Clark C500 915 Perkins Gas Forklift Overhaul Manual (OH544)

On a Clark C500 with the Perkins gas setup, you’re usually working in tight warehouse aisles or loading docks where downtime hurts right away. This overhaul manual is what I’d pull when the truck is worn enough that quick fixes won’t cut it—full engine and drivetrain teardown, cleaning, and build-back. If, for example, the truck has weak power under load and a mix of ignition, carb/LPG, and compression issues, this book helps you strip it down methodically, inspect each assembly, and put it back together so it starts, lifts, and idles like it should.

Applications & Use Cases

• Planning a full rebuild of the engine, transmission, and related components so you don’t miss hidden wear points.
• Tracing hard-start or no-start issues back through starter, distributor, and alternator after a long service life.
• Inspecting wear surfaces on shafts, gears, and valve train during teardown to decide what must be replaced.
• Verifying correct reassembly of carburetor/LPG hardware and linkages to avoid lean, rich, or stalling complaints.
• Checking alignment and routing of belts, wiring, and hoses before final run-up and leak checks.

FAQ

Q: Can I keep this manual open on a tablet while I work?

A: Yes, it’s handy on a tablet; you can zoom in on diagrams and keep it beside you on the truck.

Q: Is it worth printing sections of this manual?

A: Many techs print the pages they need for a specific job so they can mark notes and keep greasy hands off their device.

Safety Note

Always lock out the truck, support raised components securely, and follow proper ventilation practices when working on the gas/LPG system.

Clark C500 915 Perkins Gas Forklift Index:

Eng i ne
Carburetor ( IMPCO/LPG)
Transmi ssion (Hydratork)
Starter (De I co— Remy)
Distri butor
Al ternator (De Ico—Remy)
Al ternator (Motorola)
Drive Axle (C lark)
Hydrovac (Bend i x)
Master Cyl inder (Wagner)
Brake Assembly (C lark)
Steer Gear (Saginaw)
Steer Cyl i nder (Hydrau lic Prod.)
Steer pump (Hydreco)
Hydrau lic Pump (Hydreco)
Tilt Cylinder (Clark)
Lift Cyl inder (Clark)

Clark