Clark EC500 60, 80B Forklift Service Manual
385 pages · Publication SM-604
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- Models
- EC500 60, 80B
- Manual type
- Service Manual
- Pages
- 385
- Publication
- SM-604
- Condition
- Brand new
What's inside
From the manual's own table of contents: 21 sections, 325 entries. See sample pages (PDF, 189 KB)
Truck Models Covered by This Manual
Arrangement and Use of This Manual
Foreword
SA SAFE MAINTENANCE9 topics
- Safety
- Safety Signs and Messages
- Safe Maintenance Practices
- Lifting, Jacking, and Blocking
- Raising Drive Wheels
- Chaining the Upright in Raised Position
- Raising Rear of Truck
- Raising Entire Truck
- Shipping Tie-Down Instructions
PS PERIODIC SERVICE12 topics
- Maintenance Schedules
- Lubrication Points
- Lubrication Chart Key
- Miscellaneous Lubricants
- Planned Maintenance
- Use PM Report Form
- How to Perform the PM Periodic Inspections and Maintenance
- Test Drive Truck with Load
- Air-Cleaning
- Critical Fastener Torque Checks
- Lubrication, Fluids, and Filters
- The PM Inspection Form
BATTERY6 topics
- Battery Handling
- Battery Removal
- Battery Maintenance
- Install Battery
- Keeping Battery Records
- Battery Tests
ELECTRICAL SWITCHES10 topics
- Foot and Hand Brake Switches
- Safety
- Foot Brake Switch
- Hand Brake Switch
- Lift and Tilt Pump Switches
- Safety
- Lift and Tilt Pump Switches
- Forward and Reverse Switches
- Safety
- Forward and Reverse Switches
ELECTRICAL MOTORS31 topics
- General Information
- Safety
- Servicing Electric Motors
- Electric Motor Maintenance
- Test for Motor Insulation “Resistance to Ground
- Brush and Commutator Maintenance
- Brush Inspection Chart
- Drive Motor
- Safety
- General Information
- Operating Conditions
- Drive Motor Description
- Drive Motor Removal and Installation
- Brake Drum Removal and Installation
- Drive Motor
- Drive Motor Specifications
- Brush Inspection Chart
- Hydraulic Pump Motor
- Safety
- General Information
- Operating Conditions
- Hydraulic Pump Motor
- Pump Motor Specifications
- Brush Inspection Chart
- Steering Pump Motor
- Safety
- General Information
- Operating Conditions
- Steering Pump Motor (Permanent Magnet Type)
- Steering Pump Motor Specifications
- Brush Inspection Chart
ELECTRICAL SCHEMATICS6 topics
- Wiring Schematics and Diagrams
- Standard Wiring Schematic
- Standard Wiring Diagram
- Accessory Wiring Schematic
- Accessory Wire Harness Diagram
- Accessory Diagrams
ELECTRICAL CONTROLS28 topics
- Control Panel
- Control Panel Description
- Control Panel Maintenance
- Control Panel Troubleshooting
- Control and Contactor Panel Removal
- CONTACTOR PANEL COMPONENT IDENTIFICATION
- SCR Panel Component Identification
- Contactor Inspection
- Control and Contactor Panel Installation
- Check Capacitors (1C)
- Checking Components with VOM (Only)
- #3 and 4 Rectifiers
- Sensor
- Thermal Protector
- Reactor/Choke Module
- EV-200LX Card Factory Settings
- Oscillator Card Voltage Checks
- Oscillator Card Wiring Schematic
- Control and Contactor Panel Installation
- Recommended Tests, Equipment, and Procedures
- Recommended Tests
- Test Procedures
- Periodic Electrical Checks
- Truck Preparation
- Electrical Connectors
- Battery Tests
- EV100 LXT CONTROL PANEL
- Status Codes
DRIVE AXLE22 topics
- Drive Axle Specifications and Description
- Specifications
- Locations
- Description
- Drive Axle Troubleshooting
- Troubleshooting Techniques
- Symptoms and Causes
- Drive Axle Removal and Installation
- Drive Axle Overhaul General Practices
- General Practices
- Drive Axle Ends Overhaul
- Drive Axle Ends Removal and Installation
- Drive Axle Ends Disassembly
- Drive Axle Ends Assembly
- Drive Axle Differential Adaptor Overhaul
- Differential Adaptor Removal and Installation
- Differential Adaptor Disassembly
- Differential Adaptor Assembly
- Differential Overhaul Drive Axle
- Differential Disassembly
- Differential Assembly
- Backlash and Gear Tooth Pattern Adjustment
WHEELS AND TIRES7 topics
- Wheels and Tires Specifications and Description
- Specifications
- Description
- Cushion Wheels and Tires
- General Cushion Tire Maintenance and Inspection
- Drive/Steering Wheel Removal and Installation
- Cushion Tire Replacement
BRAKE SYSTEM35 topics
- Brake System Specifications and Descriptions
- Specifications
- General Description
- Service Brake Operation
- Park Brake Operation
- Service Requirements
- Service Brake Troubleshooting
- Pedal and Linkage Adjustments
- Introduction
- Pedal Free Travel Adjustment
- Foot Brake Linkage
- Brake System Bleeding
- When to Bleed Brakes
- Bleeding Brake System
- Brake Master Cylinder Service
- Master Cylinder Removal
- Master Cylinder Installation
- Master Cylinder Overhaul
- Service Brake Overhaul
- Operation
- Brake Removal and Installation
- Brake Disassembly
- Brake Inspection
- Brake Assembly
- Brake Lining Inspection
- Brake Lining Replacement
- Park Brake Service
- General
- Installation
- Manual Release of Brake
- Air Gap
- Maintenance
- Air Gap Renewal
- Replacing The Friction Disc
- Reworking The Air Gap Spacers
STEERING COLUMN AND GEAR15 topics
- Steering System Specifications and Description
- Specifications
- Description
- Steering System Troubleshooting
- Problem/Cause
- Steering Column Removal and Installation
- Steering Column and Component Removal
- Steering Column and Component Installation
- Steering System Relief Pressure Check and Adjustment
- Description and Operation
- Relief Pressure Setting Check and Adjustment
- Steering Gear Overhaul
- Disassembly
- Parts Inspection
- Assembly
STEERING AXLE36 topics
- Steering Axle Specifications and Description
- Specifications
- Description
- Steer Wheel Bearing Maintenance and Adjustment
- Wheel Bearing Check
- Wheel Bearing Lubrication
- Wheel Bearing Adjustment
- Steering Axle Removal and Installation
- Steering Axle Removal
- Steering Axle Installation
- Steering Axle Overhaul
- Preparation for Steering Axle Disassembly and Overhaul
- Steering Axle Disassembly
- Parts Inspection
- Steering Axle Assembly
- Steering Spider Disassembly
- Steering Spider Assembly
- Steering Cylinder Removal and Installation
- Steering Cylinder Removal
- Parts Inspection
- Steering Cylinder Installation
- Steering Cylinder Overhaul
- Preparation for Steering Cylinder Disassembly and Overhaul
- Steering Cylinder Disassembly
- Parts Inspection
- Steering Cylinder Assembly
- Steering Pump Removal and Installation
- Description
- Steering Pump Removal
- Steering Pump Installation
- Steering Circuit Schematic
- Steering Pump Overhaul
- Steering Pump Disassembly
- Inspection
- Steering Pump Assembly
- Steering Pump Exploded View
HYDRAULIC SUMP, FILTERS, AND PUMP28 topics
- Main Hydraulic Sump, Filters, and Pump Specifications and Description
- Specifications
- Description
- Main Hydraulic Circuit Schematic
- Main Hydraulic Pump Troubleshooting
- Noisy Pump
- Pump Not Delivering Hydraulic Fluid
- Failure to Build Pressure
- Pump Not Developing Sufficient Pressure
- Pump Output Low
- Foaming Fluid
- Overheated Pump and/or Fluid
- External Leakage
- Shaft Seal Leakage
- Main Hydraulic Filters and Fluid Maintenance
- Hydraulic Sump Fluid Level Check
- Hydraulic Filters Change
- Hydraulic Fluid Change
- Check Operation of Hydraulic System
- Main Hydraulic Pump Removal and Installation
- Main Hydraulic Pump Removal
- Main Hydraulic Pump Installation
- Main Hydraulic Pump Overhaul
- Preparation for Pump Disassembly
- Main Hydraulic Pump Disassembly
- Main Hydraulic Pump Inspection
- Main Hydraulic Pump Exploded View
- Main Hydraulic Pump Assembly
HYDRAULIC CONTROL VALVES9 topics
- General Description
- Main Valve Relief Pressure Check and Adjustment
- Main Valve Removal and Installation
- Main Valve Removal
- Main Valve Installation
- Main Valve Disassembly, Inspection and Assembly
- Main Valve Disassembly
- Main Valve Inspection
- Main Valve Assembly
TILT CYLINDERS20 topics
- Tilt Cylinder Specifications and Description
- Fastener Torque Specifications
- Description
- Components
- Tilt Cylinder Plumbing Layout
- Checks and Adjustments
- Tilt Check and Adjustment
- Tilt Cylinder Drift Test
- Tilt Cylinder Removal and Installation
- Tilt Cylinder Rod End Removal
- Tilt Cylinder Disassembly
- Tilt Cylinder Inspection
- Tilt Cylinder Assembly
- Tilt Cylinder Installation
- Face Seal Fittings
- Tilt Cylinder Overhaul
- Preparation For Disassembly
- Disassembly
- Inspection
- Assembly
UPRIGHTS6 topics
- Upright Specifications and Descriptions
- Troubleshooting
- Upright Inspection
- Carriage and Upright Roller Clearance Checks and Shim Adjustments
- Upright Chain Inspection, Adjustment, and Installation
- Fork and Carriage Removal and Installation
COUNTERWEIGHT AND CHASSIS17 topics
- Counterweight Specifications and Description
- Specifications
- Description
- General Maintenance
- Group 38, Counterweight and Chassis
- Counterweight Removal and Installation
- Counterweight Removal
- Counterweight Installation
- Overhead Guard Removal and Installation
- Overhead Guard Removal
- Overhead Guard Installation
- Floor Plate and Seat Deck Removal and Installation
- Floor Plate Removal and Installation
- Operator’s Seat Deck Removal and Installation
- Operator’s Seat Removal and Installation
- Operator’s Seat Removal
- Operator’s Seat Installation
SPECIFICATIONS7 topics
- Nameplate and Decals
- Nameplate and Decal Locations
- General Specifications
- Weights and Performance Specifications
- Critical Fastener Torque Specifications
- Hydraulic Specifications
- Hydraulic Fitting Tightening Procedure
Inside this manual
Real pages from this service manual (385 pages). Open the sample pages (PDF, 189 KB)
- Diagram, page 103: Group 17, Electrical Schematics
- Troubleshooting, page 163: STATUS CODE
- Specifications, page 363: Group 38, Counterweight and Chassis
This is a service manual
Here's how it compares to the other manual types.
This manual
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, 385 pages
Quantity one is the manual described above.
Fast free USA shipping
Ships in 1 business day.
60-day returns
Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy
Binder not included
Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.
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).