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Clark SM 598s Service Manual
Clark SM 598s Service Manual
Clark SM 598s Service Manual
SM498S
CGC, CGP, CDP 20-30
Shop Manual
VOLUME 1 OF 2, GROUPS 00 - 03
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
This is the cut pages sample. Download all 961 page(s) at: ManualPlace.com
Main Table of Contents
Alphabetical Index
(SEE NEXT PAGE)
Pictorial Index
Group 34. Uprights
Y
\ n n /Group 06. Transmission
GROUP SA
GROUP SA
SAFE MAINTENANCE
Section 1. Safety
16. Batteries, motors, controllers, limit switches, protec- General Industrial Standards, OSHA 2206: OSHA Safety
tive devices, electrical conductors, and connections and Health Standards (29 CFR 1910), Subpart N-Materials
must be inspected and maintained in conformance Handling and Storage, Section 1910.178 Powered Indus-
with good practice. Special attention must be paid to trial Trucks. For sale by: Superintendent of Documents,
the condition of electrical insulation. U.S. Government Printing Office, Washington, DC 20402.
Section 2.
3
Safe Parking ...................................................................................................................................
.&
2
Lifting, Jacking, and Blocking Points ..........................................................................................
3
Raising Truck with A Hoist ..........................................................................................................
4
Blocking the Upright in Raised Position ......................................................................................
4
Raising Rear of Truck ...................................................................................................................
WARNING A
Lifting or jacking any large piece of equipment such as your fork truck presents
obvious hazards. It must be done with great care and forethought. Consult the
truck weight tabulations in Group 40, “Specifications” to ensure that your
lifting equipment is of adequate capacity.
2. Put upright in vertical position and fully lower the Park truck safely as described in “Safe Parking.” Block
forks or attachment. steer wheels.
3. Put all controls in neutral. Turn key switch OFF and Be sure upright trunnion bolts are tight. Bolt torques
remove key. must be 75-80 Nom (55-59 ft-lb).
4. Apply the parking brake and block the wheels. Start the engine. Tilt the upright fully back. Adjust
upright height as necessary to put blocking underneath
A WARNING
Defective equipment can cause accidents.
the lower end of the upright.
Put a solid 100 x 100 mm (4 x 4 in) hardwood block
All tools and lifting equipment must be in under the front section of each upright rail. Put a 3-6
good condition, meet the load capacity re- mm (.125-.250 in) steel plate on top of each block.
quirements and have OSHA labels when
required. Tools with defects can have fail-
ures causing severe injury or death.
AWARNING
Do not attempt to lift the truck by the over-
head guard or the counterweight. Severe
injury may result and the truck can be
damaged.
6. Insert blocking under the frame behind the drive 3. To raise the front of the truck using the upright, spread
wheels or slip wheel cradles under the drive wheels. If two chains on the outer rail tiebar of the upright.
using blocking, check for safe clearance between drive
wheels and floor and blocks.
NOTE
A
When forks are raised as in illustration
above, use shop rags, paper, or bright tape WARNING
on fork tips to signal the danger of trip- Chain and hoist used to lift truck should be
ping. checked to make sure they are of safe Iift-
ing capacity. See the truck data plate for
7. Check for stable condition of the truck. Be sure that the information.
blocks are located securely under the truck frame
before operating the drive or working on truck. 4. Slowly lift truck and lower drive wheels onto the
cradles or place blocking under frame prop points.
8. Lower the drive wheels to the floor and remove the
blocks by reversing the above procedure.
n ! CAUTION
When lifting the front of the truck watch
truck for signs of lateral instability. It may
tip sideways. You may have to support or
guide the side of the truck or overhead
guard to prevent tipping.
A WARNING
An incorrectly installed counterweight can
move or fall unexpectedly. Never lift or
block a truck using the counterweight. Fail-
ure to follow procedures outlined in this
manual can result in injury or death.
6. Hold the shorter block against the outer rail and lower
the upright until inner rail rests on the block.
2. Put a floor jack under the steer axle mounting frame 6. When maintenance work is completed, lower the rear
member, centered between the two wheels. of truck to the floor by reversing the above procedure
and lowering each side of the truck 50 mm (2 in) at a
A WARNING
Never lift the truck by the counterweight.
time:
l Put jack under frame and raise truck
l Carefully remove blocks and lower truck.
l Remove jack and blocks from drive wheels.
Raising EntireTruck
Refer to truck data plate for truck weights.
1. Park truck safely as described in “Safe Parking.”
Lower upright fully.
2. If necessary, drive truck onto boards to increase
undercLearance.
NOTE
If there is insufftcient clearance under
frame for your jack, the truck may fmt be
A WARNING
SIDE-TO-SIDE TIPOVER. When jacking
driven onto shims, such as 25 x 150 x 300 side of truck, be sure upright is lowered
mm (1 x 6 x 12 in) pieces of board, to fully and do not raise one side of the truck
increase the truck frame underclearance. more than about 50 mm (2 in) higher than
the other, to avoid tipping truck over later-
3. Raisethetruckonlyashighasnecessary toperformthe
ails*
maintenance work
END-TO-END TIPOVER. If the upright
4. Put blocks at both sides of the truck, fully under the and &ansaxle are removed while the truck
frame main side structure. Put the blocks in front of but is blocked up, the truck will tip backwards
close to the counterweight and steer wheels for best due to the heavy counterweight. Both up-
truck stability. right and counterweight must be removed
before attempting to raise the truck for
transaxle removal. The back of the truck
must be supported by blocking under the
steer axle to prevent movement.
The reverse is also true. If the counter-
weight is removed while the truck is up on
blocks, the weight of the upright and
transaxle will cause the truck to tip on the
front blocks and fall forward.
n ! CAUTION
Before performing any maintenance, check
the truck for stabilitY on the blocks.
SM 598, Apr ‘96 Copyrighted Material Lifting, Jacking, and Blocking l SA-2-5
Intended for CLARK dealers only
Do not sell or distribute
Main Table of Contents
3. Put the jack under side frame near the center of the
truck. 0! CAUTION
Before performing any maintenance work,
check the truck for stable condition on the
blocking.
Section 3.
Towing
If your truck is disabled but can be moved freely on its own 4. Check that the counterweight bolts on both trucks are
wheels without further damage, use the following proce- in place and properly torqued to 340-380 Wm (250-
dures to tow the truck safely to a repair area. 280 ft-lb). These bolts are made of special, high-tensile
steel and are not commercially available. When neces-
A WARNING sary, replace these bolts only with a genuine Clark
It is important for your safety and to the replacement part.
care of your lift truck to use the proper 5. Use an approved, solid metal tow bar with towing
equipment and carefully follow these rec- couplers that connect to the towing pins in the counter-
ommendations for safe towing. weights.
Do not tow a lift truck if there is a problem NOTE
with the brakes or tires, or if the steering DOT-approved towing equipment is avail-
cannot be operated. able from your Clark dealer.
Do not tow the disabled truck up or down
ramps or steep inclines. 6. Release the parking brake on the towed vehicle. Place
directional control lever in neutral.
Do not attempt to tow the disabled truck if
traction or weather conditions are poor. 7. Tow the disabled truck backwards. An operator must
be on the disabled truck.
Be sure to apply the parking brake or block the drive
wheels on the disabled truck while working around it. /\ ! CAUTION
The power steering wiI1 not operate on the
When possible, raise the carriage (forks) on the dis-
abled truck 300 mm (12 in) from the floor or ground. disabled truck when the, engine is not run-
ning. The steering handwheel will be dif’fi-
Secure the carriage on the upright with a chain.
cult to turn.
Use a truck for towing that is of equal or larger capacity
than the disabled truck. Carry a partial load on the tow 8. Tow the truck slowly. Careful towing is necessary to
truck for improved traction. prevent injury to personnel or damage to the disabled
truck. The truck should be towed at a speed of less than
8 kph (5 mph, or a moderate walking speed) with a
driver in place and steering the disabled truck.
LIFTTRUCK PARKING
GROUP PS
PERIODIC SERVICE
Section 1.
Maintenance Schedules
IMPORTANT
MAINTENANCE INTERVALS. If the lift
truck is used in severe or extreme operat-
ing conditions, the maintenance intervals
should be shortened accordingly.
Since the operating environments of lift
trucks vary widely, the above descriptions
are highly generalized and should be ap-
plied as actual conditions dictate.
TASKS
PS - Periodic Muintenunce
Thermostat - testh@a= I I I I I I
Water pump - check leaks/wear I I . I I I
Group 02 - Fuel System
Carburetor idle/air - check/adjust I I . I I I
CO level - check/adjust I I I I I .
Diesel injectors/lines - clean/inspect .
Filler cap/screen - clean/inspect .
Fuel filter, diesel - replace .
b
Fuel filter, gas - replace I .
L.PG lock-off valve filter - .
inspect/replace I I I I I
LPG tank mounting/mmrd
__ - insnect I
I I
. I I I
Group 06 - Transaxle
Air vent - inspect, clean or replace .
on standard transaxle I
Axle end lube - clean/repack During brake repairs
Axle mounting bolts - .
inspect/tighten
Charging pump - stall test standard .
transaxle
Clutch pack operation - stall test .
standard transaxle
Pressure checks .
Fluid change - drain/fill .
Fluid filter - replace . .
Fluid level/condition - check/sample
Inching operation - check/test
Oil cooler / lines - inspect
Transmission strainer - clean on .
standard transaxle I I
Group I2 - Ignition and Starting System
Diesel cold starting plug - test I I I I I .
Distributor cap/rotor - inspect .
Electronic ignition - test .
Ignition timing - check/adjust .
Ignition wiring- - inspect
.
.
L -
Neutral start - check .
Parking brake interlock - check .
Spark plugs - regap/replace .
Starter motor - inspect/test .
.
I I
inspect/tighten
Upright lift cylinder downdrift - test
Upright rollers - check
Upright trunnion bolts - tighten