SM-520R
GCS/GCS
,Foreword
This service publication provides information covering normal service, maintenance and repair of the
Clark lift trucks noted on the cover. It has been specifically prepared to help owners and service
personnel maintain these lift trucks in efficient and safe operating condition.
Regular, correct maintenance and care of lift trucks is not only important for long and efficient truck life; it
is essential for safe operation. The importance of proper maintenance through planned service, inspection
and qualified repairs cannot be emphasized too strongly.
To assist in keeping lift trucks in good operating condition, this manual includes preventive maintenance
procedures to be performed at regular intervals. These are essential to the service life and safe operation
of all fork lift trucks. Instructions for safety inspections, operational checks, cleaning, and lubrication are
provided for reference in setting-up and conducting a recommended periodic Planned Maintenance (PM)
program.
Refer to the Operator’s Manual, located on the truck, for additional information on the operation, care and
maintenance of your truck.
Genuine Clark replacement parts should be used for all service and repair requirements. Substitute parts
from other sources may be different than original parts and may not meet OSHA or other safety
requirements.
Any reference to brand names other than Clark in this manual is made simply as an example of the type of
tools and materials recommended for use and, as such, should not be considered as an endorsement.
Equivalents, if available, may be used.
For more information on maintenance and repair of these trucks, contact your authorized Clark dealer.
NOTICE - The descriptions and specifications included in this manual were in effect at the time of
printing. C/ark Equipment Company reserves the right to discontinue models at any time, or make
improvements and changes in specifications or design without notice and without incurring
obligation. Specifications, torques, pressures, measurements, adjustments, illustrations and other
items may change at any time. Contact your authorized CLARK dealer for information on possible
updates or revisions.
0 1989 Clark Equipment Company
1211I89 SM520
ii
, Contents
Subject Part
1
General Information ...........................................................................
2
Specifications........................................................................................
Planned Maintenance .......................................................................
3
Engine (Group 00) .................................................................................... 4
Fuel System (GROUPS 02,03) ................................................................. 5
Electrical System (Groups 11-15) ........................................................ 6
Transaxle (stops 06,07,20) ................................................................. 7
Brakes and Inching System (GIOUPS 22,23) ................................... 8
Steering System (Groups 25,26) ......................................................... 9
Hydraulic System (Groups28-33)..................................................... IO
Wheels and Tires (Groups 22,23) .................................................... 11
Counterweight and Chassis (Group 38) ...................................... 12
Uprights (Group 34). ............................................................................. 13
14
Index.. ....................................................................................................
SM520 212719
1
...
III
, About This Manual
This manual is intended for use by persons who are trained and authorized to do lift truck maintenance.
It is designed to provide essential information about the correct and safe service maintenance and repair of
the lift truck by trained mechanics of service technicians.
The information is organized into 14 major Parts of related components or topics as outlined by
the Table of Contents at the front of the manual:
. 1 General information including precautions and safe maintenance practices.
l 2 Service specifications and reference information including lubricants, capacities, pressures, etc.
l 3 Planned Maintenance (PM) service procedures.
l 4-13 Adjustment, service and repair procedures for truck components.
In Parts 4-13, the detailed service and repair procedures are arranged in Sections for each
procedure, component or subsystem. Some Sections include explanations that cover service procedures
common to several components or subsystems.
In general, each Section is written to show and describe the general arrangement, adjustment,
removal, disassembly, inspection, repair, and assembly steps that are normally required to service the
component. Component specifications (as applicable), information notes and safety messages are included
within those procedures. In most cases, specifications are shown in Section 2, Service Specifications, for
convenience of reference.
Each Section includes Parts GROUP number(s) at the bottom of each page for cross reference.
The Parts GROUP numbers are the same as the component group in the Master Parts Book and Service
Parts Book. They are parts system reference numbers; use only the appropriate Parts Manual for ordering
parts. Do not order parts from numbers shown in this manual.
The Table of Contents lists major headings of Parts of the manual. Additional content listings are
placed at the beginning of each Section of the manual, subsection or component heading to simplify
reference to multiple topics or procedures covering optional equipment, such as engines and transaxles.
If you cannot find a topic in the respective Table of Contents, check the Alphabetical Subject Index at
the back of the manual.
This manual has been made easier to use by providing only specific steps and instructions
necessary to explain the activity, component, assembly, or process being worked on. The technician is
expected to include obvious additional steps of standard procedure for removal, disassembly, cleaning,
inspection, reassembly, installation, etc., as needed.
To be better prepared to do the necessary service work, take time to completely read the entire
procedure, including any special instructions, before doing any work.
The technician is cautioned and expected to always work in a safe manner by using the correct
procedure. Do not take chances which may result in injuries.
12/l/89 SM520
-v
GCS/GCS
,Foreword
This service publication provides information covering normal service, maintenance and repair of the
Clark lift trucks noted on the cover. It has been specifically prepared to help owners and service
personnel maintain these lift trucks in efficient and safe operating condition.
Regular, correct maintenance and care of lift trucks is not only important for long and efficient truck life; it
is essential for safe operation. The importance of proper maintenance through planned service, inspection
and qualified repairs cannot be emphasized too strongly.
To assist in keeping lift trucks in good operating condition, this manual includes preventive maintenance
procedures to be performed at regular intervals. These are essential to the service life and safe operation
of all fork lift trucks. Instructions for safety inspections, operational checks, cleaning, and lubrication are
provided for reference in setting-up and conducting a recommended periodic Planned Maintenance (PM)
program.
Refer to the Operator’s Manual, located on the truck, for additional information on the operation, care and
maintenance of your truck.
Genuine Clark replacement parts should be used for all service and repair requirements. Substitute parts
from other sources may be different than original parts and may not meet OSHA or other safety
requirements.
Any reference to brand names other than Clark in this manual is made simply as an example of the type of
tools and materials recommended for use and, as such, should not be considered as an endorsement.
Equivalents, if available, may be used.
For more information on maintenance and repair of these trucks, contact your authorized Clark dealer.
NOTICE - The descriptions and specifications included in this manual were in effect at the time of
printing. C/ark Equipment Company reserves the right to discontinue models at any time, or make
improvements and changes in specifications or design without notice and without incurring
obligation. Specifications, torques, pressures, measurements, adjustments, illustrations and other
items may change at any time. Contact your authorized CLARK dealer for information on possible
updates or revisions.
0 1989 Clark Equipment Company
1211I89 SM520
ii
, Contents
Subject Part
1
General Information ...........................................................................
2
Specifications........................................................................................
Planned Maintenance .......................................................................
3
Engine (Group 00) .................................................................................... 4
Fuel System (GROUPS 02,03) ................................................................. 5
Electrical System (Groups 11-15) ........................................................ 6
Transaxle (stops 06,07,20) ................................................................. 7
Brakes and Inching System (GIOUPS 22,23) ................................... 8
Steering System (Groups 25,26) ......................................................... 9
Hydraulic System (Groups28-33)..................................................... IO
Wheels and Tires (Groups 22,23) .................................................... 11
Counterweight and Chassis (Group 38) ...................................... 12
Uprights (Group 34). ............................................................................. 13
14
Index.. ....................................................................................................
SM520 212719
1
...
III
, About This Manual
This manual is intended for use by persons who are trained and authorized to do lift truck maintenance.
It is designed to provide essential information about the correct and safe service maintenance and repair of
the lift truck by trained mechanics of service technicians.
The information is organized into 14 major Parts of related components or topics as outlined by
the Table of Contents at the front of the manual:
. 1 General information including precautions and safe maintenance practices.
l 2 Service specifications and reference information including lubricants, capacities, pressures, etc.
l 3 Planned Maintenance (PM) service procedures.
l 4-13 Adjustment, service and repair procedures for truck components.
In Parts 4-13, the detailed service and repair procedures are arranged in Sections for each
procedure, component or subsystem. Some Sections include explanations that cover service procedures
common to several components or subsystems.
In general, each Section is written to show and describe the general arrangement, adjustment,
removal, disassembly, inspection, repair, and assembly steps that are normally required to service the
component. Component specifications (as applicable), information notes and safety messages are included
within those procedures. In most cases, specifications are shown in Section 2, Service Specifications, for
convenience of reference.
Each Section includes Parts GROUP number(s) at the bottom of each page for cross reference.
The Parts GROUP numbers are the same as the component group in the Master Parts Book and Service
Parts Book. They are parts system reference numbers; use only the appropriate Parts Manual for ordering
parts. Do not order parts from numbers shown in this manual.
The Table of Contents lists major headings of Parts of the manual. Additional content listings are
placed at the beginning of each Section of the manual, subsection or component heading to simplify
reference to multiple topics or procedures covering optional equipment, such as engines and transaxles.
If you cannot find a topic in the respective Table of Contents, check the Alphabetical Subject Index at
the back of the manual.
This manual has been made easier to use by providing only specific steps and instructions
necessary to explain the activity, component, assembly, or process being worked on. The technician is
expected to include obvious additional steps of standard procedure for removal, disassembly, cleaning,
inspection, reassembly, installation, etc., as needed.
To be better prepared to do the necessary service work, take time to completely read the entire
procedure, including any special instructions, before doing any work.
The technician is cautioned and expected to always work in a safe manner by using the correct
procedure. Do not take chances which may result in injuries.
12/l/89 SM520
-v
