Clark Sm 555 Service Manual

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SM=555
TM 12/25 36Volt
EV-100 Supplement

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Intended for CLARK dealers only
Do not sell or distribute
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 SM555

CONTENTS
..
III INTRODUCTION
iv HOW TO USE THIS MANUAL
V SUBJECT / PICTORIAL INDEX
vi SAFETY INFORMATION
Driver’s Daily Checklist
PM Report Form
1.1 PM - PLANNED MAINTENANCE PROGRAM
1.2 1 Visual Inspection
2.1 2 Operational Checks / Test Drive
3.1 3 Air Cleaning
4.1 4 Critical Fastener Torque Checks
5.1 5 Chassis Components Maintenance / Inspection
6.1 6 Lubrication, Filters & Fluid Level Checks
7.1 7 Electrical Tests

GROUP Section PROCEDURE

01 1 PLANNED MAINTENANCE SCHEDULE

01 2 PLANNED MAINTENANCE AND LUBRICATION CHARTS
12 1 BATTERY REMOVAL
12 2 BATTERY MAINTENANCE

13 1 LIFT PUMP MOTOR MICROSWITCH ADJUSTMENT

13 2 SERVICE BRAKE MICROSWITCH ADJUSTMENT
13 3 PARKING BRAKE MICROSWITCH ADJUSTMENT
13 6 ACCELERATOR CONTROL

14 1 ELECTRICAL SYSTEM

16 1 ELECTRICAL MOTOR MAINTENANCE

16 2 DRIVE MOTOR BRUSH REPLACEMENT

16 4 STEER MOTOR BRUSH REPLACENT
16 22R/22 STEER PUMP MOTOR
16 23 R/23 DRIVE MOTOR
16 24RI24 LIFT PUMP MOTOR
16 27 GENERAL MOTOR MAINTENANCE
17 4 STEER AXLE TRUNNION MICROSWITCH ADJUSTMENT

19 1 SCR CONTROL PANEL

19 2 SCR CONTROL OPRERATION AND TROUBLESHOOTING

20 1 DRIVE AXLE MAINTENANCE

20 lOR/lO DRIVE AXLE
22 PNUEMATIC TIRE AND WHEEL MAINTENANCE
23 : BRAKE BLEEDING PROCEDURE
23 4 PARKING BRAKE ADJUSTMENT
23 17R/17 BRAKE CALIPER ASSEMBLY
23 18R/18 BRAKE MASTER CYLINDER
25 5 PYLON RELEASE ADJUSTMENT

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25 1 OR/l 0 STEERING GEAR CONTROL
26 1 STEER AXLE TRUNNION BEARINGS ADJUSTMENT
26 2 STEER WHEEL BEARING MAINTENANCE
26 3 POWER STEERING RELIEF PRESSURE CHECK
26 STEER CYLINDER LINKAGE CHECK & ADJUSTMENT
26 ;: STEER AXLE, STEERING LINKAGE, STEERING TRUNNION
26 9R/9 STEERING CYLINDER
26 14w14 STEER PUMP
29 1 HYDRAULIC SUMP FLUID AND FILTER CHANGE
29 1 OR/l 0 LIFT PUMP

30 HYDRAULIC SYSTEM RELIEF PRESSURE CHECK AND ADJUSTMENT

30 lR19 HYDRAULIC VALVE (MAIN HYDRAULIC VALVE)
31 1 HYDRAULIC SYSTEM SCHEMATIC DIAGRAM
32 1 TILT CYLINDER ADJUSTMENT
32 11 TILT CYLINDER
32 2 TILT CYLINDER DRIFT TEST
34 1 LIFT CHAIN CHECK AND ADJUSTMENT
34 3 UPRIGHT DOWNDRIFT TEST
4 FORK MAINTENANCE
;:: 7 LIFT CHAIN MAINTENANCE
34 9R UPRIGHT REMOVAL

1 COUNTERWEIGHT REMOVAL
:: 2 FRONT BATTERY PLATE ADJUSTMENT
3 MACHINE JACKING AND BLOCKING
z: 1 OVERHEAD GUARD REMOVAL
39 2 HOOD REMOVAL

40 1 TRUCK DATA PLATES AND DECALS

40 SUGGESTED EQUIPMENT FOR ELECTRIC TRUCK PM
40 3” FIRE EXTINGUISHER RECOMMENDATIONS
40 4 LUBRICANT SPECIFICATIONS AND RECOMMENDATIONS
40 5 TRUCK SPECIFICATIONS
40 17 MEASURING VOLTAGES WITH THE V - 0 - M
40 18 MEASURING RESISTANCE WITH THE V - 0 - M

NOTE: “R” denotes Removal Procedure for components

SM555 ii
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 INTRODUCTION

Clark Equipment Company welcomes you to the growing group of professional

people who own, operate, and maintain Clark lift trucks. We take great pride in
the long tradition of quality products and superior value that the Clark name
represents. This manual has been written to help you maintain your Clark lift
truck in an efficient and safe operating condition.

Regular maintenance and care of your lift truck is not only important for
economy and utililization reasons, it is essential for your safety. A faulty lift
truck is a potential source of danger to the operator, and to other personnel
working near it. Approved methods of service and correct procedures of
repair are important for the safety of personnel and the safe operation of a
lift truck.

Genuine Clark parts should always be used when replacements are needed.
Substitute parts from other sources may not be designed like original parts and
may not meet OSHA or other safety requirements.

The mechanic is cautioned and expected to always work in a safe manner by

using the correct procedure. If a mechanic does not understand a safety
procedure when performing maintenance on a truck, the maintenance
supervisor should be consulted for assistance. Do not take chances which may
result in injuries.

Operator Inspection

Lift trucks should be inspected daily by the operator, or at the start of each
shift and the Operator’s Daily Checklist carefully completed. Be sure that all
safety items are checked and in good condition. Use the daily inspection sheet
as a check list and a record for your findings. This form is illustrated in this
manual. Also, please refer to the Operator’s Manual located on the truck.

Planned Maintenance Program

In addition to the daily operator inspection, Clark recommends that a planned

maintenance and safety inspection program be performed on a regular basis.
The program will provide an opportunity to make a thorough inspection of the
safety and operating condition of your lift truck. Necessary adjustments and
repairs can be done during the PM which will increase the life of components
and reduce unscheduled downtime. The PM can be scheduled to meet your
particular application and lift truck usage.

This manual includes repair procedures as well as instructions for a periodic

planned maintenance program which covers inspections, operational checks,
cleaning, lubrication and minor adjustments. A table of recommended planned
maintenance items and typical schedule is included. Also shown is the PM
report form which can be obtained from your local Clark dealer. He is
prepared to help you with a Planned Maintenance Program with trained
service personnel who know your lift truck and can keep it operating safely
and efficiently.

SM555 iii
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 HOW TO USE THIS MANUAL

This manual is intended to be used by persons who are trained and authorized to do lift
truck maintenance. The recommended procedures for routine servicing and adjustments
as well as for removal and overhaul of major components of the truck are outlined. It is
written to show and describe the adjustment, removal, disassembly, inspection, repair,
and assembly steps that are normally required to service these components.

The detailed procedures are arranged in sequence by numbered GROUP and Section.
The GROUP numbers are the same as the component group in the Master Parts Book.
Each GROUP has its own Table of Contents, so that you can find the various topics within
more easily. If you cannot find a topic in the Table of Contents, check the Index at the
back of the manual.

Component specifications, information notes and safety messages are included at the
proper step of each procedure. To be better prepared to do the necessary service work,
please take time to read the entire procedure, including any special instructions, before
doing any work.

Specifications of selected truck components are included at the back of the manual for
easy reference.

Also refer to the Operator’s Manual, located on the truck, for additional information and
instructions on the operation and maintenance of your truck.

If you have need for more information on the care and repair of your truck, please contact
your authorized Clark dealer.

NOTICE - The descriptions and specifications included in this manual were in effect at the time of printing.
Clark Equipment Company reserves the right to make improvements and changes in specifications or design,
without notice and without incurring obligation. Please check with your authorized CLARK dealer for
information on possible updates or revisions.

0 Clark Equipment Company 1989

SM555 iv
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 OH
CLqRK

PICTORIAL INDEX TYPICAL FORK TRUCK

BASIC GROUP NUMBERS

L 26

23

12 BATTERY
13 ACCELERATOR CONTROL ASSEKBLY
14 WIRING
16 MOTORS
17 DRIVE MOTOR CUT-OUT, DIRECTIONALCOMROLS
19 CONTACTORS, CONTROLS
20 DRIVE AXLE
22 BRAKES
23 BRAKES, WHEELS/TIRES
25 STEERING COLUHN, LINKAGE
26 STEER AXLE, CYLINDER, PUMF, LINES
29 BYDRAULIC PUMP 6 FILTER
30 HYDRAULIC VALVE 6 LINKAGE
32 TILT CYLINDER
34 UPRIGHT 6 LIFT CYLINDER
38 FRAME 6 COUNTERWEIGHT
39 SHEET METAL, SEAT 6 OVERHEAD GUARD

SM555 v
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SAFETY SIGNS AND SAFETY
MESSAGES
Improper or careless techniques cause accidents.
Don’t take chances with incorrect or damaged
equipment READ and UNDERSTAND the proce-
dures for safe driving and maintenance outlined in
this manual.
STAY ALERT ! Follow safety rules, regulations
and procedures. Accidents can be avoided by
recognizing dangerous procedures or situations
before they occur.
DRIVE AND WORK SAFELY and follow the safety
signs and their messages displayed on the truck
and in this manual.
SAFETY SIGNS and MESSAGES are placed in
this manual and also on the lift truck to provide in-
structions and to identify specific areas where
potential hazards exist and special precautions
should be taken. Be sure you know and under-
stand the meaning of these instructions, signs and
messages. Damage to the truck or death or
serious injury to you or other persons may result if
these messages not being followed.
NOTICE
This message is used when special information is
required to clarify procedures or identify compo-
nents pertaining to the truck.
IMPORTANT
This message is used when additional attention is
required for proper operation or maintenance of
the truck.
fi ! CAUTION
This message is used as a reminder of safety
practices which can result in personal injury if
proper precautions are not taken.
iz!! WARNING
This message is used when a hazard exists which
can result in injury or death, if proper precautions
are not taken.
A DANGER
This message is used when an extreme hazard
exists which will result in death or serious injury if
proper precautions are not taken.
SM555 vi
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USER SAFE INSPECTION
PRACTICES
The following instructions have been prepared
from current industry and government safety
standards applicable to industrial truck operations
and maintenance. They are listed here for the
reference and safety of all workers during
inspection / maintenance operations. When in
doubt of any inspection / maintenance procedures,
please contact your local CLARK dealer.
1 .Powered industrial trucks can become
hazardous if maintenance is neglected. Therefore,
suitable maintenance facilities, trained personnel
and procedures shall be provided.
2. Maintenance and inspection of all powered
industrial trucks shall be done in conformance with
the manufacturer’s recommendations.
3. A scheduled planned maintenance, lubrication
and inspection system shall be followed.
4. Only trained and authorized personnel shall be
permitted to maintain, repair, adjust and inspect
industrial trucks and in accordance with the
manufacturer’s specifications.
5. Properly ventilate work area, vent exhaust
fumes, keep shop clean and floor dry.
6. Avoid fire hazards and have fire protection
equipment present in the work area. Do not use
an open flame to check electrolyte level. Do not
use open pans of fuel or flammable cleaning fluids
for cleaning parts.
7.Before Starting To Work On Truck:
a) Raise drive wheel free of floor or disconnect
power source and use blocks or other positive
truck positioning devices.
b) Put blocks under the load-engaging means,
innermast( or chassis before working on them.
c) Disconnect battery before working on the
electrical system.
8. Operation of the truck to check performance
must be conducted in an authorized, safe, clear
area.
9. Before Starting to Drive the Truck:
a) Be in operating position.
b) Turn on power.
c) Check functioning of lift and tilt systems.
d) Check directional and speed controls.
e) Check steering.
f) Check brakes.
g) Check warning devices.
h) Check any load handling attachments.
ii) Release parking brake.
10. Before Leaving the Truck:
a) Stop truck.
b) Fully lower forks or attachment device.
c) Put directional control in neutral.
d) Apply the parking brake.
e) Turn off the power switch.
ff) Chock wheels if truck must be left on an
incline.
11. Brakes, steering mechanisms, control
mechanisms, warning devices, lights, lift overload
devices, guards and safety devices, lift, reach and
rotation mechanisms, and frame members must be
carefully and regularly inspected and maintained in
a safe operating condition.
12. 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.
13. All hydraulic systems must be regularly
inspected and maintained in conformance with
good practices. Tilt and lift cylinders, valves and
other similar parts must be checked to assure that
“drift” or leakage has not developed to the extent
that it would create a hazard.
14. When working on hydraulic system, be sure
the battery is disconnected and upright is in its fully
lowered position, and hydraulic pressure relieved
in hoses and tubing
fi ! WARNING
Always put blocks under the carriage and
upright rails when necessary to work with
upright in an elevated position.
15. The truck manufacturer’s capacity, operation
and maintenance instruction plates, tags or decals
must be maintained in legible condition.
SM555 vii
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16. Batteries, motors, controllers. limit
switches, protective device, electrical conductors
and connections must be inspected and
maintained in conformance with good practices.
Special attention must be paid to the condition of
electrical insulation.
17. To avoid injury to personnel or damage to the
equipment, consult the manufacturer’s procedures
in replacing contacts on any battery.
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, operation 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 procedures.
Always use genuine CLARK or CLARK - approved
parts.
21. When removing tires, follow industry safety
practiced. Most important, deflate pneumatic tires
completely prior to removal. Following assembly
of tires on multi-piece rims, use a safety cage or
restraining device while inflating.
22. Use special care when removing heavy
components from the truck, such as
counterweight, upright, etc. Be sure that lifting and
handling equipment is of the correct capacity and
in good condition.
INDUSTRIAL TRUCK DMSION

DRIVER’S DAlFY CHECKLIST

CldRK Check Before Start Of Each Shift

CJATE
CHECK ONE: 0 GAS, LPG OR DIESEL TRUCK 0 ELECTRIC TRUCK

TRUCK NO. OPERATOR: S”PERYISOR’SOK

START OF DAY ENDOFDAY HRS. FOR DAY

HOUR METER READING:

J Boxes Accordingly
q OK
cl
Needs Attention or Repair

VISUAL CHECKS OPERATIONAL CHECKS

I, I OTHER GAUGES AND INSTRUMENTS II I I HYDRAULIC CONTROLS

1 1 OBVIOUSDAMAGEANDLEAKS SEAT BRAKE

I I I

ENGINE OIL LEVEL BA7TERY LOAD TEST

FORM NO. 597704937 HO” 80

See your Clark dealer
for copies of this form.

Copyrighted
1321-z
Material JUN 84
Intended for CLARK dealers only
Do not sell or distribute
 ELECTRIC TRUCK
PLANNED MAINTENANCE REPORT

e. Plugging & Directional Control i...

.,..,
....
f. Return to Neulral i...
.i...
....
g. Hydraulic System Operation ..::
....
.:.:,
h. Pedal Pads & Linkages

j. Seat Brake Operation I I 1&::::

...L b.
..““I Cu
1 c. Control Acceleralic
01 ClEANING & LUBRICAli~___ d. 1A Contactor Drop

d. Inspect Fan&Control ECAlEPA 1 f 1.x.:.:.:

:;:$$.
1 h. 1A Time Delay (SEC)

,
13 ~UGES.LlGHTS-INDICATDRS c. Security of Mounting
a. Hour Meter Oprahon ..:.:.
I I F:::::,
 PM - PLANNED MAINTENANCE PROGRAM

As an aid in performing and documenting the PM inspections, Clark has prepared

an "ELECTRIC TRUCK PLANNED MAINTENANCE REPORT" form. See opposite paqe.
Copies of this form may be obtained from your authorized Clark dealer: We
recommend that you use this form as a checklist and to make a record of your
inspection and truck condition.

This manual is intended to be used in conjunction with the PM Report Form.

It is arranged by groupings of items of work that are done in a logical and
efficient sequence.

PM Report Form

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.

For safety, it is good practice to:

DISCONNECT THE BATTERY AND RE-
MOVE ALL JEWELRY BEFORE WORK-
Remove all jewelry (watch, rings,
ING ON ANY ELECTRICAL SYSTEM.
bracelets, etc.) before working
SEVERE BURNS CAN RESULT FROM
on the truck.
CONTACT WITH ELECTRICAL SYSTEMS
Disconnect battery from truck receptacle
before working on electrical components.

Always wear safety glasses. Wear a

safety (hard) hat in industrial plants
and in special work areas where protec-
tion is necessary or required.
K MAINTENANCE

DO NOT WORK ON THIS TRUCK

SHOES AND CORRECT FITTING
CLOTHING WHEN WORKING ON
LIFT TRUCKS. INJURY CAN
RESULT IF YOU 00 NOT WEAR
UNLESS YOU ARE TRAINED AND
AUTHORIZED AND KNOW THE
CORRECT MAINTENANCE PROCE-
DURES.

Copyrighted Material
Code: PM-540, NOV 85 Page 1.1
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 PM CLqRK

1 Visual Inspection

85M549

The objective of the visual inspection is to be sure

that all components of the lift truck are:

1) in place
2) attached securely
3) in a safe and efficient operating condition

Be sure to make a thorough inspection of the critical

components that handle or carry the load.

Page 1.2 Copyrighted Material Code: PM-540, NOV 85

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Do not sell or distribute
Cl!!!!RH PM

1 First, perform a visual inspection

of the truck and its components.

o Walk around the truck and take note

of any obvious damage.
a Check for loose fasteners
and fittings.
o Check for leaks.

When you find oil leaks due

simply to a loose fitting,
tighten the fitting. 85M501
Report other leakages as major ,.,_
repairs on the PM Report form.

2 Inspect the overhead guard for damage.

Be sure that it is properly positioned
and all mounting fasteners are in place
and tight.

85M473

3 Inspect the load back rest extension

for damage. Be sure that the mounting
fasteners are all in place and tight.

4 Inspect the fork carriage for damage,

cracks, wear, and high stress areas.

5 Inspect the complete upright assembly; rails,

rollers, lift chains, and lift cylinders.
Look for any loose parts or fittings. Be sure
that a17 safety guards and chain retainers are
in place and not damaged.
Inspect the carriage stops and cylinder
retainer bolts.
Check all welded connections.

6 Check the lift cylinder piston rods for wear

marks, grooves and scratches. Check the
cylinder seals for leaks.
85M502

Copyrighted Material
rnr(a* PM-540. NOV 85 Intended for CLARK dealers only Page 1.3
Do not sell or distribute
7 Check the upright 1ift chains for equal
tension.

8 Inspect the condition of the carriage and

rail lift chains. Look for wear, rust and
corrosion, cracked plates, tight joints or
other damaged parts.

If the chains show slack due to an

increase in length they should be 85M538
measured for wear. When chains have
stretched by wear more than 3% of
their original length they are not
safe and must be replaced.

Please refer to GROUP 34, Section 7,

Lift Chain Maintenance.

On Triple Stage uprights, carefully

inspect both sets of chains and fittings.

85M769

9 Inspect lift chain anchors at both ends

of chain. Inspect each lift chain attachment
point, clevis end and retainer. Be sure
both nuts for each chain anchor are in place.
Be sure there is a retaining pin (cotter pin)
in the end of each anchor.

NOTICE - Style and location of lift chain

anchor fittings varies between upright
models.

10 Inspect the condition of the carriage and

upright rollers. Check for correct roller
clearance.

11 Inspect the rails for roller wear and correct

roller pattern. Look for deep grooves,
scratches, rust, grease and contamination.
Inspect the tie bars.

85M770

Page 1.4 Code: PM-540, NOV 85

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Cl!!RK PM

12 Check carriage chain adjustment.

If you are unfamiliar with this procedure,

please refer to GROUP 34, Section 1,
Upright Lift Chain Check and Adjustment
Procedure.

Also see operational tests for correct

fork height check.

17643

13 Inspect all lift line hydraulic hoses and

connections for damage and leaks.

DO NOT USE YOUR HANDS TO CHECK

FOR HYDRAULIC LEAKAGE. FLUID
UNDER PRESSURE CAN PENETRATE
YOUR SKIN ANU CAUSE SERIOUS

85M632
NOTICE
If necessary, raise the carriage for access
to upright components, hoses, fittings, etc.
l APPLY THE PARKING BRAKE AND BLOCK
THE WHEELS.
l BE SURE TO PUT BLOCKING UNDER THE
CARRIAGE AND UPRIGHT RAILS FOR SAFETY.

Refer to:
GROUP 38, Section 3, FALLING FORKS
Machine Jacking and Blocking.
00 NOT liALK OR STAND UNDER
RAISED FORKS. THE FORKS CAN 85M626
FALL AND CAUSE INJURY OR
DEATH.

NOTE - When carriage is raised and blocked,

the oil level in drive axle may also be
checked. Refer to section "6 Lubrication,
Filters and Fluid Level Checks”.

Also, check upright cylinder mounting bolt

torque while the upright is raised.
Refer to section "4 Critical Fastener
Torque Checks".

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PM Cl!!‘lRIK

14 Inspect all lift cylinder mounting

retaining bolts to be sure they are
in place and tight. (NOTE - Style and
location varies with upright model.)

Refer to GROUP 40, Section 5 for torque

specification.

85M632

15 Check tilt cylinder rods for any damage

and scratches which may cause cylinder
seals to leak.

85M539

16 If carriage was blocked up for previous

inspections, raise carriage slightly and
remove the blocking. Lower the carriage.

,“_% d
85M627

85M630

Page 1.6 Copyrighted Material Code: PM-540, NOV 85

Intended for CLARK dealers only
Do not sell or distribute
 PM
Cl!!!!RK

IMPORTANT

FORKS ARE A CRITICAL SAFETY ELEMENT OF

THE LIFT TRUCK. THEY MUST BE CAREFULLY Please refer to:
INSPECTED AT EACH PM INTERVAL AND ALWAYS GROUP 34, Section 4
MAINTAINED IN A SAFE CONDITION. Fork Maintenance.

FORKS THAT ARE BENT OR TWISTED WILL CAUSE

THE LOAD TO SHIFT OR SLIDE OFF AND BE DROPPED.
FORKS THAT ARE CRACKED OR WORN EXCESSIVELY
CAN BREAK SUDDENLY AND CAUSE SEVERE INJURY
OR DEATH.

17 Inspect the lift forks for:

l Cracks l Breaks l Bending l Wear
Move the fork blades together (side-by-
side). Check the fork blades for bent
or twisted condition, with respect to
each other and also to the fork shank.
Check for cracks and wear all around
the fork heel area.
18046

Inspect the fork blades carefully for

twists and bends.

The fork surfaces should be level and

even with each other. The height differ-
ence between both fork tips should be
no more than [6mm] 0.25 inch maximum.

25455

Check the forks to be sure they are not

bent or twisted at the heel. Put a
steel bar on the fork blade and use a
carpenter's square to check for 90' angle
Carpenter square
between blade and shank. Angle at fork
blade and shank must not be more than
dimension specified in chart shown in
GROUP 34, Section 4, Fork Maintenance.

25456

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PM Cl!lRn;

Check the amount of wear at the heel

of the forks. If the fork blade at
the heel of the fork is worn down by
more than 10 percent, the load capacity
of the forks is reduced and they must
be replaced. Please refer to GROUP 34,
Section 4, Fork Maintenance. 10% of “A” max. wear

18 Inspect the fork latches. Be sure

they are not damaged or broken.

84M252

The fork latches are spring loaded.

Test them to be sure that they operate
freely and lock correctly. Inspect
for broken or damaged springs.

2498;

19 If your upright has a carriage with fork

stop pins, inspect the stop pins for secure
condition. Be sure that none are broken
or missing, on top and bottom (if so
equipped) of the carriage fork bar.

Page 1.8 Copyrighted Material Code: PM-540, NOV 85

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Do not sell or distribute
CLSRK PM

20 Check the condition of the drive and steer

wheels and tires. Remove objects that are
embedded in the tread.

Inspect cushion tires for excessive wear

and breaks or "chunking out", and bond
failure between tire and rim.

Inspect pneumatic tires and wheels

carefully for:

Damaged tire.

Damaged wheels or loosening of the PERSONNEL WORKING ON WHEELS

locking rings on multi-piece rims. AND TIRES MUST BE QUALIFIED
AND TRAINED TO DO WHEEL AND
Loosening of the clamping bolts and TIRE MAINTENANCE.
nuts on two-piece, split-rim wheels.

Low inflation pressure.

Please refer to section "6 Lubrication,

Filters and Fluid Level Checks" for tire
inflation pressure check.. Also, refer to
GROUP 40, Section 5, Truck Specifications.

24308

If pneumatic tire pressure is low, do not

add air. The tire may need to be removed
and repaired.
REMOVE THE AIR FROM TIRES
Move the truck to a maintenance area and BEFORE DOING ANY WORK ON
perform, or schedule, a careful and complete TIRES
RIMS
OR RIMS.
CAN
MULTI-PIECE
SEPARATE WITH
inspection of the tire and rim installation. ENOUGH FORCE TO CAUSE
INJURY OR DEATH.

Refer to GROUP 22, Section 1, Pneumatic

Tire and Wheel Maintenance.
24988

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Clark Sm 555 Service Manual
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PM CMRK

21 Inspect the brake pedal for loose mounting.

Check for free movement and correct, full
travel of the pedal. Inspect the pedal
pad for wear and secure attachment.

Push down on the pedal and release to

check the return-spring action.

** See note below.

85M513

22 Inspect the accelerator pedal for correct

mounting to the floorboard and travel
movement.

** NOTE - Refer to section "5 Inner Chassis

Components Inspection", Page 5.6, for
additional inspection recommendations
with floorboard removed.

85M514

23 Inspect the directional control lever.

Be sure that it is mounted securely
and operates freely. Inspect the lever
knob for damaged condition. Be sure the
knob is attached securely and the screw
is tightened correctly. Refer to
GROUP 40, Section 5, for torque speci-
fication.

85M497

24 Check the hydraulic control levers for free-

dom of operation and security of mounting.
Inspec t the valve lever knobs for damaged
condit ion. Be sure that they are attached
secure ly to the lever and the screws are
tight.

Refer to GROUP 40, Section 5, for torque

specification.

85M491

Copyrighted Material
Page 1.10 Code: PM-540, NOV 85
Intended for CLARK dealers only
Do not sell or distribute
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