2019 CLARK S25D IC Pneumatic 50-250 Hours PM

Inspect the:

• upright assembly

• load backrest (LBR)

• rails

• carriage

• rollers

• lift chains

• lift and tilt cylinders

Carefully check the lift chains for

• wear

• rust

• corrosion

• cracked or broken links

• stretching

Critical items include:

• Drive axle mounting

• Overhead guard

• Drive and steer wheel mounting

• Tilt cylinder mounting and yokes

• Counterweight mounting

• Upright mounting and components

It is recommended to:

• Drain and replace the engine crankcase oil every 500 oper-ating hours. (depending on application). Contact your nearest CLARK Dealer for further information.

• Engine Oil Filter must be changed at every PM when the oilis changed.

• Remove the oil pan drain plug to drain old oil after the truckhas been in operation and the engine (oil) is at operating temperature.

Engine oil at operating temperature is hot and can cause burns. Beware of splashing oil.

• Carefully check for leaks after changing oil and installing new filter.

Inspect the

• engine coolant hoses

• fan belt(s)

• Look for leaking

• obvious damage

• worn (frayed) condition

• breaks

If the level is low, add a 50/50 mixture of specified coolant and water to the correct fill level. If you have to add coolant more than once a month or if you have to add more than one litre at a time, check the coolant system for leaks.

• Check engine oil for presence of coolant leaking into engine.

• Inspect the coolant for condition. Look for excessive contamination or rust or oil in the coolant solution.

• Check the PM time interval for need to change coolant.

• Check the condition of radiator cap rubber seal and radiator filler neck for damage. Be sure they are clean.

• Check overflow hose for clogging or damage.

You will start the engine to complete the functional tests, so be sure that:

• The automatic parking brake is applied.

• Directional control is in NEUTRAL

• Forks are fully lowered to the floor or ground

• All controls are in neutral or other correct position

• You are familiar with the safety procedures given in Section4, “Operating Procedures,” in this manual.

• As you test the following components, be sure they are properly mounted and working correctly.

Be sure that the travel area is clear in front of the truck.

• Push firmly on the brake pedal. Move the directional control lever from NEUTRAL to FORWARD.

• Remove your right foot from the service brake pedal and put iton the accelerator pedal.

• Push down until the truck moves slowly forward.

• Remove your foot from the accelerator pedal and push down on the service brake pedal to stop the truck

• Put the directional control lever in the REVERSE travel position.

• Release the service brake and push down on the accelerator pedal until the truck moves slowly in the reverse direction.

• Remove your foot from the accelerator pedal and push down on the service brake pedal to stop the truck.

• The brakes should apply smoothly and equally.

• Put the directional control in FORWARD.

• Press the inching pedal fully down and hold.

• Depress the accelerator. The truck should not move.

• Now, with the accelerator still depressed, slowly release the inching pedal until the truck “inches” forward smoothly and slowly.

Inspect the battery for

• damage

• cracks

• leaking condition

Before checking

• run the engine until the unit is at operating temperature. This is important since transmission oil temperature should be 65°C~120°C (150°F~250°F), the engine should also be at operating temperature.

• Block the drive wheels.

• With the engine operating at idle the transmission in NEUTRAL and the drive wheels blocked, check the fluid on the dipstick.

• Fill, if necessary, to the FULL mark on the dipstick, using CLARK transmission fluid (Mobil 424, US market).

• If unable to determine actual oil temperature, use this alternate check method: With the unit cold, start and run the engine at idle for 30 seconds then check the level and fill only to the ADD mark.

Change drive axle fluid. (cooling system not equipped) - Cooling system equipped : 2,000 hours

• Check the planned maintenance interval (operating hours) or the condition of the oil to determine if the drive axle fluid needs to be changed.

• Park the forklift truck on level ground, incline the mast forward to the largest extent, and check oil level of the drive axle.

• When the oil temperature is same as the ambient temperature, makeup the oil up to "LOW" mark on the oil level gauge.

• When filling oil up to "FULL" mark at temperature beyond engine running temperature, oil may overflow.

Parking Brake

• Check the function of the parking brake.

• To check parking brake holding capability, park the lift truck on a grade and apply the parking brake.

• The parking brake should hold a lift truck with rated load on a 15% grade.

Critical items include:

• Drive axle mounting

• Overhead guard

• Drive and steer wheel mounting

• Counterweight mounting

• Upright mounting and components

Lubrication and inspection of truck chassis components, including :

• steer wheels

• steer axle linkage

• steering cylinder

• wheel bearings

Inspect the steering cylinder piston

• rods

• seals

• fasteners for damage

• leaks

• looseness

Horn Button

• The horn button is located in the center hub of the steering handwheel.

• Depressing the button will sound the horn.

• Separate horn buttons may be available as options, on the lift lever and/or rear handle.

Lift Chain Wear and Replacement Criteria:

• (NEW CHAIN LENGTH) The distance from the first pin counted to the last pin counted in a span while the chains are lifting a small load.

• (WORN CHAIN LENGTH) The dis- tance from the first pin counted to3 the last pin counted in a span while the chains are lifting a small load.

• (SPAN) The number of pins in the length (segment) of chain to be measured.

• (PITCH) The distance from the 4 center of one pin to the center of the next pin.