Clark C500, Y180-200-225S-225L, 250S-250L-300S-300L Forklift Service Manual
705 pages · Publication SM-575
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- Models
- C500, Y180-200-225S-225L, 250S-250L-300S-300L
- Manual type
- Service Manual
- Pages
- 705
- Publication
- SM-575
- Condition
- Brand new
What's inside
From the manual's own table of contents: 25 sections, 247 entries. See sample pages (PDF, 291 KB)
ENGINES4 topics
- 00-01 ENGINE TROUBLESHOOTING
- 00-02 ENGINE REMOVAL
- 00-03 FORD ENGINE SPECIFICATIONS
- 00-04 CUMMINS ENGINE SPECIFICATIONS
COOLING SYSTEM4 topics
- 01-01 TROUBLESHOOTING
- 01-02 RADIATOR REMOVAL
- 01-03 TESTING AND MAINTENANCE
- 01-04 RADIATOR REPAIR
FUEL SYSTEM5 topics
- 02-01 TROUBLESHOOTING
- 02-02 INDUCTION SYSTEM
- 02-03 ACCELERATOR LINKAGE
- 02-04 IMPCO LPG LOCK-OFF VALVE
- 02-05 IMPCO LPG VAPORIZER-REGULATOR
TRANSMISSION21 topics
- 06-01 TROUBLESHOOTING
- 06-02 TRANSMISSION STALL TEST
- 06-03 TRANSMISSION REMOVAL
- 06-04 TRANSMISSION CLUTCH MODULATION
- 06-05 TRANSMISSION MAINTENANCE AND SERVICE
- HOW THE UNITS OPERATE
- SECTIONAL VIEWS AND PARTS IDENTIFICATION
- DISASSEMBLY OF TRANSMISSION
- CLEANING AND INSPECTION
- REASSEMBLY OF TRANSMISSION
- SERVICING MACHINE AFTER TRANSMISSION OVERHAUL
- SPECIFICATIONS AND SERVICE DATA-POWER SHIFT TRANSMISSION AND TORQUE CONVERTER
- LUBRICATION
- TROUBLE SHOOTING GUIDE
- HR MODEL TYPICAL THREE SPEED POWER FLOW
- CLUTCH AND GEAR ARRANGEMENT
- SHIELDED BEARING INSTALLATION
- RING GEAR INSTALLATION
- SPEED SENSOR BUSHING INSTALLATION
- DRIVE PLATE INSTALLATION
- 06-06 LINKAGE AND CONTROLS
ELECTRICAL12 topics
- 14-01 GENERAL TROUBLESHOOTING
- 14-02 STARTER AND BATTERY TROUBLESHOOTING
- GENERAL INFORMATION
- MINIMUM TOOLS REQUIRED
- STARTING SYSTEM INSPECTION
- ELECTRICAL CHECKS
- VOLT DROP TESTS
- 14-03 ALTERNATOR TROUBLESHOOTING
- ALTERNATOR MAINTENANCE PRECAUTIONS
- TROUBLESHOOTING PROCEDURES
- SYMPTOMS, CAUSES, AND REMEDIES
- 14-05 ELECTRICAL TOOLS
DRIVE AXLE33 topics
- 20-01 TROUBLESHOOTING
- 20-02 DRIVE AXLE REMOVAL
- 20-03 DRIVE AXLE WHEEL BEARING ADJUSTMENT AND PLANETARY AXLE WHEEL ENDS
- AXLE DESIGNATION CHART
- AXLE DESCRIPTION
- DISASSEMBLY OF PLANETARY WHEEL ENDS
- PREPARE FQR REASSEMBLY - CLEAN, INSPECT AND REPAIR
- REASSEMBLE PLANETARY WHEEL END
- LUBRICATION
- STEERING ALIGNMENT
- TANDEM/TRIDEM AXLE TIRE MATCHING
- FASTENER TORQUE VALUES
- PLANETARY AXLE MODEL CROSS-REFERENCE CHART
- 20-04 DRIVE AXLE MAINTENANCE AND SERVICE
- DESCRIPTION
- RECOMMENDED LUBRICANTS FOR CLARK DRIVE AXLES
- SECTIONAL VIEWS AND PARTS IDENTIFICATION
- AXLE ASSEMBLY INSTRUCTION ILLUSTRATION
- DIFFERENTIAL ASSEMBLY INSTRUCTIONS
- DISASSEMBLY OF AXLE
- DISASSEMBLY OF DIFFERENTIAL
- CLEANING AND INSPECTlON
- REASSEMBLY OF DIFFERENTIAL RING GEAR AND DIFFERENTIAL CASE
- PLANET CARRIER DISASSEMBLY AND REASSEMBLY
- REASSEMBLY OF AXLE
- SERVICE BRAKES
- AIR BRAKE ADJUSTMENT
- PINION STAKING
- WHEEL BEARING ADJUSTMENT PROCEDURE
- SPIRAL BEVEL AND HYPOID TOOTH BEARING CONTACT CHART (RIGHT HAND)
- SPIRAL BEVEL AND HYPOID TOOTH BEARING CONTACT CHART (LEFT HAND)
- CLARK RECOMMENDED WHEEL MOUNTING TORQUE
- TABLE OF TORQUE LIMITS
SINGLE REDUCTION DIFFERENTIAL CARRIERS41 topics
- INTRODUCTION
- DISASSEMBLY
- REMOVE DIFFERENTIAL CARRIER FROM AXLE HOUSING
- REMOVE THE DIFFERENTIAL AND RING GEAR FROM THE CARRIER
- DISASSEMBLE THE DIFFERENTIAL AND RING GEAR ASSEMBLY
- REMOVE THE DRIVE PINION AND BEARING CAGE FROM CARRIER
- DISASSEMBLE THE DRIVE PINION AND BEARING CAGE
- PREPARE PARTS FOR ASSEMBLY
- CLEAN, INSPECT, AND REPAIR PARTS
- GENERAL PROCEDURES
- USE OF DRI-LOC FASTENERS AND ROCKWELL LIQUID ADHESIVE 2297-C-3747 OR LOCTITE 277
- APPLICATION OF ROCKWELL ADHESIVE IN BEARING BORES OF THE DIFFERENTIAL
- APPLICATION OF SILICONE GASKET MATERIAL
- INSTALL "TIGHT FIT" YOKES WITH THREE-PIECE PILOT TOOL
- GEAR SET INFORMATION (DRIVE PINION AND RING GEAR MARKINGS)
- VEHICLE TOWING INSTRUCTIONS
- ASSEMBLY
- ASSEMBLE DRIVE PINION, BEARINGS AND BEARING CAGE
- ADJUST PRELOAD OF PINION BEARINGS
- ADJUST THICKNESS OF SHIM PACK FOR PINION CAGE
- INSTALL THE DRIVE PINION, BEARING CAGE AND SHIM PACK INTO THE CARRIER
- ASSEMBLE THE MAIN DIFFERENTIAL AND RING GEAR ASSEMBLY
- ROTATING RESISTANCE CHECK OF DIFFERENTIAL GEARS
- INSTALL DIFFERENTIAL AND RING GEAR ASSEMBLY
- ADJUST PRELOAD OF DIFFERENTIAL BEARINGS
- CHECK RUNOUT OF RING GEAR
- ADJUST BACKLASH OF THE RING GEAR
- CHECK TOOTH CONTACT PATTERNS OF THE GEAR SET
- INSTALL AND ADJUST THE THRUST SCREW
- INSTALL DIFFERENTIAL CARRIER INTO AXLE HOUSING
- DRIVER CONTROLLED MAIN DIFFERENTIAL LOCK
- REMOVE DIFFERENTIAL CARRIER FROM AXLE HOUSING
- REMOVE DIFFERENTIAL AND GEAR ASSEMBLY
- INSTALL DIFFERENTIAL SHIFT ASSEMBLY
- INSTALL CARRIER INTO AXLE HOUSING
- CHECK THE DIFFERENTIAL LOCK
- LUBRICATION
- FASTENER TORQUE INFORMATION
- GENERAL INFORMATION
- TORQUE CHARTS
- ADJUSTMENTS AND SPECIFICATIONS
PROP SHAFT3 topics
- 21-01 TROUBLESHOOTING
- 21-02 PROPSHAFT REMOVAL
- 21-03 PROP SHAFT OVERHAUL
WHEELS AND TIRES3 topics
- 22-01 LIFTING, JACKING AND BLOCKING
- 22-02 WHEEL AND TIRE MOUNTING
- 22-03 SAFE HANDLING OF MULTI-PIECE RIM WHEELS
PARKING BRAKE2 topics
- 23-01 TROUBLESHOOTING
- 23-02 MECHANICAL RELEASE OF PARKING BRAKE
SERVICE BRAKE19 topics
- 24-01 TROUBLESHOOTING
- 24-02 AIR BRAKE SYSTEM
- 24-03 AIR BRAKE TREADLE VALVE
- 24-04 AIR BRAKE CHAMBERS
- 24-05 AIR BRAKE COMPRESSOR
- 24-06 ROCKWELL AXLE CAM BRAKES
- ASBESTOS AND NON-ASBESTOS FIBERS WARNINGS
- INTRODUCTION
- DISASSEMBLE BRAKES
- PREPARE PARTS FOR ASSEMBLY
- ASSEMBLE BRAKES
- RECLINE BRAKES
- LUBRICATION
- VISUAL INSPECTION OF THE BRAKE SYSTEM
- RECOMMENDED PERIODIC SERVICE
- FEDERAL ROADSIDE BRAKE ADJUSTMENT INSPECTION
- TORQUE CHART
- Q SERIES AND Q PLUS BRAKE CONVERSION KITS
- CAM BRAKE TIPS
STEERING COLUMN AND STEERING GEAR4 topics
- 25-01 TROUBLESHOOTING
- 25-02 REMOVING STEERING HANDWHEEL
- 25-03 REMOVING COLUMN AND GEAR AND GEAR FROM COLUMN
- 25-04 STEERING PUMP REMOVAL AND OVERHAUL
STEER AXLE10 topics
- 26-01 TROUBLESHOOTING
- 26-02 STEER AXLE REMOVAL
- 26-03 STEER AXLE OVERHAUL
- 2-PIECE KINGPIN DESIGN-26-3-1
- REDESIGNED STEER AXLE (SINGLE PIECE KINGPIN DESIGN-26-3-11)
- 26-04 STEER CYLINDER REMOVAL AND OVERHAUL
- 26-05 STEERING CYLINDER OVERHAUL (LOT 7056 AND ABOVE)
- 26-06 STEERING SYSTEM PRESSURE CHECK
- STEERING CONTROL CIRCUIT
- PRESSURE CHECKS
HYDRAULIC FILTERS7 topics
- 29-01 HYDRAULIC FILTERS (LOTS PRIOR TO 8506)
- FILTER LOCATIONS
- FILTER SERVICE
- 29-02 HYRAULIC FILTERS (LOTS 5806 AND ABOVE)
- FILTER LOCATIONS
- FILTER SERVICE
- REFILL SUMP TANK
HYDRAULIC COMPONENTS21 topics
- 30-01 TROUBLESHOOTING
- 30-02 MAIN HYDRAULIC PUMP
- DISASSEMBLY
- REASSEMBLY
- 30-03 TYRONE HYDRAULIC PUMP OVERHAUL
- 30-04 J.S. BARNES HYDRAULIC PUMP OVERHAUL
- 30-05 VICKERS VALVE OVERHAUL
- DESCRIPTION
- PRINCIPLES OF OPERATION
- INSTALLATION AND OPERATING INSRUCTIONS
- SERVICE, INSPECTION AND MAINTENANCE
- OVERHAUL
- EXPLODED VIEW
- TESTING
- 30-06 LIFT AND TILT CONTROL VALVE
- 30-07 COMMERCIAL INTERTECH CONTROL VALVE OVERHAUL
- 30-08 HYDRAULIC SYSTEM PRESSURE CHECK
- PIPING DIAGRAM AND TESTER CONNECTION
- CHECKING PRESSURE WITH HYDRAULIC TESTER
- CHECKING PRESSURE WITH SCHROEDER HYDRAULIC TESTER
- 30-09 HYDRAULIC DIAGRAMS
TILT CYLINDERS15 topics
- 32-01 TILT CYLINDER REMOVE AND REPLACE
- LO-TILT MODELS
- HI-TILT MODELS
- 32-02 TILT CYLINDER SERVICE PROCEDURES (THROUGH LOT 7045)
- DISASSEMBLY
- CLEANING AND INSPECTION
- REASSEMBLY
- SEAL INSTALLATION TOOL
- 32-03 TILT CYLINDER SERVICE PROCEDURES (LOT 7055 AND ABOVE)
- DISASSEMBLY
- CLEANING AND INSPECTION
- REASSEMBLY
- SEAL INSTALLATION TOOL
- 32-04 TILT CYLINDER DRIFT TEST
- 32-05 TILT CYLINDER ADJUSTMENT
HYDRAULIC VALVES9 topics
- 33-01 HYDRAULIC RELIEF VALVE
- EXPLODED VIEW
- CLEANING AND INSPECTION
- DISASSEMBLY AND REASSEMBLY
- 33-02 HYDRAULIC TILT LOCK VALVE(S)
- CLEANING AND INSPECTION
- DISASSEMBLY AND REASSEMBLY
- PACKINGS
- TILT CONTROL CIRCUIT "FACTORY PRESET" RELIEF VALVE CHECK
UPRIGHT, CARRIAGE AND FORKS2 topics
- 34-01 UPRIGHT TROUBLESHOOTING
- 34-02 FORK REMOVAL AND INSPECTION
COUNTERWEIGHT1 topic
- 37-01 COUNTERWEIGHT REMOVAL AND INSTALLATION
DECAL REPLACEMENT AND PLACEMENT1 topic
- 39-01 DECAL REPLACEMENT AND PLACEMENT
Show all 25 sections
SPECIFICATIONS5 topics
- 40-01 GENERAL SPECIFICATIONS
- SPECIFICATIONS (GENERAL - ALL MODELS)
- SPECIFICATIONS (FORD MODELS)
- SPECIFICATIONS (CUMMINS ENGINE)
- 40-02 PM INSPECTION AND DRIVERS DAILY INSPECTION FORMS
Inside this manual
Real pages from this service manual (705 pages). Open the sample pages (PDF, 291 KB)
- Diagram, page 41: Group 00, Engine
- Specifications, page 381: Adjustments and 5
- Troubleshooting, page 681: GROUP 34
- Foldout diagram, page 218: SINGLE REDUCTION
This is a service manual
Here's how it compares to the other manual types.
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 705 pages
Quantity one is the manual described above.
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Other editions and similar models
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).