Hot wheel bearings, a failed stall test, a mast that drifts under load: this 705-page Clark C500 Y180 service manual PDF is the factory shop book for those jobs, covering 15 variants of the C500 lift truck from the Y180 through the 350. Hydraulic diagrams trace flow from the Tyrone and J. S. Barnes pumps through the Vickers and Commercial Intertech control valves, and the wiring diagram lays out your starter, alternator, and battery circuits. Drive axle and transmission work fill close to half the book, from Clark-Hurth and Rockwell axle overhauls to clutch modulation, plus air brake service and steering pressure checks. Change the hydraulic filters every 500 operating hours, and torque the drive axle to frame bolts to 447-503 lbf-ft (606-681 N·m). Hub on, adjusting nut in hand, seating torque unknown. That number (with its model exceptions) sits one bookmark away in a text-searchable PDF, and your truck is stacking pallets again by end of shift.
What's Inside This Clark C500Y180 to C500Y350 Manual
| System | Pages | Key Topics |
|---|---|---|
| Engine | 21-47 | Engine Troubleshooting, Engine Removal, Ford Engine Specifications, Cummins Engine Specifications |
| Cooling System | 48-60 | Troubleshooting, Radiator Removal, Testing and Maintenance, Radiator Repair |
| Fuel System | 61-87 | Troubleshooting, Induction System, Accelerator Linkage, Impco LPG Lock-Off Valve, Impco LPG Vaporizer-Regulator |
| Transmission | 88-203 | Troubleshooting, Transmission Stall Test, Transmission Removal, Transmission Clutch Modulation, Transmission Maintenance and Service, Linkage and Controls |
| Electrical | 204-228 | Starter and Battery Troubleshooting, Alternator Troubleshooting, Wiring Diagram, Electrical Tools |
| Drive Axle | 229-381 | Troubleshooting, Drive Axle Removal, Drive Axle Wheel Bearing Adjustment, Clark-Hurth and Rockwell Drive Axle Maintenance and Service |
| Prop Shaft | 382-388 | Troubleshooting, Prop Shaft Removal, Prop Shaft Overhaul |
| Wheels and Tires | 389-405 | Lifting Jacking and Blocking, Wheel and Tire Mounting, Safe Handling of Multi-Piece Rim Wheels |
| Parking Brake | 406-411 | Troubleshooting, Mechanical Release of Parking Brake |
| Service Brake | 412-482 | Troubleshooting, Air Brake System, Air Brake Treadle Valve, Air Brake Chambers, Air Brake Compressor, Rockwell Cam Brakes |
| Steering Column and Steering Gear | 483-493 | Troubleshooting, Removing Steering Handwheel, Removing Column and Gear and Gear From Column, Steering Pump Removal and Overhaul |
| Steer Axle | 494-543 | Troubleshooting, Steer Axle Removal, Steer Axle Overhaul, Steer Cylinder Removal and Overhaul, Steer Cylinder Overhaul, Steering System Pressure Check, Hydraulic Filters |
| Hydraulic Components | 544-680 | Troubleshooting, Hydraulic Pump-General, Tyrone Hydraulic Pump Overhaul, J. S. Barnes Hydraulic Pump Overhaul, Vickers Control Valve Overhaul, Lift & Tilt Control Valve Overhaul |
| Upright-Carriage-Forks | 681-685 | Upright Troubleshooting, Fork Removal and Inspection |
| Counterweights | 686-689 | Counterweight Removal and Installation |
| Decal Replacement and Placement | 690-693 | Pinch Point Decal, Transmission Oil Requirements, Fuel Requirements, Directional Control Decal, Shift Control Decal, Nameplate |
| Specifications | 694-705 | General Specifications |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Drive axle to frame bolts torque | 447-503 lbf-ft [606-681 N·m] | p. 236 |
| Parking brake release bolt storage pocket nut torque | 10 lbs-ft | p. 236 |
| Mounting bolt torque | 300 - 400 lb.ft. (406 - 461 N·m) | p. 526 |
| Retainer bolt torque | 25 - 28 lb.ft. (34-38 N·m) | p. 526 |
| Hydraulic filter replacement interval | 500 operating hours | p. 533 |
| Hydraulic fluid drain and pick up screen cleaning interval | 2,000 operating hours or once a year | p. 533 |
| Pump Capacity | 65.5 GPM @ 2500 RPM | p. 550 |
| Capscrew Torque | 80 - 90 lb. ft. (108 - 122 N·m) | p. 550 |
| Wheel Lug Nut Torque | 100-120 lbf ft | p. 11 |
| Engine Oil Pressure (at normal operating speed) | 30-60 PSI | p. 12 |
| Front Engine Mount Bolt Torque | 60-65 lbf-ft | p. 36 |
| Flywheel Housing Bolt Torque | 30-33 lbf-ft | p. 36 |
Clark C500Y180 to C500Y350 Common Problems This Manual Covers
Clark C500 engine cranks but will not start, or starts and runs with a rough idle and surging
Check the fuel system first using the no-start and rough idle checks starting on page 61. On LPG trucks, inspect the Impco lock-off valve and vaporizer-regulator. Once it runs, verify idle at 600-650 RPM on Ford engines (page 39) or 800 RPM on Cummins engines (page 47), and confirm 30-60 PSI oil pressure at operating speed.
Manual Section: Fuel System p. 61Hydraulic pump noisy or failed with no lift and no tilt function on the upright
Check the reservoir oil level first. Replace the hydraulic filters if they are past the 500 operating hour interval (page 533), and drain the fluid and clean the pick up screens if it has been 2,000 hours or a year. Then work through the noisy pump and no lift/tilt checks in the hydraulic troubleshooting starting page 544.
Manual Section: Hydraulic Components p. 544Transmission light comes on with slow shifting, noisy operation, no pull, or no truck movement
Test the transmission with the stall test first, following the troubleshooting in the transmission section starting on page 88. Inspect the linkage and controls, then check clutch modulation. If the transmission has to come out, torque the bellhousing bolts to 30-33 lbf-ft and the mount to frame bolts to 35-40 lbf-ft on reinstall (page 96).
Manual Section: Transmission p. 88Air brake system builds no air pressure, brakes drag, or pedal travel feels excessive
Check the air brake compressor output first, since a failed compressor leaves the system with no pressure and no brakes. Then inspect the treadle valve and air brake chambers, and check the Rockwell cam brakes for drag. Work through the service brake troubleshooting in the section starting page 412 before replacing parts.
Manual Section: Service Brake p. 412Parking brake will not release and the truck will not move from a standstill
Check the parking brake troubleshooting in the section starting page 406. To move the truck, mechanically release the parking brake with the release bolt. After repair, reinstall the release bolt, flat washer and nut in the storage pocket and torque the nut to 10 lbs-ft against the washer (page 236).
Manual Section: Parking Brake p. 406Drive axle constant or intermittent noise with lubricant leaks and excessive tire wear
Check the drive axle troubleshooting starting page 229 to separate constant from intermittent noise. If wheel bearings need adjustment, seat them by tightening the adjusting nut to 400 lb. ft. while rotating the hub both directions (page 258); exception models use 100 lb. ft. (page 259). Install the jam nut and torque to 800 lb. ft. (page 260).
Manual Section: Drive Axle p. 229Frequently Asked Questions
What are the fuel transfer pump replacement specs for the Clark C500Y180 to C500Y350 lift truck?
If the fuel transfer pump is defective, it must be replaced. To verify a defect, remove the outlet line from the pump, place it in a suitable container, and crank the engine; if no fuel is observed, the fuel transfer pump should be replaced. p. 23
What is the torque spec for the front engine mount bolts on the Clark C500Y180 to C500Y350 lift truck?
The front engine mount bolts must be torqued to 60 - 65 lbf-ft (81 - 88 N·m). p. 36
What is the correct cold tire inflation pressure for the Clark C500Y180 to C500Y350 lift truck?
The proper cold inflation pressure for the tires is 100 p.s.i. p. 11
How often should I change the engine crankcase oil on a Clark C500Y180 to C500Y350 lift truck?
It is recommended to drain and replace the engine crankcase oil every 50 to 250 operating hours, depending on the application and operating conditions. p. 17
What is the torque specification for the flywheel housing bolts on the Clark C500Y180 to C500Y350 lift truck?
The flywheel housing bolts must be torqued to 30 - 33 lbf-ft (40 - 45 N·m). p. 36
Is this Clark C500 Y180 manual a PDF I download?
All 705 pages arrive as one searchable PDF at checkout. Read it at the desk, then take the phone out to the machine.
Is this Clark C500 Y180 manual print-friendly?
You can. The PDF is unlocked and carries no copy protection, so print the sections you want and keep the file as your backup.
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