CLARK FORKLIFT C500 OVERHAUL MANUAL

CL'IRK

Industrial Truck Division

OVERHAUL INSTRUCTIONS

CLARK LIFT

C500

ALL LP OAS POWERED ALL GASOLINE POWERED 10,000 LB. THRU 12,000 LB. RATED CAPACITY BOOK NO. OH-430, 1st REV lop)TlghtcJ M;ucrial lnicnJal for CL\RK d.-"1cn only llo not di or dl•tnhutc

MASTER MAINTENANCE MANUAL

SERVICE ENGINE "S" ASSEMBLY WARRANTY Service engine "S" assemblies and parts thereof are warranted to be free of defects in material or workmanship for a period of six months after date of delivery by Teledyne Continental Motors. Purported defects in material or workmanship shall be reported promptly by the Buyer to Teledyne Continental Motors.

Teledyne Continental Motors' sole responsibility or obligation for defects in material or workmanship shall be to repair or replace such defective part or parts which have been returned to Teledyne Continental Motors, at Buyer's expense; and shall be deemed by Teledyne Continental Motors to be attributable to faulty material or workmanship.

This Warranty is granted IN LIEU OF ALL WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, OR STATUTORY, and all

other obligations or liabilities including special or consequential damages or contingent liabilities, and no person is authorized to give any Warranty or to assume any additional responsibility or obligation on Teledyne Continental's behalf, unless made in writing and property authorized by an officer of Teledyne Continental.

H APR 79 OOM152AF SUPPCopynghtcd Maten.ti ln1.:_ndcd for CLARI( deJlcrs onl) Do nnl '<:II o, di 1rihu1c

INDUSTRIAL TRUCK DIVISION -CL'IRK EQUIPMENT SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK

WORK SAFELY

DRIVE SAFELY BE CAREFUL

ALWAYS GIVE MACHINE SERIAL NUMBER WHEN ORDERING PARTS

Rev OCT 73

l127•Z

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INDUSTRIAL TRUCK DIVISION

CUSTOMER SERVICES GROUP

I N D E X ASSEMBLY

gQh!f

SECT I ON

�

Engine (Continental)

OTS152A - OOS152K

Carburetor ( I MPC 0/LPG)

02

Carburetor (Zenith/Gas)

02M150A - 02M150P

Transmission (Hydratork)

26H206A - 06S206A

Starter (Delco-Remy)

11M103A - 11M103F

Distributor (Prestolite)

11

03

- 20

A 1 ternator (Delco-Remy)

12

03

1 - 20

Drive Axle (C 1 ark)

20

06

1 - 7

Hydrovac (Bendix)

23M503P - 23M503T

Master Ly 1 inder (Wagner)

23

02

1 - 6

Brake Assembly (Clark)

23

11

- 7

Steer Gear (Saginaw)

25

05

1 - 15

Steer Cylinder (Hydraulic Prod.)

26

09

1 - 13

Steer Pump ( Hydreco)

29

01

1 - 7

Hydrau 1 ic Pump (Hydreco)

29

13

- 3

Tilt Cy 1 inder {Clark)

32

09

- 4

Cylinder (C 1 ark)

34

01

- 52

Lift

Code: OH-430, SEP 79

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10

1 - 9

INDEX

GROUP

OH

F O R EW O R D O VERHAUL 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 exp loded 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 p ossible, 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, GROU P 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 \>klich a section appears bears the same group number as Service Parts Books list for most assemb1 ies. In some cases, however, an overhaul procedure wi 11 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 (GROU P 20), It is usually necessary to deal with certain brake assembly parts (GRO UP 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 O CT 77

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Foreword

MASTER MAINTENANCE MANUAL

Instructions

L-HEAD ENGINES FOUR CYLINDER

NS6-N62 Y69-Y91-Yl 12 F124-F13S-F140-F162-F163

SIX CYLINDER Fl 86 - F209 - F226 - F227 - F244 - F24S M271 - M290 - M330 - M363 8371 - 8427

COURTESY OF:

�"TELEDYNE CONTINENTAL MOTORS

TELEDYNE CONTINENTAL MOTORS Ptinted in U. S. A.

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

OOTS152A

Copyright 1971

REV SEP 72

lopynghted M.'lt<n.11 lni�dcd for CL\RK d�alers onl) Do nnl acll or d,-tnbutc

MASTER MAINTENANCE MANUAL

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

A preventive maintenance system including in­ spection. lubrication and adjustment as recom­ mended in our }Iaintenance Section will prevent the greater portion of gasoline engine tl'Oubles.

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 senses of feeling. hearing, seeing and smelling 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 timethen locate the trouble by a process of elimination. ncmember 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.

1 - Broken or grounded high tension wire 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 be caused by:

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

A- STARTING MOTOR - WILL NOT CRANK ENGINE:

1- Weak or dead battery.

Loose ignition wiring connectioni-.

Burned or pitted distributor points.

Wet spark plug wires.

Defective condenser.

Cracked distributor cap.

Weak ignition coil.

3- GOOD SPARK AT EACH PLUG- indica tc>:: that ignition system is OK and trouble is in fu!'l system - which may be due to :

2 - Poor g1·ound connection.

3 - Faulty starting switch or relay.

4 - Defective starting motor.

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

(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.

B- ENGINE CRANKS - BUT DOES NOT START:

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

5 - Pluggt?d vent in fuel tank cap.

1-NO SPARK:

(B) Gas in Carburet or- whi c h ma�· be flooded due to: 1 - Too much choking- plugs are wet.

2 - Wrong float level.

3 - Choke not operating correctl�·4 - Water in Gas.

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

2 - Open primary wires.

3- Defective ignition switch.

4 - Faulty coil.

OOTS152B

REV SEP 72

CopvnghtcJ Mat.:nul

I mended ror CLARK dcalcn onl\• Do not sell or J, tribute

MASTER MAINTENANCE MANUAL C- ENGINE RUNS WITH CONTINUOUS MIS-FIRING: 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. ,- LACK OF POWER- which may be due to:

1- Poor Compression.

2-Wrong Timing.

3 - Throttle control not opening fully.

4 - Air leak in fuel system.

5 - Restriction in a i r 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.

G - POOR COMPRESSION-check 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:

2- At High Speed - which 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 p i s tons and bearings and is caused by pre-ignition o r using inferior grade of gas.

3 - Engine Idles Too Fast - indicates im­ 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.

OOTS152C

H - OVERHE.ATING

1- Lack of water 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 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 SEP 72

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MASTER MAINTENANCE MANUAL J - HIGH OIL PRESSURE-should not exceed rec­ ommended pressures except when engine is starting up cold. Abnormally high oil pressure is not desirable because it. increases. oil con­ sumption - possible causes of high oil pres­ sures are : 1 - Engine oil too heavy.

2 - Stuck relief valve.

3 - Obstruction in distributing line.

4 - Faulty oil pressure gauge.

K - HIGH OIL CONSUMPTION

1 - Oil leaks.

2 - Too high oil level.

3 - Incorrect grade of oil used.

4 - Clogged crankcase breather.

5 - Oil pressure too high - stuck relief valve.

6 - Piston rings not run-in, due to too smooth cylinder bore finish or glazed con­ dition.

7 - Worn, broken or stuck piston rings and clogged oil control rings.

8 - Worn pistons and sleeves.

9 - Wom bearings.

10 - Worn valve guides.

(Manifold may be removed for visual inspec­ tion.)

L - ENGINE KNOCKS AND OTHER NOISES

1 - Operating Knocks - which may be due to: (A) Pre-Ignition - Most common cause is due to wrong type plugs which are too hot.

(B) Carbon - noticeable when engine is accelerated while hot - clean head and pistons.

(C) Timing-early timing causes knocks similar to carbon - but may tend to kick back when starting.

(D) Fuel - detonation knock caused by poor gas.

(E) Overloads - particularly at lowet operating speeds.

2 - �1echanical Knocks-result from wear, abuse or improper adjustments - which may be due to: ( A) Crankshaft and !\fain Bearings : ( 1 ) Worn or burned-out Main Bearings - A heavy, dull knock when accelerat­ ing under load. Locate by shorting out plugs on l>oth sides of the bad l>earing.

(2) Crankshaft End-Play - excessive end-play is indicated by nn intermittent

OOTSl52D

knock which will come and go when the load is released and engaged.

(B) Connecting Rod Bearings ( 1 ) Worn or Burned-out Bearings The worst condition, a light pound or metallic knock, is noted at idling and to about % maximum speed. Bad bear­ ings can be determined by shorting out plugs. {C) Pistons and Wrist-Pins ( 1 ) Loose Wrist Pins - noise doubles when the correct plug is shorted out most noticeable at idling speed.

(2) Piston Loose in Cylinder - "Pis­ ton-Slap" is noted by metallic knocking at low speed under load ; but disappears at high speed - also most noticeable when starting cold -test by shorting out plugs.

(D) Broken Piston Ring or Pin sharp clicking noise that won't short out.

(E) Vah•es ( 1 ) Burned Valvesand Seats- engine misses, especially at low speeds, or ac­ celeration under load.

(2) Weak or Broken Valve Springs missing at low or high speeds when un­ der load.

(3) Sticking Valves - loss of power and popping sound when bad.

(4) Tappet noise - excessive clear­ ances cause noise when cold - which diminishes at.normal operating temper­ ature.

(F) Camshaft - Noise due to loose bear­ ings or end play - usually occurs at half engine speed. ( G) Timing Gear Noise - Loose or worn gears rattle or knock - tight gears hum.

3 - Vibration Originating at Engine - The most common sources of vibration originat­ ing in or on the engine, as distinguished from causes created outside the engine are as follows : (A) Misfiring (B) Misalignment of engine (C) Bent or off-center coupling (D) Engine loose on bed and type of mountings.

(E) Out of balance condition of flywheel and clutch assembly.

REV S E P 72

lop>ngbtcJ M111enal lmendctl for CLARK de�hir- onl) Do no1 'ICII or d,stnbu1e