820)

29

08

- 6

Hydrau 1 ic Pump (Main)

29

12

1 - 7

Ti It Cylinder

32M500A - 32M500E

Li ft Cy! inder

34

Code: OH-428, OCT 79

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

01

PAGES

1 - 52

CONTENTS

CIARK

GROUP OH FOREW ORD OVERHA L U 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 I 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 I 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 I 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 O verhaul 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 o C ntents 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 wi II 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 electric 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 L C ARK dealer's Service Parts Book for correct part numbers when ordering parts or assemblies.

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

Code: OH-121. REV OCT 77

GROUP 00

GROUP 00 SECTION

0 F O R D

E N G

N E

3 0 0

C

T U N E - U P D

( 4

9

LJTER)

Ford engine manuals for the 300 CID can be purchased from Ford Motor Company.

Request manuals from:

Code: OH-428, OCT 79

Ford Motor Company Industrial Engine Operations Ford Parts & Service Division 300 Reaissance Center P .o, Box 43338 Detroit, Michigan 48243

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

Section 0, Page 1

INDUSTRIAL TRUCK DIVISION SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK

WORK SAFELY DRIVE SAFELY BE CAREFUL

ALWAYS GIVE MACHINE SERIAL NUMBER WHEN ORDERING PARTS

Copyrighted Material Intended for CLARK dealers only Rev OCT 73 Do not sev1�7.d_tStribute

GROUP 02

GROUP 02 SECTION

10

I M P C O

L P G

C A R B U R E T O R

MODEL --

CLARK P/N

REPAIR KIT P/N

CA125-66

2350247

998838

CA 125-86

2364358

998838

Refer to Product Identification Card for Model Usage

T A B L E

O F

C O N T E N T S

Exploded View Remova 1 Disassembly Cleaning and Inspection Reassembly Bench Adjustments Installation

Code: OH-400, APR 79

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

2 3 4 5 7 9 9

Section 10, Page 1

INDUSTRIAL TRUCK DIVISION CUSTOMER SERVICES GROUP

02.100 02. 101 02. 103 02. 104 02.114 02.116 02.117 02.118 02.188 02.395 02.397 02.407 02.414 02 .421 02.440

c!!}-92.837 ®-___92.836 --02.421

ASSEMBLY COMPLETE

CARBURETOR ASSEMBLY REPAIR KIT, CARBURETOR SCREW, IDLE ADJUSTING SPRING, IDLE ADJUSTING SCREW SCREW, THROTTLE LEVER CLAMP GASKET, CARBURETOR MOUNTING SPRING, THROTTLE STOP SCREW SCREW, THROTTLE STOP SCREW, THROTTLE PLATE SCREW, METER DIAPHRAGM COVER SPRING, METERING DIAPHRAGM SCREW, METERING VALVE GASKET, METERING VALVE STUD, AIR CLEANER ADAPTOR LEVER, THROTTLE

03.089 SHAFT, THROTTLE 03.203 PLUG, AIR HORN 03.209 LEVER, THROTTLE STOP

REPAIR KIT INCLUDES ITEMS MARKED "R"

102.104

I �-02.103 25N

NOTE: NON SERVICEABLE ITEMS MARKED "N"

92.836 WASHER, AIR CLEANER ADAPTOR FASTENER 92.837 NUT, AIR CLEANER ADAPTOR FASTENER 92.865 LOCKWASHER, METER VALVE FASTENER 92.967 LOCKWASHER, METER DIAPHRAGM COVER FASTENER *23N *24N *25N *26N *27N *28N *29N *30N *31N *32N

ADAPTOR, AIR CLEANER COVER, METER DIAPHRAGM HOUSING, METERING VALVE SEAL, THROTTLE SHAFT RETAINER, THROTTLE SHAFT SEAL BUSHING, THROTTLE SHAFT BODY, CARBURETOR PLATE, THROTTLE PIN, THROTTLE STOP SCREW, THROTTLE STOP LEVER PIN ;'<USE 02.100

Fig. 19356 Carburetor Part No. 2350247

Section 10, Page 2

ena Intended for CLARK dealers only Do not sell or distribute

Code: OH-400, APR 79

I.) :;z;, 0 C: ""O

0

N

•

GROUP 02 REMOVAL:

STEP 6.

C A U T I O N

WEAR SAFETY GLASSES AT ALL

DISASS EMBLY:

TIMES TO PROTECT YOUR EYES. STEP 1.

Close manual shut-off valve on LPG tank.

STEP 2.

Start engine, allow to run until it stops, then turn off ignition switch.

STEP 3.

Disconnect or remove air cleaner assembly,

This supplement covers the overhaul procedure for two variations of the IMPCO Model CA125 LPG carburetor. Air intake housings are identical. The difference is in the flange size of the throttle body, and the lever arrangement on the throttle shaft.

See Table 1 and Fig. A1662, C A U T I O N

THESE CARBURETORS ARE CERTIFIED

!L.6.Bl::!.ll::!.�

TO MEET STATE OF CAL IFORNIA

DO NOT SMOKE WHILE REMOVING

EMISS ION CONTROL STANDARDS,

ANY ASSEMBLIES FROM THE LPG SYSTEM.

Remove carburetor from intake manifo 1 d.

DO

NOT TURN THE POWER ADJUSTMENT

DISCONNECT GROUNDED

SCREW.

CABLE (-) AT THE BATTERY TO

THIS SCREW HAS BEEN

PRESET AT THE FACTORY FOR

PREVENT ACCIDENTAL SPARKING.

MAXIMUM POWER AT FUL L LOAD

LPG IS HIGHLY INF LAMMABLE.

GOVERNED RPM. FURTHER ADJUST­

STEP 4.

Disconnect accelerator return spring, governor and throttle linkage from carburetor.

STEP 5.

Disconnect vacuum and fuel lines from carburetor.

MENT IS NOT REQUIRED. Disassemble carburetor on a clean work bench,

MODEL

CLARK PART NO.

SAE FLANGE

AIR HORN DIA.

OPERATION

CA125-66

2350247

1-1 /2

2-5/16

DOWN DRAFT

CA125-86

2364358

1-1/4

2-5/ 16

DOWN DRAFT

T A B L E

Code: OH-400, APR 79

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

Section 10, Page 3

INDUSTRIAL TRUCK DIVISION

CUSTOMER SERVICES GROUP

POWER ADJUST­ . MENT (PRESET) DO NOT ADJUST

AIR INLET·

\

FUEL INLET

IDLE SPEED

. ·IDLE MIXTURE SCREW

'SCREW

. SAE FLANGE - J-½-11

Part No. 2350247 STEP 1.

VACUUM FITTING TO LOCK-OFF VALVE

Fig. A1662

· SAE FLANGE -

lt;11

Part No. 2364358

Remove air intake housing and gasket.

"' .,,C :x,

Fig. A1663 STEP 2.

Remove (4) screws and lift off metering valve cover.

Fig. A1664

Section 10, Page 4

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

Code: OH-400, APR 79

0

0 N