CLARK FORKLIFT OH-539 685Y685 Gas and Diesel OVERHAUL MANUAL

OH-539 685/Y685 Gas and Diesel

CUARK C:or,)nah1,-J M,1cnol ln1cn,kd for(.L\RI,. dealer onl, Do nol Kil or d1�1nbu1c

Technical Pu�lications Lexington, KY

40508

CIARK

GROUP

THIS MANUAL INCLUDES

OVERHAUL INSTRUCTIONS

FOR CSOO 60/SlOO (D) AND CSOO Y 60/lOO(D)

FORK LIFT TRUCKS

CODE: OH-539, NOV 85

Cop}righted Material

Intended for CLARK deolers only Do not sci I or distribute

Page i

TABLE OF CONTENTS Introduction Subject index / Pictorial index

0.1 0.2 0.4

Know your truck

Safety information

GROUP

SECTION

SUBJECT

00 00 00

02A 02 03 04 05 06R 01R 08 05

Engine removaJ Engine Overhaut (3.86 L Gas/LPG) Engine Overhaw (4.06 L Diesel) Carburelgr Overhaul Governor Ovemaul lmpco Vaporizing Regula.1Dr Transmislion Remov8' HydralOtk TransmissiOn (H220-H213) Starter Overhaul AllernalorOverhauf Axte End Ortve AldeEnd Olffentndal- 2 piece case Brake Master Cytlnder (OH-224) Steering Gear Remov8' Steering Gear Overhaul StHt Axte Removal Steering Axle Ovemaut Steering Cylinder Removal Steering Cylinder Overhaul HydrauUc Pump OverhauJ HydrauUc Valve Overhaul Tilt Cylinder Removm Tilt Cylnder Overhaut Counterweight Remov8'

02

02 02 06 06 11 12 20 20 20 23 25 25 26 26

26 26

29

30 32 32 38

03

01R 06 19

03

01R 10 01R 01 02R 09 01 02 01R 13 01R

Code: OH-539, FEB 89

Page ii (.opynghtcd Mo1en3l Intended for CLARK dealers onl) Do nol sell or distribute

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INTRODUCTION Clark Equipment Company welcomes you to the growing group of professional people who own, operate and maintain Clark lift trucks. We take great pride in the long tradition of quality pro­ ducts and superior value that the Clark name represents. This manual has been written to help you maintain your Clark lift truck in an efficient and safe operating condition.

The correct maintenance and care of your lift truck is not only important for economy and utilization reasons, it is essential for your safety. A faulty lift truck is a potential source of danger to the operator, and to other personnel working near it. Approved methods of service and correct pro­ cedures of repair are important for the safety of personnel and the safe operation of a lift truck.

Component specifications, infonnation notes and safety messages are included at the proper step of each procedure.

Please be sure to read the entire procedure before doing any work.

Truck specifications are included in GROUP 40 at the back of the manual for easy reference.

Genuine Clark parts should always be used when replacements are needed.

Substitute parts from other sources may not be designed like original parts and may not meet OSHA or other safety requirements.

The mechanic is cautioned and expected to always work in a safe manner by using the correct procedure. If a mechanic does not understand a safety procedure when perfonning maintenance on a truck, the maintenance supervisor should be consulted for assistance.

Do not take chances which may result in injuries.

This manual is intended to be used by persons who are trained and authorized to do lift truck maintenance. The purpose of this manual is to outline the recommended procedures for overhaul of major components of the lift truck.

It is written to show and describe the removal, disassembly, repair and assembly required to service these components.

Please refer to the Operator's Manual located on the truck and the Planned Maintenance and Adjustment procedures manual for additional instructions on the operation and maintenance of your truck.

The detailed procedures are arranged in sequence by numbered GROUP and Section.

The GROUP numbers are the same as the component group in the Parts Manual.

If you have the need for more infonn­ ation on the care and repair of your truck, please contact your authorized Clark dealer.

Code: OH-520, REV FEB 85

Cop}righted Material

Intended for CLARK deolers only Do not sci I or distribute

Page 0.1

GROUP

KNOW YOUR TRUCK TRUCK COMPONENTS AND FEATURES SUBJECT INDEX Symbol

00 00 00 02 02 06 06 11 11 11 12 20 20 23 25 25 26 26 26 26 29 29 30 32 32 38

Page 0.2

Find In GROUP Section

OVERHAUL PROCEEDURES

ENGINE REMOVAL .................................................. 00 02R ENGINE OVERHAUL (3.86 L GAS/LPG) ..........•............... ....... 00 02 ENGINE OVERHAUL (4.06 L D IESEL) ...............................•..00 03 CARBURETOR REMOVAL.. .............................................02 04R GOVERNOR OVERHAUL............................................. ... 02 02 TRANSM ISSION REMOVAL..•........... ......•........................06 OlR TRANSMISSION OVERHAUL ....... .....................................06 01 D ISTRIBUTOR REMOVAL..............................................11 05R D ISTRIBUTOR OVERHAUL.. .......................................... .11 05 STARTER OVERHAUL...... ....•.. � •.....•............................11 06 ALTERNATOR OVERHAUL ..... ........................ ....•........... .12 03 D ISC BRAKE WEAR CHECK . ..........................................20 01 AXLE END OVERHAUL .•...•. .........................................20 13 BRAKE MASTER CYLINDER .........•..................................23 41 STEER ING GEAR REMOVAL............................................25 02R STEER ING GEAR OVERHAUL ...........................................25 10 STEERING AXLE REMOVAL............................................26 17R STEERING AXLE OVERHAUL •.............•..................... .......26 17 STEERING CYLINDER REMOVAL..............................•.........26 18R STEER ING CYLINDER OVERHAUL..............................••....... 28 18 HYDRAUL IC SCHEMATIC...................... ........................29 09 HYDRAUL IC PUMP OVERHAUL..........................................29 10 HYDRAUL IC VALVE OVERHAUL.........................................30 09 T ILT CYLINDER REMOVAL............................................32 13R TILT CYLINDER OVERHAUL...........................................32 13 COUNTERWEIGHT REMOVAL•.....................................•..... 38 01

Copyrighted Material Intended forCLt\RK dealers only Do nol sell or distribute

Code: OH-539, NOV 85

GROUP

KNOW YOUR TRUCK TRUCK COMPONENTS AND FEATURES

39

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11

29

05 06

07 10 00.

01.

02.

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06.

07.

10.

02

II. 12. 13.

14.

20.

23.

25.

26.

32.

34.

38.

39.

Code: OH-539, NOV 85

Pictorial Index

Cop) nghlcd MJtenJI Intended lor CLARK dcJlers only Do not sell or distribute

-

-

ENGINE ENGINE COOLING & OILING FUEL SYSTEM, INTAKE & EXHAUST TORQUE CONVERTER HYDRATORK TRANSMISSION DIRECTION LINKAGE TRANSMISSION MOUNTING TRANSMISSION COOLING LINES & Fl LTER STARTER ELECTRICAL, ALTERNATOR & BATTERY ELECTRICAL. GAUGES ELECTRICAL WIRING DRIVE AXLE & DIFFERENTIAL BRAKE SYSTEM, WHEELS & TIRES STEER GEAR & LINKAGE STEER AXLE. CYLINDER & PIPING HYDRAULICS, TILT CYLINDER UPRIGHT & CARRIAGE FRAME & COUNTERWEIGHT SHEET METAL & OVERHEAD GUARD

Page 0.3

GROUP KNOW YOUR TRUCK TRUCK COMPONENTS AND FEATURES Power Steering System All C500(Y)60/SlOO (D) trucks are equipped with a hydrostatic power steering system which is supplied with oil from the main hydraulic system pump through a priority­ demand valve to the steering gear. The priority demand valve gives the correct oil flow for steering as required. Oil not used for steering is added to the lift or tilt system.

85M567

The steering handwheel operates a steering control valve which directs oil flow to the 2-way steering cylinder connected to the spider on the steer axle. The steering valve also can act as a pump to provide manual steering if the engine or main pump flow stops.

Directional Control 11 FORWARD 11 or "REVERSE"

85M594

The direction-of-travel motion is selected with a control lever on the left hand side of the operators compartment alongside the steering control column.

This lever is connected with a mechanical linkage to the control valve on the transmission, and engages either the "FORWARD" or "REVERSE" clutch pack.

85M562

Speed Control This truck is not equipped with a "HIGH" and "LOW" range transmission but has a "single speed" transmission.

85M439

Page 0.4

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

Code: OH-539, NOV85

GROUP

KNOW YOUR TRUCK TRUCK COMPONENTS AND FEATURES

Accelerator Control Pedal The speed of the engine and lift speed (pump) or truck travel speed is controlled with a foot pedal suspended from the cowl and connected through a linkage to the carburetor {gasoline/LPG) or fuel control (diesel) on the engine.

I 85M451

Service Brake System All trucks have a manual (not powered) service brake system, with an extra-wide brake pedal connected to a 2-stage master cylinder. The first -portion of the brake pedal stroke moves the larger piston in the master cylinder causing an initial braking action. As the pedal continues to move, it causes the smaller piston in the master cylinder to apply a greater pressure to the system increasing the braking effort.

The wide pedal may be operated with either foot. This is very convenient when using the "INCHING" mode--a method of lifting loads at or near "FULL=SPEEO" lift rate.

If the brake pedal is partially depressed and the accelerator is used to speed the engine to give maximum pump flow to the lift system, the brake system will send a pressure signal to the transmission clutch pack that will cause the clutch plate pressure to "drop" allowing the clutch pack to "slip"--and this action allows the truck to move at a very slow rate of travel although the lift system is moving at or near maximum value.

CAUTION DO NOT USE THE INCHING MODE FOR LONG DISTANCE TRAVEL FOR THE "SLIP" OF THE TRANSMISSION PACK WILL CAUSE OVERHEATING OF TRANSMISSION O IL. II

Code: OH-539, NOV 85

II

85M594 The service brakes are hydraulic­ actuated disc brakes with the brake integral in the transaxle and the brakes are self adjusting. Only the master cylinder level requires operator servicing.

The parking brake lever is on the right hand side of the operators seat. It is pulled back and up to apply the parking brake and forward and down to release it. The upper part of the handle will turn and can be used to adjust the brake when in the released position-­ clockwise turning increases brake action and counter-clockwise will reduce brake action.

Copyrighted Material Intended forCLt\RK dealers only Do nol sell or distribute

Page 0.5

ClARK

GROUP KNOW YOUR TRUCK TRUCK COMPONENTS AND FEATURES Main Hydraulic System/Power Steering System The parts of the main hydraulic system are the hydraulic sump tank, main hydraulic pump, flow control (priority) valve, main control valve, hydraulic oil filter, and associated hydraulic lines and hoses.

The hydraulic sump is integral in the frame located on the right hand side of the truck.

It has a large opening at the top with a removable cover which includes the fill tube/breather, oil level dipstick, and oil filter return line. The cover is held on with a V-clamp for positive sealing and ease of servicing. The sump breather is a standard Clark part having a nominal 10 micron at 98.5% efficiency rating.

85M436

Oil from the sump tank is pumped to the flow control valve which in turn supplies oil to the steering control valve and to the main valve. From the main valve, the oil is directed to either the lift cylinder or to the tilt cylinders (or also to attachments if the truck is so equipped) . Oil is returned to the sump tank through the spin-on, full­ flow return-line filter.

The main hydraulic pump is mounted on the engine front cover gear driven from the engine power train.

The main hydraulic valve is mounted on the front of the vehicle main frame. It has an adjustable relief valve. A separate counterbalance valve in tilt circuit has pressure compensated flow control to control tilt speeds. When attachments are used, single or double 11 aux 11 sections may be added to the side of the standard main valve.

Page 0.6

85M438

The actuation levers for the main valve are located on the right side of the operator mounted on the cowl and mechanically linked to the main valve. The 11L IFT 11 and 11 LOWER 11 lever is nearest the steer wheel and the "TILT" lever is the outermost lever.

The system relief pressure level is tuned to match the rated capacity of the truck.

Copyrighted M'1tcri'11 Inrend.xi for CLARK dealers only Do not sell or distribute

Code: OH-539, NOV 85