Format: PDF (Printable Document)
File Language: English
File Pages: 641
File Size: 85.95 MB (Speed Download Link)
Brand: Clark
Model: C500 Forklift
Book No: OH339
Type of Document: Overhaul Manual
$ 40
A C500 is usually working hard in warehouses, yards, and loading docks, so when it’s down for an engine or major top-end issue, you can’t afford guesswork. This overhaul manual helps you tear the powerplant down methodically, inspect what’s worn, and build it back so it starts clean, pulls strong, and doesn’t come back on a hook. If you’re chasing a low-compression misfire or a forklift that’s suddenly lost lifting power under load, this is the book you keep open on the bench while you strip, measure generally, and reassemble.
Applications & Use Cases
FAQ
Q: Is this manual practical to use on a tablet in the shop?
A: Yes, many techs keep it open on a tablet for quick zooming on diagrams and step references while working at the truck.
Q: Should I still print pages from it?
A: It’s smart to print the pages for the job you’re doing so you can mark notes, oily fingerprints, and measurements right at the bench.
Safety Note
Always lock out the truck, support all raised components securely, and follow the manual’s safety warnings before starting any overhaul work.
OH-339
TABLE OF CONTENTS
FOREWORD
SAFETY MESSAGES
GROUP 00 SECTION 3 (Gas)
TROUBLE SHOOTING
CYLINDER HEAD OVERHAUL
CYLINDER HEAD REASSEMBLY
LOWER ENGINE OVERHAUL
DISASSEMBLY (ENGINE FRONT):
Gear Installation
GEAR TIMING
BASIC ENGINE DATA
GROUP 00 SECTION 4 (Diesel)
CLARK (WAUKESHA) D155D OVERHAUL
FUEL INJECTION TEST & MAINTENANCE
INSTALLATION OF NEW VALVE LIFTERS ALONG WITH NEW CAMSHAFT
ASSEMBLY OF WATER PUMP
REASSEMBLY OF WATER PUMP
Dl55D ENGINE REASSEMBLY
TIMING:
INJECTION PUMP & ENGINE TIMING:
DIESEL BASIC ENGINE DATA
TIMING GEAR/S BACKLASH
GROUP 00 SECTION 12 (Perkins)
EXHAUST EMISSION SYSTEM
SECTION I MAINTENANCE AND FIELD INSTALLATION OF LOW EMISSION EQUIPMENT
SECTION II MODELS 2267 LW 10 AND LX 9 CARBURATORS
ZENITH CARBURETOR MODEL Z267LWlO AND Z267LX9
ZENITH 68 SERIES CARBURETORS
SECTION IIIZENITH 28 & 228~SERIES CARBURETORS
ZENITH 28 AND 228 SERIES CARBURETORS
SECTION IV MODELS ZPC 2 J 10 AND ZPC 1 J 8 CARBURATORS
BENDIX-ZENITH CARBURETOR ASSEMBLY MODEL ZPCZJIO AND ZPClJ8
TYPE A-962A VAPORlZER- PRIMARY REGULATORS
GROUP 02 SECTION 5 IMPCO LPG LOCK-OFF VALVE
GROUP 02 SECTION 6 IMPCO LPG VAPORIZER-REGULATOR
GROUP 02 SECTION 8 IMPCO LPG CARBURETOR
1 SPEED FORWARD AND REVERSE HYDRATORK TRANSMISSION (MODELS H-200 THROUGH H-211)
CLEANING AND INSPECTION
SELECTOR PACK REASSEMBLY
MODEL H-200 TRANSMISSION REASSEMBLY
FLUID SEAL/S, SPECIFICATIONS
2 SPEED FORWARD AND REVERSE HYDRATORK TRANSMISSION (MODELS H-200 THROUGH H-211)
REASSEMBLY
FLUID SEAL(S), SPECIFICATIONS
MODLE H-200D MANUAL TRANSMISSION DISASSEMBLY AND REASSEMBLY
R 200 1 SPEED MANUAL TRANSMISSION
MODLE R200D MANUAL TRANSMISSION DISASSEMBLY AND REASSEMBLY
MODEL R200T MANUAL TRANSMISSION DISASSEMBLY ANDREASSEMBLY
PARKING BRAKE DISASSEMBLY AND REASSEMBLY
TRANSMISSION REASSEMBLY
SUN TESTER
GROUP 11 SECTION 4 DELCO-REMY STARTING MOTOR OVERHAUL
DELCO-REMY IGNITION DISTRIBUTORS
GROUP 12 SECTION 3 ALTERNATOR OVERHAUL
ALTERNATORS — DELCO-REMY — “DELCOTRON”
DELCOTRON” GENERATORS
DRIVE AXLE, DIFFERENTIAL AND AXLE ADAPTOR
AXLE END DISASSEMBLY AND ASSEMBLY
REASSEMBLY OF THE AXLE END ASSEMBLY
HYDRAULIC ACTUATION WHEEL CYLINDERS
OTHER WHEEL CYLINDER TYPES
TWO BLEEDING METHODS – MANUAL AND PRESSURE
PARK I NG BRAKE
WHEEL BRAKE
TO ELEVATE DRIVE WHEELS
NEUTRAL STARTING SWITCH
POWER STEER CYLINDER
GROUP 29 HYDRAULIC PUMP OVERHAUL SECTION 1
VANE TYPE HYDRAULIC PUMPS (SINGLE)
Parker Hannifin Hydraulic Unit
Section I – Parker Hannifin “D” Series Gear Pumps
TESTING THE HYDRAULIC SYSTEM
DISASSEMBLY – REASSEMBLY OF VICKERS – CM11 SERIES 21 DESIGN – VALVE
TILT LOCK VALVE TROUBLE SHOOTING
GROUP 32 GREER BLADDER ACCUMULATOR OVERHAUL
GROUP 32 SECTION 6 TILT CYLINDER OVERHAUL
GROUP 34 UPRIGHT LIFT CYLINDER OVERHAUL
GROUP 34 SECTION 2 UPRIGHT ROLLER CHECK AND ADJUSTMENT PROCEDURES
