CLARK FORKLIFT C500 Y160-S230 - Y1625 (OH-354D) OVERHAUL MANUAL

OH-354D CS00 Yl 60-5250 Y1625 Overhaul Manual

July 2013

[cLqRK)' THE fORK LI fT

Technical Publications Lexington, KY 40510 www.Clarkmhc.com 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 O F C O N T E N T S (LOT 2258 AND ABOVE) EXCEPT WHERE SPECIFIED ENGINE

. .......... .. .. ....

FUEL SYSTEM Carburetor - Gas • • • • • • • • • Impco - LPG: Lot 3872 and Above Fuel Lock-off Valve .

Vaporizer - Regulator • • . • • • • • • • • • Carburetor . . . • . • . . . . . . . .

Zenith - LPG: Lot 2258 thru Lot 3871 Primary Vaporizer and Water Jacket Primary Vaporizer • • • • • • • • • • Final Regulator .

Carburetor

TRANSMISSION

ELECTRICAL SYSTEM Alternator: Lot 2258 thru Lot 3291 .

Lot 3440 and Above .

Cranking Motor .

Electric Checks

DRIVE AXLE

DRIVE SHAFT AND UNIVERSAL JOINTS

BRAKE SYSTEM • • • • • • • • • • Hydrovac . • • • • .

Inching Check Valve: Lot 2258 thru Lot 2851 Lot 3065 and Above Inching Cylinder • • • • • Master Cylinder • • • • Wheel Brakes • • STEERING SYSTEM Steering Cylinder • • • • • • • • • . • • Steering Gear: Lot 2258 thru Lot 3871 • • • • .

Lot 3872 and Above Steering Pump

HYDRAULIC SYSTEM Lift and Tilt Valve Main Pump: Lot 2258 thru Lot 2851 Lot 3065 and Above Tilt Cylinder

UPRIGHT LIFT CYLINDER .

WIRING DIAGRAM

Code: OH-354, MAR 81

. .. ....

Copyrighted Material lnrcndcd for CLARK dealers only Do notsell or distribute

GROUP

SECTION

00

5

02

12

02 02 02

5 7 9

02M553A/D, 02S553A 02 2 02M561A/D, 02S561A 02M572A/B, 02S572A 06

2

12 12 11 12

1 3 4 5

20

21

9 1

23 23 23 23 23 23

23 6 24 1 1 10

26 25 25 29

10 2 7 4

30 29 29 32

6 19 18 9

34

1

IN-18196

Page 1

GROUP

CLARK

OH

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.

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.

A

Code: OH-51O, JAN 81 P.S.L.

Copyrighted Material Lntendcd for CLARK dealers only Do not sell orcfatribute

FOREWORD

CIARK

GROUP 00

GROUP 00 SECTION

5

E N G I N E C H R Y S L E R

0 V E R H A U L

G A S / L P G

M O D E L

LH-318

ORDERING PARTS

HOST IMPORTANT IN ORDERING PARTS IS THE PROPER IDENTIFICATION OF THE ENGINE. ALWAYS MENTION THE HODEL, TYPE ANO SERIAL NUMBER. THIS INFORMATION IS STAMPED ON THE IDENTIFICATION PLATE ANO SHOULD BE MENTIONED IN ALL PARTS ORDERS OR COHHUNICATIONS.

ORDERS FOR PARTS SHOULD BE PLACED WITH THE NEAREST AUTHORIZED CHRYSLER INDUSTRIAL ENGINE DISTRIBUTOR. AUTHORIZEO CHRYSLER INDUSTRIAL ENGINE DISTRIBUTORS ARE IN POSSESSION OF COMPLETE PARTS INFORMATION AND CAN, IN HOST INSTANCES, PROMPTLY SUPPLY YOUR PARTS REQUIREMENTS FROH THEIR INVENTORY. IF YOU 00 NOT KNOW YOUR NEAREST CHRYSLER INOUSTRAIL ENGINE DISTRIBUTOR, A CARD ADDRESSED TO THE CHRYSLER CORPORATION, INDUSTRIAL PRODUCTS DIVISION, BOX 1, MARYSVILLE, MICHIGAN, 48040, WILL BRING YOU HIS NAME AND ADDRESS PROMPTLY •

•

..

•CtiRYSLER: •1MODEL N D U ST R I AL E SERIAL NGINE TYPE

Code: OH-354, NOV 80

Copyrighted Material lnrcndcd for CLARK dealers only Do notsell ordistribute

Section S, Pagel

INDUSTRIAL TRUCK DIVISION CUSTOMER SERVICES GROUP

318 CUBIC INCH ENGINE

...

TIGHTENING REFERENCE

Location

Torque Thread Size Foot-Pounds

Alternator Adjusting Strap Bolt 5/16-18 200 (in.-lbs.)

Alternator Mounting Pivot Bolt or Nut .................... 3/8-16 30 Camshaft Sprocket Bolt ...... 7/16-14 50 Camshaft Thrust Plate Bolt ... 5/16-18 210 (in.-lbs.)

Chain Case Cover Bolt ....... 3/8-16 35 Connecting Rod Nut-Plain .. . 3/8-24 45 Crankshaft Bolt (Vibration Damper ) ................. . 3/4 -16 100 Cylinder Head Bolt .......... . 1/2 -13 95 Cylinder Head Cover-Bolt .... 1/4 -20 40 (in.-lbs.)

1/4 -28 40 (in.-lbs.)

5/16-18 20 Ex���st· Nut ..................... . 5/16-24 20 ·Exhaust Manifold Ball Joint. .. 3/8-16 24 Fan Attaching Bort ........... 5/16-24 200 (in.-lbs.)

Fuel Pump Attaching Bolt .... 3/8-16 30 Flywheel to Crankshaft ...... 7/16-20 55 Flywheel Housing to Cylinder Block .... ......... .... .... 7 /16-14 50

M�riiro,c1�so1i:::::::

Section 5, Page 2

Location

Torque Thread Size Foot-Pounds

Flex Plate to Crankshaft Flex Plate to Converter .....

Flywheel Housing Cover Bolts Ignition Distributor Clamp Bolt ......................

Intake Manifold Bolt ..........

Main Bearing Cap Bolt........

Oil Pan Drain Plug ......... .

Oil Pan Screw ............ ..

Oil Pump Cover Bolt ........

Oil Pump Attaching Bolt Rocker Shaft Retainer Bolt ....

Spark Plugs 318-1, 360 .................

318-3 .....................

Starter Mounting Bolt ....... .

Thermostat Housing Bolt .....

Vibration Damper Pulley Bolt ..

Water Pump Bolt ............

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

Ci)

� 7 /16-20 55 5/16-24 270 (in.-lbs.)

1/4 -20 40 (in.-lbs.) 'ti

2

•

0

,.

5/16-18 3/8-16 1/2 -13 1/2 -20 5/16-18 1/4 -20 3/8-16 5/16-18

200 (in.-lbs.) o 35 85 20 200 (in.-lbs.)

95 (in.-lbs.)

30 200 (in.-lbs.)

14MM 18MM 7 /16-14 3/8-16 5/16�24 3/8-16

30 20 50 35 200 (in.-lbs.)

35

Code: OH-354, NOV 80

CIARK

GROUP 00 ROCKER ARM-"LEFT"

ROCKER ARM-"RIGHT"

RELIEVED FOR ROTATOR CLEARANCE

INTAKE ROCKER ARM

SERVICE PROCEDURES

• •

ROCKER ARMS AND SHAFT ASSEMBLIES Assembly and Installation If the rocker arm assemblies are disassembled for cleaning or replacement, refer to Figure 3 for rocker arm identification, and Figure 4 for positioning on the shaft. Some exhaust rocker arms have a ground out section on the under side.

Install rocker arm and shaft assemblies with notch on end of rocker shaft pointing to center line of en­ gine and toward front of engine on the left bank, and to the rear on the right bank, making sure to install the long stamped steel retainers in the number two and four positions. Tighten to 200 inch-pounds. (Fig. 4).

EXHAUST ROCKER ARM PH1793

fig. 3-lntake and Exhaust Rocker Arm ldentlflcation plugs are located in peak of the wedge between the valves.

Removal (1) Drain cooling system and disconnect battery ground cable.

(2) Remove alternator, carburetor air cleaner and fuel line.

(3) Disconnect accelerator linkage.

(4) Remove vacuum control hose between carburet­ or and distributor.

(5) Remove distributor cap and wires.

(6) Disconnect coil wires, heat indicator sending unit wire, heater hoses and by-pass hose.

(7) Remove closed ventilation system, evaporative control system and cylinder head covers.

CYLINDER HEADS The chrome alloy cast iron cylinder heads shown in (Fig. 5) are held in place by 10 bolt�o�llRaffiaterial Code: OH-354, NOV 80

Fig, 4-Proper Rocker Arm location on Shoff

lnrcndcd for CLARK dealers only Do not sell or distribute

Section 5, Page 3

INDUSTRIAL TRUCK DIVISION

CUSTOMER SERVICES GROUP

engine on the left bank and to the rear on right bank, making sure to install the long stamped steel re­ tainers in the number two and four positions, tighten to 210 inch-pounds.

(8) Cut the three inch strip of sealer material into four equal parts and install under cylinder bead gas­ ket lock tabs. Do not use sealer or cement.

(9) Position rubber seals over rails at front and rear of cylinder block. Center hole in seals must en­ gage dowel pins and end holes locked in tangs of head gasket.

(10) Coat intake manifold side gaskets lightly with number 3419115 sealer or equivalent. Install gaskets with the bead down.

(11) Carefully lower intake manifold into position on the cylinder block and cylinder heads. After in­ take manifold is in place, inspect to make sure seals are in place.

'19. 5-Cyllnder Head Assembly

(8) Remove intake manifold, ignition coil and car­ buretor as an assembly.

(9) Remove exhaust manifolds.

(10) Remove rocker arms and shaft assemblies. Re­ move push rods and identify to insure installation in original location.

(11) Remove the 10 bead bolts from each cylinder head and remove cylinder heads.

(12) Place cylinder beads in holding fixture Tool C-3626. Remove spark plugs.

Installation (1) Clean all gasket surfaces of cylinder block, cylinder beads and remove all burrs.

(2) Inspect all surfaces with a straightedge if there is any reason to suspect leakage. If out of flatness ex­ ceeds .00075 times the span length in any direction; either replace head or lightly machine the head gas­ ket surface. As an example, if a 12 inch span is .004 in. out of flat, allowable is 12 x .00075 .009 in. Head is OK. The cylinder head surface finish should be 70-180 micro-inches.

(3) Coat new gaskets lightly with number 3419115 Sealer and install on cylinder block.

(4) Remove cylinder heads from holding fixtures Tool C-3626 and place heads on engine.

(5) Install cylinder head bolts. Starting at top cen­ ter, tighten all cylinder head bolts to 50 foot-pounds in sequence, as shown in (Fig. 6). Repeat procedure, retighten all cylinder bead bolts to 95 foot-pounds on

=

(12) Install the twelve attaching cap screws "Fin­ ger Tight." Tighten cap screws one through four to 25 foot-pounds, in the tightening sequence shown in (Fig. 7), then retighten cap screws one through four to 35 foot-pounds and follow by retightening the re­ maining cap screws to 35 foot-pounds in sequence shown.

(13) Install exhaust manifolds, tighten to 30 foot­ pounds.

(14) Adjust spark plugs to .035 inch gap and install the plugs tightening to specifications.

(15) Install coil wires, heat indicator sending unit wire, heater hoses and by-pass hose.

(16) Install vacuum control hose between carburet­ or and distributor.

(17) Install accelerator linkage and adjust as neces­ sary.

(18) Install distributor cap and wires.

(19) Install fuel line, alternator and drive belt. G) Tighten alternator mounting bolt to 30 foot-pounds e5 C � 0 0

all engines.

(6) Inspect pw;h rods and replace worn or bent rods.

(7) Install push rods, rocker arm and shaft assemNR779 blies with the "NOTCH" on the end of rockersbaft pointing to centerline of engine and toward front:�righ1cd l\611rid-Cyllnder Head Jl9htenln9 Sequence

Section 5, Page 4

•

Lntcndcd for CLARK dealers only

Do not sell or distribute

Code: OH-354, NOV 80

,.

...

ClARK

GROUP 00 Identify valves to insure installation in original location.

the valve guide.

Fig. 7-lntake Manifold Tightening Sequence and adjusting strap bolt to 200 inch-pounds.

(20) Place new cylinder head cover gaskets in posi­ tion and install cylinder head covers. Tighten to 40 inch-pounds.

(21) Install closed crankcase ventilation system and evaporative control system.

(22) Fill cooling system and install battery ground cable.

VALVES AND VALVE SPRINGS The valves are arranged in line in the cylinder heads and inclined 18 degrees. The rocker shaft sup­ port and the valve guides are cast integral with the heads.

Removal

(1) With cylinder head removed, compress valve springs using Tool C-3422A, as shown in (Fig. 8).

(2) Remove valve retaining locks, valve spring re­ tainers, valve stem cup seals and valve springs.

(3) Before removing valves, remove any burrs

from valve stem lock grooves to prevent damage to

Valve Inspection (1) Clean valves thoroughly and discard burned, warped and cracked valves.

(2) Measure valve stems for wear. New intake valve stem diameter should measure .372 to .373 inch and exhaust valve stem diameter should measure .371 to .372 inch. If wear exceeds .002 inch, replace valve.

(3) Remove carbon and varnish deposits from in­ side of valve guides with a reliable guide cleaner.

(4) Measure valve stem guide clearance as follows: (a) Install sleeve Tool C-3973 over valve stem (Fig. 9) and install valve. The special sleeve places the valve at the correct height for checking with a dial indicator. (b) Attach dial indicator Tool C-3339 to cylinder head and set it at right angle of valve stem being measured (Fig. 10). (c) Move valve to and from the indicator. The total dial indicator reading should not exceed .017 inch.

Ream the guides for valves with oversize stems if dial indicator reading is excessive or if the stems are scuffed or scored.

(5) Service valves with oversize stems are available in .005, .015 and .030 inch oversize. Reamers to ac­ commodate the oversize valve stem are as follows: Reamer Reamer Valve Guide Tool Number Oversize Size C-3433 .005 in. .379-.380 in.

C-3430 .015 in. .389-.390 in.

C-3427 .030 in. .4�.405 In. (6) Slowly turn reamer by hand and clean guide thoroughly before installing new valve. Do not •t• tempt to ream the valve guides from standard di­ rectly to .030 Inch. Use step procedure of .005, .015 and .030 inch so the valve guides may be reamed true in relation to the valve seat.

CYLINDER HEAD ASSEMBLY

TOOL

..----

HOLDING FIXTURES _,,-

NR782

Fig. I-Compressing Valve Spd.,.,rightcd Material Code: OH-354, NOV 80

Inrcndcd for CLARK dealers only Do notsellordlstribute

Fig. 9-1nstalllng Valve and fool C-3973 Section 5, Page 5

INDUSTRIAL TRUCK DIVISION CUSTOMER SERVICES GROUP

EXHAUST VALVE

INTAKE VALVE

VALVE SPRING RETAINER LOCK GROOVES

---------....

Fl9. J 0-Measurln9 Valve Gulde Wear

Refacing Valves and Valve Seats

(1) The intake and exhaust valve seats and intake valve face have a 45 degree angle. The exhaust valve face has a 43 degree angle. The valve face and valve seat angles are shown in Figure 11.

(2) Inspect the remaining margin after the valves are refaced (Fig. 12). Valves with less than 3/64 inch margin should be discarded.

(3) When refacing valve seats, it is important that the correct size valve guide pilot be used for re-' seating stones. A true and complete surface must be obtained.

(4) Measure the concentricity of valve seat using dial indicator No. 13725. Total runout should not ex­ ceed .002 inch (total indicator reading).

(5) Check the valve seat with Prussian blue to de­ termine where the valve contacts the seat. To do this, coat valve seat lightly with Prussian blue then set valve in place. Rotate the valve with light pressure. If the blue is transferred to the center of valve face, contact is satisfactory. If the blue is transferred to top edge of valve face, lower valve seat with a 30 degrees stone. If the blue is tranferred to bottom edge of. valve face raise valve seat with a 60 degrees stone.

A-SEAT WIDTH (INTAKE 1/16 TO 3/32 INCH EXHAUST: 3/64 TO 1/16 INCH) B-FACE ANGLE !INTAKE: 45°-EXHAUST: 43°) C-SEAT ANGLE <INTAKE: 45°-EXHAUST: 45°1 D-CONTACT SURFACE

.._

rr

• --

•

Fig. J J -Yalve Face and Seat Angle

Section 5 , Page 6

Fi9. 1 2-lntake and Exhaust Valves

KH3300

(6) 3 1 8-1, 360 Cubic Inch Engine, when seat is properly positioned the width of intake seats should be 1/16 to 3/32 inch. The width of the exhaust seats should be 3/64 to 1/16 inch.

3 1 8-3, 360-3 Cubic Inch Engine, the width of intake seats should be 5/64 to 7 /64 inch. The width of ex­ haust seats should be 3/32 to 7 /64 inch.

Testing Valve Springs (Fig. 13)

(1) Whenever valves have been removed for in­ spection, reconditioning or replacement, valve springs should be tested. As an example the compression length of the spring to be tested is 1-5/16 inches.

Turn table of Tool C-647 until surface is in line with the 1-5/16 inch mark on the threaded stud and the zero mark to the front. Place spring over stud on the table and lift compressing lever to set tone device.

Pull on torque wrench until ping is heard. Take read­ ing on torque wrench at this instant. Multiply this Gl reading by two. This will give the spring load at test � C

"Cl

0 0

NH64 �opy righted Material g, ln1endcd for CLARK dca1L.fiS1m'11-T•stlng Valve Sprin te o Do not sell r distribu

NR786

Code: OH-354, NOV 80