CLARK FORKLIFT PMA-452 C500 Y60100 Planned Maintenance and Adjustment Manual

PMA-452 C500 Y60/100

CUARK

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Technical Pu�llcations LeXJngton, KY 40508

CIARK

PM

C500 Y60-70-80-90-100 HYDRATORK GASOLINE AND L.P.G.

Code:

PMA-452 T@mporary

Apr. 85

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Page 1

CL'IAK

INDUSTRIAL TRUCK DIVISION

EQUIPMENT

CUSTOIIU SCUIC[S CUINEUIN' O!PUTIIENT. IHTL[ CUCK

I L LU S T R A T E D

CL'IAK·

EQUIPMENT

I N D E X

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Code: PH-276, JUN 75

Page 2 Co11yrigh1<d M�icri�I lnt�nd.J for CLARK dc�lcrs only Do not �II or d1>tnhule

CLARK

PM

I N D E X Alternator Maintenance Axle End Lubrication .

Brake Bleeding . . . .

Brake Pedal Adjustment . .

Carriage Roller Adjustment Cooling System Maintenance Counterweight Removal . .

Driver Restraint System Checks Engine Trouble Shooting Engine Tune Up . . . . . . . .

Fuel Pump Tests . . . . . . . . . .

Hydratork Transmission Drain & Refill . .

Hydratork Transmission Fluid Aeration Check Hydratork Transmission Oil Cooler Hydratork Transmission Pressure Checks .

Hydraulic Sump Tank Drain Hydraulic System Pressure Check Lift Chain Adjustment . .

Lift Chain Maintenance . . . .

Lubrication . . . . . . . . .

Lubrication Key . . . . . . .

Name Plates/Machine Stampings Neutral Start Switch . .

Parking Brake Adjustment Safety/Inspection Fonns Service Brake Adjustment Specifications . . . . • .

Starter Maintenance Steering Adjustments • .

Steering Pressure Check Steer Wheel Bearings . .

Tilt Cylinder Adjustments Upright Roller Adjustment • . . . � Upright & Tilt Cylinder Drift Tests Wheels & Tires . .

Wiring Color Code . . . . . . . . .

Code: PM-276, FEB 84 REV

Cupyri�ht�-d Mo.lcrul lntmdcd f«CL-\RK d,-alcr.onl> Do nol ,ell« diotribtJlc

GROUP GROUP GROUP GROUP GROUP GROUP GROUP Group GROUP GROUP GROUP GROUP GROUP GROUP GROUP GROUP GROUP GROUP GROUP GROUP GROUP GROUP GROUP GROUP GROUP GROUP GROUP GROUP GROUP GROUP GROUP GROUP GROUP GROUP GROUP GROUP

12, 20, 23, 23, 34, 01, 38, 39, 00, 00, 02, 06, 06, 06, 06, 29, 30, 34, 34, 01, 40, 40, 13, 23, 40, 23, 40, 11, 26, 26, 26, 34, 34, 34, 22, 14,

Section Section Section Section Section Section Section Section Section Section Section Section Section Section Section Section Section Section Section Section Section Section Section Section Section Section Section Section Section Section Section Section Section Section Section Section

1 1 l 2 l 2 1 1 1 2 1 4 2 3 l l l 3 7 l 4 l 1 4 3 3 2 1 2 1 3 5 2 4 1 1

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INDUSTRIAL TRUCK DIVISION CUSTOIIER SEUICES UGINHIIN& OEPUTIIUT, UTTLE ClEU

FO R EW O R D PLANNED MAINTENANCE SECTION The Planned Maintenance Procedures located in the front of this book provide a basic step by step guide �ich should be fol lowed in servicing the vehicle. Adjustment Procedures, specifications and other data including lubrication guides, are found in the rear of this book and are listed under GROUP and Section Numbers. Refer to the Index or the Product Identification Card.

About Planned Maintenance Planned Maintenance is a program in �ich Inspections, minor adjustments, lubrication, oil changes and replacement of filters are performed on a scheduled and systematic basis. A solid PM program should incorporate a method of record keeping �ich enables you to better determine PM schedules and enables you to track the maintenance costs per machine.

An effective PM program should Incorporate two basic phases: 1. An inspection performed by the driver or maintenance man at the beginning of each shift. This is a quick visual check for obvious damage and leaks ••• a check of engine oil and water levels, 1ights, Instruments and warning devices.

2. THE PLANNED MAINTENANCE ROUTINE IS BASED ON 50 TO 250 OPERATING HOURS ••• WITH THE INTERVAL B EING D ETERMINED BY O PERATING C ONO ITIOHS • Records will tel 1 you how often PM should be done. If an operation is clean and not punishing, a PM interval can be extended. If an operation Is extremely dirty and punishing, the PM Interval may have to be reduced. Thus the PM Interval can be tailored to answer the needs of your operation.

If the PM is religiously followed, needs for repair, major adjustment and component replacement wl II be discovered automatlcal ty and such work wi I I be done only as needed, For

instance, brake checks which are part of the PM wilt uncover the need for adjustments and/or repairs which may be required periodically.

Who can say? The point is that this wi 11 be done only �en needed and that's true for all Systems and components. Thus, in this program we are able to elimlnate 500, 1000 and 2000 hour inspections and the things normally covered in these Inspections wi II be done only �en the PM uncovers the need for repairs.

The objectives of PM are: 1.

To reduce costly unscheduled downtime.

2,

Reduce maintenance costs,

J. Increase vehicle productivity, 4.

Above all, to increase personal safety of drivers and other personnel,

Inspection Forms To Insure that the daily inspection and PH are properly performed, we reconmend the use of the inspection forms in GROUP 40, Such forms not only provide a guide for the Inspections and procedures, but serve as a record in tracking maintenance requirements for each vehicle.

Moreover, they wi II assist you in determining when to schedule a vehicle for major repairs which can be done without the disruptive effect of unscheduled downtime, Inspection Forms may be purchased from your local CLARK Dealer.

SPECIAL NOTICE TO ALL USERS OF THIS MANUAL. IF ·�· in the process of using this manual for PH procedures, adjustments, references, etc ••• you find that this manual can be improved .!.!J. !.!!.Y �• put your Ideas ln writing and send them to: CUSTOMER SERVICES ENGINEERING CLARK EQUIPMENT COMPANY BATTLE CREEK, MICHIGAN (49016) We can 1 t promise that your idea will be used, but it wil I be seriously considered, If you do submit any such Ideas, please understand that Clark Equipment Company can use It without obi igation, Page 4

Code: PM-366, REV HAY 77 Cop) ,ightcd '-fatcrial Intended for <..L.-\RK deulen< onl) Do not ""II or dL�nnutc

CIARK

PM

PERFORMING A PM: First check the oil level and add oil if the level is below the add mark.

Fig. AOO74 Cushion Only Check the transmission fluid level. The dipstick is located here on cushion machines.

Fig. AO1O3 Yardlift Only The transmission dipstick is located here on the yardlift machines.

Fig. AOOO3 Check the main hydraulic system sump level with the carriage lowered.

Fig. AOO35

Code: PM-276, REV JUL 81 P.S.L.

Cop) ,ightcd '-fatcrial Intended for C..l.-\RK deulen< onl) Do not ""II or dL�nnutc

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CLqRK

INDUSTRIAL TRUCK DIVISION

EQUIPMENT

CISTl■U

mmu UIIIUIIH DEPUT■(n, UTTU CIHJ

LPG Only Check all LPG fittings and connections for security.

Fig. A0088 LPG Only Check the safety relief valve for damage.

Fig. A0044 LPG Only Open the LPG fuel valve.

Fig. A0087 LPG Only Using a soapy solution, check all fittings and connections for leaks and tighten or repair all found.

Fig. 14707

Code: PH-276, JUN 75

Page 6 Co11yrigh1<d M�icri�I lnt�nd.J for CLARK dc�lcrs only Do not �II or d1>1nbule

ClARK

PM

LPG Only Check the wire from the oil pressure switch to the solenoid to make sure it is not loose.

Fig. AOO 11 LPG Only Check the wires connected to the oil pressure switch for security.

Fig. AOO79 Gas Only Check the main fuel valve for operating position.

Fig. AO1O2 Set the heat riser valve for proper operating position. It should be closed on LPG machines and open on gas machines.

....

Fig. AOO45

Code: PH-276, REV SEP 77

Copyrighted M,ucri:d lnt.:ndcd for lL,�RK dcalc,. only Ou not �II or d101nbutc

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INDUSTRIAL TRUCK DIVISION tUSTOMll $[1lltlS CNGINHIING OEPUTIHNT, Ullll UEEK

Check the fuel level.

GAS

L.P. GAS

Fig. 16628 Check the water level and add the right coolant mixture.

Fig. AOO36 Push do,-1n on the brake pedal, If the pedal drifts dm-m, check for leaks In the system. I f the pedal is spongy, the system needs bleeding.

(See GROUP 23, Section 1 .)

Fig. AO1O1 Now, set the parking brake, start the engine, shift into low gear and slowly accelerate. The truck should not move. If it does then see GROUP 23, Section 4 for adjustment procedures.

Fig. AOO49

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Code: PM-276, JUN 75 Copn11htcd \fa1.-nal lnt,,t<kd r,-,,-l'l.Altt.: dc�k.-. univ I>.> no1 .rll or d1.,1r1huu: