CLARK Forklift C500 20/30 Workshop Service Shop Repair Manual

OH-367 C50020/30 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

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

INDUSTRIAL TRUCK DIVISION MARKETING TRAINING DEPT. CL!mK 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 recommenda- tion in this manual and the following practices. 1. 2. 3. A scheduled preventive maintenance, lubrication, and inspection system must be followed. Only qualified and authorized personnel should be permitted to maintain, repair, adjust, and inspect industrial trucks. Before Leaving The Truck: A. Stop Truck. B. Fully lower the load engaging means. C. Put directional controls in neutral. D. Apply the parking brake. E. Stop the engine or turn off power. F. Lock the control or ignition circuit. G. Put blocks at the wheels if truck is on a ramp, or being worked on. 4. Before Working On Truck: A. Raise wheels free of floor or disconnect power source. B. Use blocks or other positive truck positioning devices. C. Put blocks under the load engaging means, innermast( 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. 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). C. Put the directional controls in neutral. D. Start engine or turn on power. 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. - continued - 1023-Z REV SEP 83 (FRONT) Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

INDUSTRIAL TRUCK DIVISION MARKETING TRAINING DEPT. Cl!!Rl4 OWNER SAFE MAINTENANCE PRACTICES (CONT.) 6. 7. 8. 9. 10. 11. 12. Avoid fire hazards and have fire protection 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 flammable cleaning fluids for cleaning parts. Provide ventilation to the work area, vent exhaust fumes, and keep shop clean and floor dry. Handle LP gas cylinders with care. Do not drop, dent, or damage in any way. Brakes, steering mechanisms, control mechanisms, warning devices, lights, governors, lift overload devices , guards and safety devices must be inspected regularly and maintained in a safe operating condition. All parts of lift and tilt mechanisms and frame members must be carefully and regularly inspected and maintained in a safe operating condition. Special trucks or devices designed and approved for hazardous area operation must receive special attention to make sure that maintenance keeps the original, approved safe operating features. 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. 14. 15. 16. 17. 18. 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 developed to the extent that it would create a hazard. Capacity, operation and maintenance instructions plates, tags, or decals must be maintained in legible condition. Batteries, motors, controllers, limit switches, protective devices, electrical conductors and connections must be inspected and maintained in conformance with good practice. Special attention must be paid to the condition of electrical insulation. Industrial trucks must be kept in a clean condition to minimize fire hazards and help in the detection of loose or defective parts. 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. 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-z REV SEP 83 (BACK) Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

TABLE OF CONTENTS ASSEMBLY Engine IMCO Carburetor (LPG) Marvel-Schebler Carb. (Gas) Hydratork Trans. (H123A E H127A) Starter (Delco-Remy) Distributor (Prestolite) Alternator (Delcotron) GROUP SECTION PAGES OOTS152A - OOS152K 02 01 l-5 02 11 1-13 06M20lG - 06TS202B llM103A - llM103F 11 03 12 03 20 05 23 02 23 09 23 14 Axle End Master Cylinder Service Brake Master Cylinder (s erv ce> (inch ing) Steeri ng Gear (Char-Lynn) 25 02 Steeri ng Gear (Manual) 25 05 Steeri ng Gear (Ross) 25 06 Steer Cylinder 26 10 Hydraulic Pump (Cushion Machines) 29 07 Hydraulic Pump (Yardlifts) 29 11 Hydraulic Valve 30 01 Tilt Cylinder 32 06 Lift Cylinder 34 01 l-20 l-20 l-10 l-5 l-9 1-6 1-17 l-15 1-12 1-6 1-16 l-10 1-13 l-9 l-52 Code: OH-367, MAY 79 CONTENTS Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

CMRK GR&UP FOREWORD OVERHAUL 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 sect ion includes al 1 relevant i 1 lustrat ive material avai lable, 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 sect ion. Each section is self- contained (or modular), with consecutive page numbers and pub1 ication date at the bottom of al 1 pages included therein. Where possible, general instructions are presented as appl icable to a family of assembl ies. Any necessary variations in specifications are given in column form with a CLARK part number on each line. 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 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 which a section appears bears the same group number as Service Parts Books list for most assembl ies. In some cases, however, an overhau 1 procedure wi 11 mention a sub-assembly from another parts grouping simply because it would be impractical to attempt to overhau 1 the sub-assemb ly . For example, a motor brake must be d is- 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 overhau 1 ing 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 OCT 77 Foreword Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

MASTER MAINTENANCE MANUAL Instructions MEAD ENGINES FOUR CYLINDER N56 - N62 Y69 -Y91 -Y112 F124 - F135 -Fl40-Fl62--163 SIX CYLINDER F186 - F209 - F226 - F227 - F244 - F245 M271 - M290 - M330 - M363 B371 - B427 COURTESY OF: 7WELEDYNE CONTINENTAL MOTORS TELEDYNE CONTINENTAL MOTORS Printed in U.S. A. Form No. X-27053A-Revised 9-71 Copyright 1971 oo~si52~ REV SEP 72 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

MASTER MAINTENANCE MANUAL TROUBLE SHOOTING A preventive maintenance system including inspection, lubrication and adjustment as recom- mended in our Maintenance Section will prevent the greater portion of gasoline engine troubles. 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 time - then locate the trouble by a process of elimination. Remember 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 gasoline engines and the probable causes. A- STARTING MOTOR - WILL NOT CRANK ENGINE: 1 - Weak or dead battery. 2 - Poor ground connection. 3 - Faulty starting switch or relay. 4 - Defective starting motor. 5 - Interna! engine seizure - turn engine man- ually to determine cause. B- ENGINE CRANKS - BUT DOES NOT START: Disconnect one spark plug wire, turn ignition on with starter cranking engine and free end of wire i/j{” from cylinder head - note spark. 1 - NO SPARK: (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. OOTSl52B (B) - Normal Ammeter Reading (2-5 Amps) - this indicates that primary circuit is OK - trouble may be in secondary circuit due to : 1 - Broken or grounded high tension wire from coil to distributor. 2 - Wet high tension wires. 3 - Faulty distributor cap or rotor. .4 - 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) Loose ignition wiring connections. 03) Burned or pitted distributor points. (C) Wet spark plug wires. (D) Defective condenser. (El Cracked distributor cap. (F) Weak ignition coil. 3 -GOOD SPARK AT EACH PLUG-indicates that ignition system is OK and trouble is in fuel system - which may be due to : (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. 5 - Plugged vent in fuel tank cap. (B) Gas in Carburetor-which may be flooded due to: 1 - Too much choking - plugs are wet. 2 - Wrong float level. 3 - Choke not operating correctly. 4 - Water in Gas. REV SEP 72 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

MASTER MAINTENANCE MANUAL c- ENGINE RUNS WITH CONTINUOUS MIS-FIR- ING: 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. 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. 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 incorrect gap. E- ENGINE RUNS IMPROPERLY I- Back-Firing into Manifold - indicates Too Rich a fuel mixture ; into carburetor indicates Too Lean a mixture-may be due to : (A) Late Ignition Timing. 03) Clogged Air Cleaner. (0 Fuel line restrictions. 0) Clogged carburetor jets. (El Sticking Valves. (F) Weak or broken valve springs. 2 - Excessive Ping (Detonation)-Results in damaged pistons and bearings and is caused by pre-ignition or using inferior grade of gas. 3 - Engine Idles Too Fast - indicates improper throttle adjustment or weak throttle return springs. 4 - Engine Dies When Idling-which indicates incorrect speed or mixture adjustment; clogged idling circuit in carburetor or wrong choke adjustment, or air leaks in intake manif old. 5 - Engine “Stumbles” on Acceleration - which may be due to defective accelerator pump or air in fuel lines. OOTSl526 6 - Defective Spark Plugs. F - 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 air 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. G - POOR COMPRESSION--check with compression 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: 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. H- OVERHEATING 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 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

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 consumption - possible causes of high oil pressures 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 condition. 7 -Worn, broken or stuck piston rings and clogged oil control rings. 8 - Worn pistons and sleeves. 9 -Worn bearings. 10 - Worn valve guides. (Manifold ma,y be removed for visual inspection.) 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 lower operating speeds. 2 - Mechanical Knocks--result from wear, abuse or improper adjustments - which may be due to : (A) Crankshaft and Main Bearings : (1) Worn or burned-out Main Bearings - A heavy, dull knock when accelerat- ing under load. Locate by shorting out plugs on both sides of the bad bearing. (2) Crankshaft End-Play - excessive end-play is indicated by an intermittent 00~~152~ 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 bearings 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) Valves (1) Burned Valves and Seats - engine misses, especially at low speeds, or acceleration under load. (2) Weak or Broken Valve Springs - missing at low or high speeds when under 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 bearings 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 originating 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 SEP 72 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

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CLARK Forklift C500 20/30 Workshop Service Shop Repair Manual

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