Clark c500, y200 forklift service repair manual

Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
SM-575
C5OOYlSO-200-225S-225L
25OS-25OL-3OOS-3OOL-350

C500 Y2235 Series Pictorial Index
Group 30 Group 29
Hydraulic Hydraulic
Valves, Sump, Filters
Circuit Pres-
1
Group 32
Tilt Cylinders,
Low-Tilt and
Hi-Tilt Mod-
els.
Tilt Cylinder
Adjustment
Tilt Cylinder
Lines; Drift
Test
Group 33
Hydraulic
Relief Valve
(M arina
Models)
Tilt Lock
!2 Relief
Valves.
I
Group 06
Transmission
Group 20
Drive Axle
Group 21
Univ. Joints
Group 34
Upright....
Carruage &
Forks. Lift
Circuit Pres-
sure Check.
Group 39 Decal Replacement and Placement
Group 40 Truck and Engine Specifications. Lubrication Specifications and Grease Chart
PM Inspection and Drivers Daily Inspection Forms
SM575 Pictorial Index July 97

INDEX
GROUP
00
00
00
00
00
01
01
01
01
01
02
02
02
02
02
02
06
06
06
06
06
06
06
14
14
14
14
14
14
20
20
20
20
20
SECTION DESCRIPTION
0 Clark Material Handling Company 1997
1
Forward
Introduction
PM Section
ENGINE
Engine Troubleshooting
Engine Removal
Ford Engine Specifications
Cummins Engine Specifications
COOLING SYSTEM
Troubleshooting
Radiator Removal
Testing and Maintenance
Radiator Repair
FUEL SYSTEM
Troubleshooting
Induction System
Accelerator Linkage
lmpco LPG Lock-off Valve
lmpco LPG Vaporizer-Regulator
TRANSMISSION
Troubleshooting
Transmission Stall Test
Transmission Removal
Transmission Clutch Modulation
Transmission Maintenance and Service
Linkage and Controls
ELECTRICAL
General Troubleshooting
Starter and Battery Troubleshooting
Alternator Troubleshooting
Wiring Diagram
Electrical Tools
DRIVE AXLE
Troubleshooting
Drive Axle Removal
Drive Axle Wheel Bearing Adjustment
Clark-Hurth and Rockwell Drive Axle Maintenance and
Service

INDEX
GROUP
21
21
21
21
SECTION
1
2
3
DESCRIPTION
PROP SHAFT
Troubleshooting
Prop Shaft Removal
Prop Shaft Overhaul
22
22
22
22
1
2
3
WHEELS AND TIRES
Lifting, Jacking and Blocking
Wheel and Tire Mounting
Safe Handling of Split Rim Wheels
23
23
23
1
2
PARKING BRAKE
System Troubleshooting
Mechanical Release of Parking Brake
24
24
24
24
24
24
24
SERVICE BRAKE
Troubleshooting
Air Brake System
Air Brake Treadle Valve
Air Brake Chambers
Air Brake Compressor
Rockwell Cam Brakes
25 STEERING COLUMN AND STEERING
GEAR
25 1
25 2
25 3
Troubleshooting
Removing Steering Handwheel
Removing Column and Gear and Gear From
Column
25 4 Steering Pump Removal and Overhaul
26
26
26
26
1
2
3
STEER AXLE
Troubleshooting
26 4
26 5
26 6
Steer Axle Removal
Steer Axle Overhaul
2-Piece Kingpin Design-26-3-l
Single Piece Kingpin Design-26-3-l 1
Steer Cylinder Removal and Overhaul
Steer Cylinder Overhaul (Lot 7056 and above)
Steering System Pressure Check
2

INDEX
GROUP SECTION DESCRIPTION
29 1 Hydraulic Filters (Prior to lot 8506)
29 2 Hydraulic Filters (Lot 8506 and above)
30
30
30
30
30
30
30
30
30
30
HYDRAULIC COMPONENTS
Troubleshooting
Hydraulic Pump-General
Tyrone Hydraulic Pump Overhaul
J. S. Barnes Hydraulic Pump Overhaul
Vickers Control Valve Overhaul
Lift & Tilt Control Valve Overhaul
Commercial Inter-tech Control Valve Overhaul
Hydraulic System Pressure Check
Hydraulic Diagrams
32 1 Tilt Cylinder Remove and Replace
32 2 Tilt Cylinder Service Procedures (Thru Lot 7045)
32 3 Tilt Cylinder Service Procedures (Lot 7055 & above)
32 4 Tilt Cylinder Drift Test
32 5 Tilt Cylinder Adjustment
33 1 Hydraulic Relief Valve
33 2 Hydraulic Tilt Lock Valve(s)
34
34
34
37
37
39
39
40
40
40
1
2
1
2
UPRIGHT-CARRIAGE-FORKS
Troubleshooting
Fork Removal and Inspection
COUNTERWEIGHTS
Counterweight Removal and Installation
DECAL REPLACEMENT AND PLACEMENT
Decal Replacement and Placement
SPECIFICATIONS
General Specifications
PM Inspection and Drivers Daily Inspection Forms
3

INTRODUCTION
SAFETY SIGNS AND MESSAGES
Safety signs and messages are placed in this manual
and also on the lift truck to provide instructions and to
identify specific areas where potential hazards exist
and special precautions should be taken. Be sure you
know and understand the meaning of these instruc-
tions, signs and messages. Damage to the truck or
death or serious injury to you or other persons may
result if these messages are not followed.
NOTICE
This message is used when special information,
instructions or identification is required relating to
procedures, equipment, tools, pressures, capaci-
ties and other special data.
IMPORTANT
This message is used when special precautions
should be taken to ensure a correct action or to
avoid damage to or malfunction of the truck or a
component.
A CAUTION
This message indicates a potentially hazardous
situation which, if not avoided, may result in minor
or moderate injury. It may also be used to alert
against unsafe practices.
A WARNING
This message indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
A DANGER
This message indicates an imminently hazardous
situation which, if not avoided, will result in death
or serious injury. This signal word is to be limited
to the most extreme situations.
NOTE: The above terms have been adopted by Clark
Material Handling Company. The same terms may be
used in different context in service literature supplied
directly or indirectly by vendors of truck components.
USER SAFE MAINTENANCE PRACTICES
The following instructions have been prepared from
current industry and government safety standards ap-
plicable to industrial truck operation and maintenance.
These recommended procedures specify conditions,
methods, and accepted practices that aid in the safe
maintenance of industrial trucks. They are listed here
for the reference and safety of all workers during
maintenance operations. Carefully read and under-
stand these instructions and the specific maintenance
procedures before attempting to do any repair work.
When in doubt of any maintenance procedure, please
contact your local Clark dealer.
1. Powered industrial trucks can become hazardous if
maintenance is neglected. Therefor, suitable mainte-
nance facilities, trained personnel and procedures
must be provided.
2. Maintenance and inspection of all powered indus-
trial trucks shall be done in conformance with the
manufacturers recommendations.
3. A scheduled planned maintenance, lubrication and
inspection program shall be followed.
4. Only trained and authorized personnel shall be
permitted to maintain, repair, adjust and inspect indus-
trial trucks and in accordance with the manufacturer’
s
specifications.
5. Properly ventilate work area, vent exhaust fumes
and keep shop clean and floor dry.
6. Avoid fire hazards and have fire protection equip-
ment present in the work area. Do not use an open
flame to check for level or leakage of fuel, electrolyte or
coolant. Do not use open pans of fuel or flammable
cleaning fluids for cleaning parts.
7. Before Starting Work On Truck:
(a) Raise drive wheels off of floor or disconnect power
source and use blocks or other positive truck position-
ing devices.
(b) Disconnect battery before working on the electrical
system.
8. Before working on engine fuel system of gasoline or
diesel powered trucks, be sure the fuel shut-off valve is
closed.
9. Operation ofthe truck to check performance must be
conducted in an authorized, safe, clear area.
INTRODUCTION-1-1 July 97

INTRODUCTION
10. Before Starting To Drive Truck:
(a) Be in operating position.
(b) Be sure parking brake is engaged.
(c) Put direction control in neutral.
(d) Start engine.
(e) Check functioning of direction and speed controls,
steering, brakes, warning devices and any load han-
dling attachments.
Before Leaving The Truck
Stop truck.
Put directional control in neutral.
Apply the parking brake.
Stop the engine by turning off the ignition circuit.
Put blocks at the wheels if truck is on an incline.
Brakes, steering mechanisms, control mecha-
nisms, warning devices, lights, governors, guards and
safety devices and frame members must be carefully
and regularly inspected and maintained in a safe
operating condition.
13. Special trucks or devices designed and approved
for hazardous area operation must receive special
attention to ensure that maintenance preserves the
original approved safe operating features.
14. Fuel systems must be checked for leaks and
condition of parts. Extra special consideration must be
given in the case of a leak in the fuel system. Action
must be taken to prevent the use of the truck until the
leak has been corrected.
15. The truck manufacturer’
s capacity, operation and
maintenance instruction plates, tags or decals must be
maintained in legible condition.
16. Batteries, motors, controllers, limit switches, pro-
tective devices, electrical conductors and connections
must be inspected and maintained in conformance
with good practice. Special attention must be paid to
the condition of electrical insulation.
17. To avoid injury to personnel or damage to the
equipment, consult the manfacturer’
s procedures in
replacing contacts on any battery connection.
18. Industrial trucks must be kept in a clean condition
to minimize fire hazards and help in the detection of
loose or defective parts.
19. Modifications and additions that affect capacity
and safe truck operation must not be done without the
manufacturer’
s prior written approval. Capacity, op-
eration and maintenance instruction plates, tags or
decals must be changed accordingly.
20. Care must be taken to assure that all replacement
parts, including tires, are interchangeable with the
original parts and of a quality at least equal to that
provided in the original equipment. Parts, including
tires, are to be installed per the manufacturer’
s proce-
dures. Always use genuine CLARK or CLARK-ap-
proved parts.
21. Use special care when removing heavy compo-
nentsfromthe truck, such ascounterweight, seatdeck,
upright, etc. Be sure that lifting and handling equip-
ment is of the correct capacity and in good condition.
NOTICE -- You should also be familiar with additional
operating and maintenance safety instructions con-
tained in the following publications:
ANSVASME B56.1 - Operator Control-Industrial Tow
Tractors (Safety Standard For Powered Industrial
Trucks). Published by: Society of Mechanical Engi-
neers, United Engineering Center, 345 E. 47th Street,
New York, N. Y. 10017.
NFPA 505-1982: Fire Safety Standard for Powered
Industrial Trucks: Type Designations, Areas of Use,
Maintenance and Operation. Available from: National
Fire Protection Assoc., Inc., Batterymarch Park,Quincy,
Ma 02269.
General Industrial Standards, OSHA 2206: OSHA
Safety and Health Standards (29 CFR 1910), Subpart
N-Materials Handling and Storage, Section 1910.178
Powered Industrial Trucks. For sale by: Superinten-
dent of Documents, U.S. Government Printing Office,
Washington, D. C. 20402.
July 97 INTRODUCTION-l-2 SM575

PM Section CLclRK
PM - PLANNED MAINTENANCE PROGRAM.
A planned maintenance program of regular, routine HOW TO PERFORM THE PM PERIODIC INSPEC-
TION AND MAINTENANCE
inspections and lubrication is important for long life and
trouble-free operation of your lift truck. Make and keep
records of your inspections. Use these records to help
establish the correct PM intervals for your application
and to indicate maintenance required to prevent major
problems from occurring during operation.
PM Report Form
As an aid in performing and documenting your PM
inspections, Clark has prepared a “
GAS, LPG OR
DIESEL PLANNED MAINTENANCE REPORT” form.
Copies of this form may be obtained from your author-
ized Clark dealer. We recommend that you use this
form as a checklist and to make a record of your
inspection and truck condition.
The periodic maintenance procedures outlined in this
manual are intended to be used with the PM report
form. They are arranged in groupings of maintenance
work that are done in a logical and efficient sequence.
A check mark or entry is made on the PM Report Form
when the PM is performed. Please note the special
coding system for indicating the importance of needed
repairs and/or adjustments.
When you have finished the PM inspections, be sure to
give a copy of the report to the designated authority or
the person responsible for lift truck maintenance.
Do not make repairs or adjustments
unless authorized to do so.
Remove all jewelry (watch, rings, bracelets, etc.) before
working on the truck.
Disconnect the batterygroundcable (-) fromthe engine
or frame before working on electrical components.
Always wear safety glasses. Wear a safety (hard) hat
in industrial plants and in special areas where protec-
tion is necessary or required.
Visual Inspection
First, perform a visual inspection of the lift truck and its
components. Walk around the truck and take note of
any obvious damage and maintenance problems.
Check for loose fasteners and fittings.
Check to be sure all capacity, safety and warning
plates and decals are attached and legible.
NOTICE: Do not operate a lift truck with damaged or
missing decals and nameplates. Replace them imme-
diately. They contain important information.
Inspect the truck, before and after starting engine, for
any signs of external leakage: fuel, engine oil or cool-
ant, transmission fluid, etc.
Check for hydraulic oil leaks and loose fittings. DO
NOT USE BARE HANDS TO CHECK. Oil may be hot
or under pressure.
A CAUTION
HYDRAULIC FLUID PRESSURE
Do not use your hands to
check for hydraulic leakage.
Fluid under pressure can
penetrate your skin and cause
serious injury.
SM575 PM-l-l July 97

CL’
IRK PM Section
Be sure that the driver’
s overhead guard and any other
safety devices are in place, undamaged and attached
securely.
Check the overhead guard for damage. Be sure that it
is properly positioned and all mounting fasteners are in
place and tight.
inspect the welds on the carriage and upright for
cracks. Report any cracks noted immediately. Be sure
that the mounting fasteners are in place and tight.
Inspect the upright assembly: rails, carriage rollers, lift
chains, lift and tilt cylinders. Lookforobvious wear and
maintenance problems, damaged or missing parts.
Check for any loose parts or fittings. Check for leaks,
any damaged or loose rollers and rail wear (metal
flaking). Carefully check the lift chains for wear, rust
and corrosion, cracked or broken links, stretching, etc.
Check that the lift and carriage chains are correctly
adjustedto have equal tension. Checkthatthe lift chain
anchor fasteners and locking means are in place and
tight.
Be sure all safety guards and chain retainers are in
place and not damaged. Inspect the carriage stops
and cylinder retainer bolts. Check all welded connec-
tions.
Inspect all lift line hydraulic connections for leaks.
Check the lift cylinder rods for wear marks, grooves
and scratches. Check the cylinder seals for leaks.
A CAUTION
Uprights and lift chains require
special attentionand maintenance
to maintain them in a safe operat-
ing condition. Refer to Lift Chain
Maintenance section for addition
information.
Forks
Inspect the load forks for cracks, breaks, bending and
wear. The fork top surface should be level and even
with each other. The height difference between both
fork tips should be no more that 3% of the fork length.
A WARNING
If the fork blade at the heel is worn
down more than 10 per cent, the
load capacity is reduced and the
fork must be replaced.
Inspect the forks for twists and bends. Put a 2” thick
metal block, at least 4” wide by 24” long on the blade of
theforkwith the 4” surface against the blade. Put a24”
carpenters square on the top of the block and against
the shank. Check the fork 20” above the blade to make
sure it is not bent more than 1 inch maximum.
Ifthe fork blades are obviously bent or damaged, have
them inspected by a trained maintenance person be-
fore operating the truck.
Inspect the fork locking pins for cracks or damage.
Reinsert them and note wherther they fit properly.
July 97 PM-1 -2 SM575

PM Section
Wheels and Tires Function Tests
Check the condition of the drive and steer wheels and
tires. Remove objects that are embedded in the tread.
Inspect the tires for excessive wear or breaks or
“
chunking out”
.
Now be sure that all
functioning correctly.
After checking that the parking brake is set, test horn,
lights and all other safety equipment and accessories.
Be sure they are properly mounted and working
correctly.
Check all wheel lug nuts or bolts to be sure none are
loose or missing. Have missing bolts or lug nuts
replaced and tightened to the the correct torque before
operating truck. Torque to 100-l 20 Ibfft [135,6 - 162,7
f&m]. _
A WARNING
Check tire pressure from a posi-
tion facing the tread of the tire, not
theside. Usea long handled gauge
to keep your body away from the
side. Iftires are low, do notadd air.
Check with a mechanic. The tire
may require removal and repair.
Incorrect (low) tire pressure can
reduce stability of your lift truck.
Proper cold inflation is 100 p.s.i.
controls and systems are
Press the horn button to check horn function. If the
horn or any other part does not operate, report the
failure and have it repaired before the truck is put in
operation.
g:::
.:::..
..:?
Y:::..
Y:.,
2 “$
l!ciqpiB
.::,
“
‘
:‘
~::::i::i::i:,::, .,,,.:.:
g$c?.‘
..
:<A’
Check the operation of the neutral start switch by
placing direction control lever in forward or reverse and
turning key switch to START position. Starter must not
engage until direction control lever is moved to NEU-
TRAL position.
Water Oil
Pressure
Temperature _
Hour
Meter
Brake Air
Pressure
y Converter
/ Light
Key/Start
Switch
SM575 PM-l-3 July 97

USE PERMATEX & CRANE SEALER ONLY WHERE SPECIFIED.
ALL LEAD IN CHAMFERS FOR OIL SEALS, PISTON RINGS & ‘
0’ RINGS
MUST BE SMOOTH & FREE FROM BURRS. INSPECT AT ASSEMBLY.
LUBRICATE ALL PISTON RING GROOVES & 0” RINGS WITH OIL
BEFORE ASSEMBLY.
APPLY VERY LIGHT COAT OF PERMATEX NO. 2 TO O.D. OF ALL OIL
SEALS BEFORE ASSEMBLY.
AFTER ASSEMBLY OF PARTS USING PERMATEX OR CRANE SEALER,
THERE MUST NOT BE ANY FREE OR EXCESS MATERIAL THAT COULD
ENTER THE OIL CIRCUIT.
APPLY LIGHT COAT OF CRANE SEALER TO ALL PIPE PLUGS.
APPLY A THIN COATING OF GREASE BETWEEN SEAL LIPS ON LIP
TYPE SEALS PRIOR TO ASSEMBLY.
APPLY A LIGHT COAT OF PERMATEX NO. 2 TO ALL THRU HOLE STUD
THREADS.

BEFORE ASSEMBLY OF BVSHING TO COVER
-( NOTE POSITION OF SEAL
TIGHTEN TURBINE BOLTS
3. _ 35 Lb_FT
[40,7 - 47,4 N.m]
/
GEAR TOWARD RETAINER RING
MUST SE LOOSE/INTERNAL FIT BRG.
/ /
SEE ELASTIC STOP NUT
TORQUE CHART
a/f _$PPLY PERMATEX NO. 2 TO 0.0.
OF PLUG BEFORE ASSEMBLY.
LOW CLVTCH
S-OUTER STEEL PLATES
9 INNER FRICTION PLATES
ASSEMBLE ALTERNATELY STARTING
WITH OUTER STEEL PLATE.
OUTPUT II
k-
7
SEE ELASTIC STOP NUT
TORQUE CHART
.
-;3K$LM~“‘
CAL
/
“~ 1-I
1
TIGHTEN OIL SCREEN ASSY.
10 - 15 Lb-FT
[13,6 - 20.3 N-m] NOTE METRIC DIMENSIONS
SHOWN !N BRACKETS [ 1
28310 SERIES POWER SHIFT TRANSMISSION WITH VARIOUS OPTIONS
FIGURE I

COOLER
INSTALL GAUGE IN THIS LINE
FOR CONVERTER “
OUT” PRESSURE*
FROM COOLER TO
TRANSMISSION LUBE
DISTRIBUTOR
CLUTCH PRESSURE
i i CHECK POINT**
/
OIL LEVEL
CHECK POINT
CHARGING PUMP
OIL SUCTION SCREEN
28000 SERIES PLUMBING DIAGRAM
FROM CONVERTER
INSTALL GAUGE IN THIS
LINE FOR CONVERTER
“
OUT” PRESSURE*
TYPE “
A” FILTER
USE REPLACEMENT
ELEMENT 215502
DO NOT SUBSTITUTE
CLUTCH PRESSURE
CHECK POINT**
FROM COOLER TO CHECK POINT
TRANSMISSION
LUBE DISTRIBUTOR
w
CHARGING PUMP OIL
SUCTION SCREEN
28000 SERIES PLUMBING DIAGRAM
(WITH REMOTE FILTER)
NOTE: ALL TYPE “
A” FILTERS
USE CLARK FILTER REPLACEMENT
ELEMENT PART NO. 215502.
DO NOT SUBSTITUTE.
*CONVERTER OUT
PRESSURE
**CLUTCH PRESSURE
CONVERTER OUTLET OIL TEMP. 160°-2OO=‘
F [82,3°-93,30C1TRANSMlSS10N IN NEUTRAL
OPERATING SPECIFICATIONS:
25 P.S.I. [172,4 kPa] MINIMUM PRESSURE AT 2000 R.P.M. ENGINE SPEED
AND A MAXIMUM OF 70 P.S.I. L482.6 kPa1 OUTLET PRESSURE
WITH ENGINE OPERATING AT NO-LOAD GOVERNED SPEED.
240-280 PSI [I 654,8 - 1930,5 kPa1 WITH PARKING BRAKE SET (SEE NOTE). OIL TEMPERATURE
180-200” F. [82,2 - 93,3 o C.], ENGINE AT IDLE (400 TO 600 RPM). SHIFT THRU DIRECTION AND
SPEED CLUTCHES. ALL CLUTCH PRESSURE MUST BE EQUAL WITHIN 5 PSI. [34,5 kPa] IF CLUTCH
PRESSURE VARIES IN ANY ONE CLUTCH MORE THAN 5 PSI. [34,5 kPa1 REPAIR CLUTCH.
NOTE: NEVER USE SERVICE BRAKES WHILE MAKING CLUTCH PRESSURE CHECKS. UNITS
HAVING BRAKE ACTUATED DECLUTCHING IN FORWARD AND/OR REVERSE WILL NOT GIVE A
TRUE READING.
ALWAYS USE PARKING BRAKE WHEN MAKING CLUTCH PRESSURE CHECKS.
FIGURE J

MAINTENANCE AND SERVICE
The instructions contained herein cover the disassembly
and reassembly of the transmission in a sequence that
would normally be followed after the unit has been
removed from the machine and is to be completely
overhauled. It must also be understood that this is a basic
28000 transmission with many options. Companion flanges
and output shafts with and without disconnect assemblies
may vary on specific models. The units are very similar to
trouble shoot, disassemble, repair, and reassemble.
DISASSEMBLY
CAUTION: Cleanliness is of extreme importance and an
absolute must in the repair and overhaul of this unit. Before
attempting any repairs, the exterior of the unit must be
thoroughly cleaned to prevent the possibility of dirt and
foreign matter entering the mechanism.
Figure 1
Side view of 3-speed short drop output power shift
Transmission.
Figure 3
Remove charging pump to regulating valve stud nuts.
Remove pump and filter adaptor.
Figure 2
Remove filter housing and filter element.
NOTE: See lubricationsection for filter cartridgechange interval.
Figure 4
Remove pressure regulating valve assembly.
1

Figure 5
Remove pump drive sleeves.
Figure 6
Remove control valve bolts and washers. Remove control
valve. Use caution as not to lose detent springs and balls.
Figure 7
Remove impeller cover bolts.
Figure 8
Install two bolts in threaded holes 180’ apart to remove cover
from impeller. NOTE: Some units may have pry slots instead
of threaded holes.
Figure 9
Remove impeller cover.
Figure IO
If impeller cover bearing is to be replaced, remove retainer
ring. Pry bearing from pocket.
2

Figure 11
Remove turbine retaining ring.
Figure 14
Remove reaction member retainer ring.
Figure 12 Figure 15
Remove turbine and hub assembly. NOTE: For special turbine
to hub assemblv see Daae 33.
Remove reaction member and spacer.
Figure 13
Remove turbine locating ring.
Figure 16
Remove oil baffle retainer ring.
3

Figure 20
Remove pump drive gear bearing support bolts.
Figure 17
Using pry slots in converter housing, pry oil baffle and
impeller from housing.
NOTE: Impeller, oil baffle and impeller hub gear are
removed as an assembly.
Figure 21
Move center gear toward the rear of converter housing.
Remove pump drive gear on the right.
Figure 18
Remove stator support to housing bolts.
Figure 19
Remove stator support.
NOTE: Support must be turned to clear pump drive gear.
Figure 22
Remove pump drive gear on the left.
4

Figure 23
Remove center pump drive gear.
Figure 24
Remove bolts securing converter housing to transmission
housing.
Figure 25
Support converter housing with a chain fall. Using
spreading type snap ring pliers, spread ears on forward
clutch front bearing retaining ring. Holding snap ring open
pry converter housing from transmission housing.
5
Figure 26
Figure 26 shows forward & 2nd clutch locating ring with
forward and 2nd clutch in position.
Figure 27
Figure 27 shows forward and 2nd clutch in converter
housing. If clutch remained in converter housing, spread
ears on snap ring as explained in Figure 25 and remove
clutch. If clutch assembly remained in transmission case
remove same by pulling straight out.
Figure 28
Remove turbine shaft gear retainer ring and gear.

Figure 29
From rear of converter housing tap turbine shaft and
bearing from housing.
Figure 30
Remove turbine shaft and bearing from converter housing.
Figure 31
Remove impeller hub gear retainer ring.
Figure 32
Remove impeller hub gear.
Figure 33
Lift oil baffle and oil seal assembly from impeller.
Figure 34
Remove impeller to hub bolts.
6

Figure 35
Remove impeller hub O-Ring.
Figure 36
Remove 2nd gear retaining ring and 2nd gear.
Figure 38
Remove output flange nut, washer and O-Ring.
Figure 39
Remove output flange.
NOTE: If parking brake is used, remove brake drum and
flange, upper and lower brake shoe return springs, brake
shoes, and actuator arm. Remove brake backing plate bolts
and backing plate.
Figure 37
Remove 2nd speed clutch shaft pilot bearing.
Figure 40
Remove low shaft bearing cap bolts and bearing cap.
7

Figure 41
Remove output shaft bearing cap bolts and bearing cap.
Figure 42
Remove low shaft rear bearing locating ring.
Figure 43
Remove output shaft rear bearing locating ring.
Figure 44
Remove rear cover bolts. Using pry slots provided, pry
cover from transmission housing tapping on low clutch and
output shaft to allow cover to be removed without shaft
binding.
CAUTION: Do not lose output shaft rear bearing lock ball.
Figure 45
Remove low shaft rear bearing retainer ring.
Figure 46
Remove low clutch rear bearing.
6

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F iaure 50
Figure 47
Remove low speed drive gear snap ring and drive gear.
Figure 48
Remove reverse and 3rd clutch assembly.
Figure 49
From the front of the transmission housing, tap the output
shaft, gear and bearing from pilot location in case.
9
Remove output shaft assembly from housing.
Figure 51
Remove low clutch assembly from housing.
CLUTCH DISASSEMBLY
NOTE: Two clutches are shown being disassembled. The low
clutch, and the forward and second. All clutches are disassem-
bled in a similar manner. The quantity of clutch discs will differ
between the low clutch and the forward, reverse, second and
third. Do not mix the friction discs inthe low clutch with the fric-
tion discs of any of the other clutches. (See note, Figure 86.)
LOW CLUTCH DISASSEMBLY
Figure 52
Remove low clutch shaft rear bearing.

Figure 56
Remove clutch end plate and inner and outer clutch disc.
See Note Figure 86.
Figure 53
Remove low speed gear retainer ring.
Figure 54
Remove low speed gear and outer bearing.
Figure 55
Remove clutch end plate retainer ring.
10
Figure 57
Remove low gear inner bearing.
Figure 58
Remove clutch piston return spring. A sleeve with a portion
removed is recommended for removing the clutch piston
return spring, washer, and retainer ring. Sleeve shown is a
common pipe, with a l-1/2” . wide x 1” high
(39,Ox26,0mm) opening. The pipe is 6” long, 3-l/4” O.D.,
2-314” I.D. (155,Ox85,0x78,0mm). Compress spring
retainer washer. Through opening remove spring retainer
snap ring. Release tension on spring retainer. Remove spring
retainer and spring. Turn clutch over and tap clutch shaft
on a block of wood to remove clutch piston.

FORWARD & 2ND CLUTCH DISASSEMBLY
Figure 62
Remove front bearing locating ring.
Figure 59
Remove clutch shaft piston rings and expander springs.
Figure 60
Remove front bearing retainer ring.
Figure 61
Remove front bearing.
Figure 63
Remove clutch driven gear and outer bearing.
Figure 64
Remove inner bearing.
11

Clark c500, y200 forklift service repair manual

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Clark c500, y200 forklift service repair manual