CLARK Forklift C500 OVERHAUL Workshop Service Workshop Repair Manual

OH-339 a00 OVERHAUL MANUAL

INDUSTRIAL TRUCK DIVISION MARKETING TRAINING DEPT. TABLE OF CONTENTS SUBJECT GROUP SECTION ENGINE OVERHAUL (GAS) .................. ENGINE OVERHAUL (DIESEL). ................ ENGINE OVERHAUL (PERKINS DIESEL). ............ EXHAUST EMISSION SYSTEM ................. CARBURETOR OVERHAUL (BENDIX-ZENITH) ........... LPG SYSTEM MAINTENANCE ................. ................. ................. TRANSMISSION OVERHAUL (HYDRAT~RK) ............ TRANSMISSION OVERHAUL (MANUAL) ............. ENGINE TEST PROCEDURES ................. STARTER OVERHAUL .................... DISTRIBUTOR MAINTENANCE ................. ALTERNATOR MAINTENANCE ................. ALTERNATOR OVERALL ................... AXLE END MAINTENANCE .................. BRAKE MAINTENANCE .................... NEUTRAL STARTING SWITCH ................. STEER CYLINDER MAINTENANCE ............... HYDRAULIC PUMP OVERHAUL (GEAR) ............. HYDRAULIC PUMP OVERHAUL (VANE) ............. HYDRAULIC VALVE OVERHAUL ................ TILT LOCK VALVE ..................... TILT CYLINDER ...................... ACCUMULATOR OVERHAUL .................. UPRIGHT LIFT CYLINDER OVERHAUL. ............. UPRIGHT ROLLER CHECK AND ADJUSTMENT PROCEDURES. ..... 00 03 00 04 00 12 02TS200A-K 02M200A-02S553A 02 05 02 06 02 08 06TS205A-06M406E 08M104A-08TS106A llTSOOOA-1lTSOOOBK llM103A-llS199C llM602A-llM602D 12TSlOOA-12S102A 12 03 20M801A-20S801B 23M500HB-23M867G 23M900A-26TSlOlA 26TSlOlA-26SlOlA 29 01 29M007A-30S202B 30M203A-30TS203A 30TS301A-30M301D 32 06 32 01 34 01 34 02

INDUSTRIAL TRUCK DIVISION MARKETING TRAINING DEPT. FOREWORD 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.

INDUSTRIAL TRUCK DIVISION MARKETING TRAINING DEPT. SAFETY MESSAGES La ! WARNING LIFT TRUCK MAINTENANCE DO NOT WORK ON THIS TRUCK UNLESS YOU ARE TRAINED AND AUTHORIZED AND KNOW THE CORRECT MAINTENANCE PROCE- DURES. a ! WARNING BATTERY SERVICE BATTERY SERVICE MUST BE DONE BY TRAINED PERSONNEL. BATTERY ACID CAN CAUSE SEVERE BURNS AND INJURY. a ! WARNlNG -~ HYDRAULlC FLUID PRESSURE DO NOT USE YOUR HANDS TO CHECK FOR HYDRAULIC LEAKAGE. FLUID UNDER PRESSURE CAN PENETRATE YOUR SKIN AND CAUSE SERIOUS INJURY. a ! WARNING STEAM DO NOT REMOVE THE RADIATOR CAP WHEN THE RADIATOR IS HOT. STEAM FROM THE RADIATOR WILL CAUSE SEVERE BURNS. c WEAR EYE GLASSES, SAFETY SHOES AND CORRECT FITTING CLOTHING #IEN WORKING ON LIFT TRUCKS. INJURY CAN RESULT IF YOU DO NOT WEAR PROTECTION. a ! WARNING CARBON MONOXIDE INTERNAL COMBUSTION ENGINES GENERATE TOXIC GASES WHICH CAN CAUSE SERIOUS INJURY OR DEATH WHEN INHALED. BE SURE THERE IS ENOUGH VENTILATION. I a ! WARNING AIR PRESSURE WEAR EYE PROTECTION & PROTEC- TIVE CLOTHING WHEN CLEANING OR DRYING WITH AIR PRESSURE. REDUCE PRESSURE TO ['207kPa] 30 PSI. DEBRIS REMOVED WITH AIR PRESSURE CAN CAUSE INJURY. /I DO NOT WALK OR STAND UNDER RAISED FORKS. THE FORKS CAN FALL AND CAUSE INJURY OR DEATH. Code: OH-339, MAY 83

cl!!wIs GR&uP GROUP 00 SECTION 3 CLARK (WAUKESHA) ENGINE OVERHAUL D 155G, D155GA, D176G (G A S> Section 3, Page 1

INDUSTRIAL TRUCK DIVISION CUSTOMER SERVICES GROUP TROUBLE SHOOTING ENGINE WILL NOT CRANK The cause of the trouble is usually in the starting system. If the trouble is not in the starting system, check for hydrostatic lock or a seized engine, as follows: Remove the spark plugs, and attempt to crank the engine with the starter. If coolant is ejected from the openings it indicates that water is leaking into the cylinders. Remove the cylinder head and inspect the gasket and head for cracks. Examine the cylinder block for cracks. ENGINE CRANKS Check the fuel supply. If there is sufficient fuel in the NORMALLY, BUT WILL tank, the cause of the trouble probably lies in either the NOT START ignition or the fuel system. To determine which system is at fault, perform the following test: Disconnect a spark plug wire, check the spark intensity at the end of the wire by installing a terminal adaptor in end of the wire. Then, hold adaptor approximately 3116 inch from the cylinder block and crank the engine. IF THERE IS NO SPARK OR A WEAK SPARK AT THE SPARK PLUGS The cause of the trouble is in the ignition system. Disconnect starter relay leads ... install an auxiliary starter switch between the battery and the starter relay. To determine if the cause of the trouble is in the primary or the secondary circuit, remove coil high tension lead from the top of the distributor, and hold it approximately 3/16 inch from the cylinder head. With the ignition on, $ crank the engine and check for a spark. % 0 If the spark at the high tension lead is good, the cause 0 of the trouble is probably in the distributor cap, rotor or spark plug wires. If there is no spark or a weak spark at the coil high tension lead, the cause of the trouble is probably in the primary circuit, coil to high tension lead, or the coil. IF THERE IS A GOOD SPARK AT THE SPARK PLUGS Check the spark plugs. If the spark plugs are not at fault, check the following items:

CMRK GR&up TROUBLE SHOOTING CHOKE Check the choke linkage for binding or damage. Make certain the choke plate closes when the choke knob is pulled out and that the plate opens when the knob is pushed in. FUEL SUPPLY AT CARBURETOR Disconnect carburetor fuel inlet line at the carburetor. Use a suitable container to catch the fuel. Crank the engine to see if fuel is reaching the carburetor. If fuel is not reaching the carburetor, check: The fuel pump, the fuel filter, the carburetor fuel inlet line for obstructions; the fuel pump inlet line for a collapsed condition; the fuel tank line for obstructions; the fuel tank vent. If fuel is reaching the carburetor, check: The fuel inlet system including fuel inlet screen, fuel inlet needle and seat assembly and the float assembly. ENGINE Mechanical failure in the camshaft drive. ENGINE STARTS BUT FAILS TO KEEP RUNNING FUEL SYSTEM Idle fuel needle not properly adjusted, engine idle speed set too low; float setting incorrect; float inlet system not operating properly; dirt or water in the carburetor fuel lines or in the fuel filter; defective fuel pump. Check for dirt in the carburetor, not allowing fuel to enter or to be discharged from the idle system. IGNITION SYSTEM Defective spark plugs, breaker points not properly adjusted. ENGINE RUNS, BUT MISSES Determine if the miss is steady or erratic and at what RPM the miss occurs by operating the engine at various RPM(s) under load.

INDUSTRIAL TRUCK DIVISION CUSTOMER SERVICES GROUP TROUBLE SHOOTING MISSES STEADILY AT ALL SPEEDS Isolate the miss by operating the engine with one cylinder not firing. This is done by operating the engine with the ignition wire removed from one spark plug at a time until all cylinders have been checked. Ground the spark plug wire removed. If the engine RPM changes when a particular cylinder is shorted out, that cylinder was delivering power before being shorted out. If no change in the engine operation is evident, the miss was caused by that cylinder not delivering power before being shorted out. In this case check the: IGNITION SYSTEM If the miss is isolated in a particular cylinder, perform a spark test on the ignition lead of the cylinder. If a good spark does not occur, the trouble is in the secondary circuit of the system. Check the spark plug wire, and the distributor cap. If a good spark occurs, check the spark plug. If the spark plug is not at fault, a mechanical component of the engine is probably at fault. ENGINE Intake manifold leak (vacuum). Perform a manifold vacuum or a compression test to determine which mechanical component of the engine is at fault. MISSES ERRATICALLY AT ALL SPEEDS EXHAUST SYSTEM Exhaust system restricted. IGNITION SYSTEM Breaker points not properly adjusted. Defective breaker points, condenser, secondary wiring, coil or spark plug. High tension leakage across the coil, rotor or distributor cap. Defective ignition switch.

C19RK GRoOo TROUBLE SHOOTING FUEL SYSTEM Float setting incorrect. Fuel inlet system not operating properly. Dirt or water in the fuel lines or carburetor. Restricted fuel filter. COOLING SYSTEM Check the cooling system for internal leakage and/or for a condition that prevents the engine from reaching normal operating temperature. ENGINE Damaged cylinder head gasket. Perform a compression or manifold vacuum test to determine which mechanical component of the engine is at fault. MISSES AT IDLE ONLY FUEL SYSTEM Idle fuel mixture needle not properly adjusted. Restriction in idle fuel system. IGNITION SYSTEM Excessive play in distributor shaft. Worn distributor cam. Defective coil, rotor, condenser, breaker points, ignition wiring or spark plugs. ENGINE Valve clearance (engines with mechanical lifters) or valve adjustment (engines with hydraulic valve lifters) set too tight. Worn camshaft lobe. Perform a compression test to determine which mechanical component of the engine is at fault.

INDUSTRIAL TRUCK DIVISION CUSTOMER SERVICES GROUP TROUBLE SHOOTING MISSES AT HIGH SPEED ONLY FUEL SYSTEM Low or erratic fuel pump pressure. Fuel inlet system not operating properly. Restricted fuel filter. Restricted main fuel system. ENGINE Perform a compression test to determine which mechanical component of the engine is at fault. COOLING SYSTEM Engine overheating. IGNITION SYSTEM Defective spark plugs. ROUGH ENGINE IDLE FUEL SYSTEM Engine idle RPM set too low. Idle fuel mixture needle not properly adjusted. Float setting incorrect. Air leaks between the carburetor and the manifold, or the manifold and cylinder head, and/or fittings. 5 0 Fuel leakage at the carburetor fuel bowl. 0 Idle fuel system air bleeds or fuel passages restricted. Leaking fuel pump, lines or fittings.

CLARK Forklift C500 OVERHAUL Workshop Service Workshop Repair Manual

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