1980–1983 Clark C500 Forklift Overhaul & Repair Manual (P/N OH-339)

Clark's C500 Overhaul Manual, publication code OH-339, covers component repair for the 1980–1983 C500 forklift range. Its contents page carries a May 1983 revision, with sections for Clark/Waukesha engines, transmissions, electrical equipment, brakes, steering, hydraulics, and uprights.

• Engine overhaul: Cylinder-head and lower-engine disassembly, valve-guide installation, gear timing, water-pump rebuilding, compression testing, and diesel injector inspection.

• Fuel and emissions: Bendix-Zenith carburetor service, low-emission system maintenance, and IMPCO LPG lock-off valve, vaporizer-regulator, and carburetor overhaul.

• Transmission service: Hydratork selector-pack inspection and rebuilding, manual gearbox disassembly and reassembly, control-cover servicing, and neutral starting switch adjustment.

• Axles and brakes: Axle-end rebuilding, differential troubleshooting, wheel-cylinder service, hydraulic brake bleeding, parking brakes, and automatic brake adjusters.

• Steering and hydraulics: Steer-cylinder diagnosis, gear and vane pump overhaul, hydraulic control-valve repair, tilt lock valve troubleshooting, and bladder accumulator servicing.

• Uprights and lift cylinders: Standard, Hi-Lo, and compound lift-cylinder service, repacking, bleeding, upright roller checks, and shim adjustment.

• Electrical diagnosis: Starter and alternator overhaul, ignition distributor tests, charging-system checks, and component wiring diagrams.

Written for mechanics trained and authorized to service lift trucks, this manual assumes workshop equipment and familiarity with component overhaul.

Engine Overhaul and Assembly Coverage

Cylinder-head, crankshaft, camshaft, and piston procedures are supported by valve-seat, main-bearing, and piston-skirt inspection data. The tables cover piston ring end gaps, crankshaft end play, timing gear backlash, and fastener torques; camshaft end play is controlled by a thrust button.

Separate illustrations distinguish early and late cylinder heads and their tightening sequences. Gear Timing diagrams and piston assembly illustrations support reassembly. The camshaft notes explain how worn lifters can cause premature failure of a replacement camshaft.

Perkins coverage: The 4.203.2 material is limited to engine identification views and a reference to separate Perkins manuals. Internal Perkins engine overhaul instructions are not included.

Carburetor and LPG Variants

Zenith 68 and 28/228 series sections cover float settings, fuel circuits, and linkage adjustments. IMPCO CA100-110 and CA100-112 carburetors differ in throttle-body flange size and lever arrangement; the manual directs application checks to the truck's Product Identification Card.

The low-emission material includes maintenance and field-installation instructions, but refers replacement-part selection to the applicable carburetor service manual. LPG sections add regulator and lock-off valve bench tests.

Transmission, Axle, and Brake Work

Hydratork chapters separate single-speed and two-speed assemblies, with selector-pack exploded views, sealing-ring inspection, and control-cover procedures. The single-speed section treats the torque converter as a replacement assembly; only its drive plate is serviced separately.

R200D and R200T manual-transmission sections cover shaft assemblies and clutch-release components. A retaining-ring caution explains how incorrect handling can fracture the retaining lip inside the transmission housing.

The axle section includes the Spiral Bevel and Hypoid Tooth Bearing Contact Chart. Brake instructions distinguish adjuster designs and cover wheel-cylinder faults, pedal adjustments, and manual or pressure bleeding.

Hydraulic Testing and Component Repair

Schroeder Hydra-Sleuth supply-system and tee tests help distinguish pump or relief-valve losses from control-valve and cylinder leakage before components are selected for repair. The Hydraulic Schematic Showing Test Points identifies the circuit locations used in those tests.

Pump coverage includes Parker Hannifin D-series gear pumps and Vickers vane pumps, alongside Vickers CM11 Series 21 control-valve service. Greer accumulator sections distinguish poppet-valve and Greerolator button-and-seat designs, with charging instructions and pressure-volume curves.

Lift Cylinders and Upright Rollers

Lift-cylinder sections show standard and Hi-Lo assemblies in section and document compound-cylinder rebuilding. The V-packing-to-U-cup replacement guide distinguishes packing styles and the associated bushing and spring arrangements.

High-pressure hydraulics, raised uprights, and heavy component handling require trained personnel and the manufacturer's specified support and pressure-release precautions.

Ignition, Starting, and Charging Tests

Sun test-equipment procedures address cylinder leakage, dwell, ignition waveforms, and fuel-pump pressure and volume. Delco-Remy chapters cover starter armatures, alternator rotors, stators, diodes, and regulators.

The Primary Wiring Insulation Test illustration and Delcotron Typical Wiring Diagram support electrical diagnosis, alongside alternator cross-sectional views. These are component and test-circuit references.

Examples from the Engine Test Specifications

These values are a small selection of the engine diagnostic specifications in the manual.

Gas-engine compression: For the warm-engine test with the throttle open, cranking compression is 170–195 psi for D155G/D155GA engines and 160–180 psi for the D176G.

Diesel injectors: D155D injector opening pressure is 3,200 psi for new injectors and 3,000 psi ± 50 psi in service.

Text Search, Section Bookmarks, and Page Contents

Navigation and diagram detail: OCR text search is available, although some codes and diagram labels are misread or missing. There are 82 embedded bookmarks, with occasional title errors. Small wiring labels benefit from zooming; some hydraulic-test text remains faint.

One printable 640-page PDF in English, including four opening pages, 10 notes pages, 15 safety/cleaning reminder pages, one supplementary information page, and a one-page hydraulic-test addendum. The 11-page R200D transmission section appears twice, with both copies already included in the total.