Clark CY-150, CY165, CY180S Forklift Service Repair Manual

Manual Type: Service Repair Manual

Table of content of the Service Repair Manual

Lube Chart …………………………………………………. 12
Operation …………………………………………………. 10, 11
Service Check Sheets ………………………………… 13, 14
Specifications ……………………………………………. 9

SECTION I – BRAKE SYSTEM

Bleeding Brakes ……………………………………….. 1-1
Brake Adjustment ………………………………………. 1-3
Brake Pedal Adjustment …………………………….. 1-2
Brake Shoes ………………………………………………. 1-3
Hand Brake ……………………………………………….. 1-3
Hydrovac ……………………………………………………. 1-3, 4
Master Cylinder …………………………………………. 1-1
Wheel Cylinder …………………………………………… 1-2

SECTION II – TORQUE CONVERTER

Description ………………………………………………… II-1
Operation …………………………………………………… II-2, 3, 4
Overhaul …………………………………………………….. II-4, 5, 6, 7
Reassembly ………………………………………………… II-7
Trouble Shooting Guide …………………………….. II-8, 9, 10

SECTION III – COOLING SYSTEM

Description ………………………………………………… III-1
Fan Assembly ……………………………………………. III-1
Thermostat ………………………………………………… III-1
Water Pump ………………………………………………. III-2

SECTION IV – DRIVE AXLE AND DIFFERENTIAL

Backlash Adjustment ………………………………….. IV-5
Cleaning and Inspection ……………………………… IV-3
Differential and Carrier ………………………………. IV-2
Disassembly ………………………………………………. IV-1
Maintenance ………………………………………………. IV-1
Pinion ………………………………………………………. IV-2
Planet Spider ………………………………………………. IV-3
Reassembly ………………………………………………… IV-4
Trouble Shooting Guide …………………………….. IV-6

SECTION V – ELECTRICAL SYSTEM

Battery ………………………………………………………. V-1
Distributor ………………………………………………….. V-1, 2
Generator ………………………………………………….. V-2, 3
Ignition Coil ………………………………………………… V-4
Solenoid ……………………………………………………… V-3
Spark Plugs ……………………………………………….. V-4
Specifications ……………………………………………. V-6
Starting Motor ……………………………………………. V-3
Trouble Shooting Guide …………………………….. V-5, 6
Voltage Regulator ……………………………………….. V-4, 5

SECTION VI – ENGINE

Camshaft ……………………………………………………. VI-5, 6
Compression ………………………………………………… VI-1
Connecting Rods …………………………………………. VI-4
Connecting Rod Bearings …………………………… VI-3, 4
Crankshaft …………………………………………………… VI-6
Cylinder Head …………………………………………….. VI-1
Flywheel ……………………………………………………….. VI-6, 7
Governor ……………………………………………………… VI-7, 8
Main Bearings …………………………………………….. VI-3
Oil Pressure …………………………………………………. VI-7
Piston, Rings and Pins ……………………………… VI-4, 5
Specifications ……………………………………………. VI-9, 10
Trouble Shooting Guide …………………………….. VI-8, 9
Valves ………………………………………………………. VI-1, 2, 3

SECTION VII – FUEL SYSTEM

Carburetor ………………………………………………….. VII-1, 2, 3
Fuel Pump ………………………………………………….. VII-1
Fuel Tank …………………………………………………….. VII-1
Metering Valve ……………………………………………. VII-3
Trouble Shooting Guide …………………………….. VII-3, 4

SECTION VIII – HYDRAULIC SYSTEM

Flow Control Valve ……………………………………… VIII-6
Hydraulic Oil ………………………………………………… VIII-1
Leakage Tests ……………………………………………… VIII-4
Pump, Main …………………………………………………. VIII-1, 2
Steering Booster Pump ……………………………… VIII-2
Tilt Cylinder ………………………………………………… VIII-5, 6
Tilt Lock Valve ……………………………………………. VIII-4, 5
Upright ………………………………………………………. VIII-6
Valve, Main ………………………………………………… VIII-2, 3, 4

SECTION IX – STEERING SYSTEM

Axle …………………………………………………………. IX-1
Booster Cylinder …………………………………………. IX-3, 4, 5
Steering Gear …………………………………………….. IX-2, 3

SECTION X – TRANSMISSION

Description ………………………………………………… X-1
Disassembly ………………………………………………. X-4, 5, 6, 7
Lubrication …………………………………………………. X-11
Operation …………………………………………………… X-11
Overhaul …………………………………………………….. X-4
Reassembly ………………………………………………… X-8, 9, 10

This service publication provides information covering normal service, maintenance and repair of the Clark industrial ltrucks noted on the cover. It has been specifically prepared to help owners and service personnel maintain these trucks in efficient and safe operating condition. Regular, correct maintenance and care of industrial trucks is not only important for long and efficient truck life; it is essential for safe operation. The importance of proper maintenance through planned service, inspection and qualified repairs cannot be emphasized too strongly.