Clark C60d, C70d, C80d, C80D900, C60L, C70L, C75L Forklift Service Manual (SM1023)

Clark C60d, C70d, C80d, C80D900, C60L, C70L, C75L Forklift Service Manual (SM1023)

Clark C60d, C70d, C80d, C80D900, C60L, C70L, C75L Forklift Index:

CONTENTS
GROUP SA SAFE MAINTENANCE
Section 1 Safety
Section 2 Lifting, Jacking, and Blocking the Truck
Section 3 Towing
GROUP PS PERIODIC SERVICE
Section 1 Maintenance Schedules
Section 2 The Planned Maintenance Program
GROUP 00 (D-IVECO) DIESEL ENGINE (Tier 3)
Section 1 GENERAL SPECIFICATIONS
Section 2 Fuel
Section 3 DUTY – INDUSTRIAL APPLICATION
Section 4 OVERHAUL AND TECHNICAL SPECIFICATIONS
Section 5 TOOLS
Section 6 Engine Replacement
GROUP 00 (D-DEUTZ) ENGINE (DEUTZ – Tier 4)
Section 1 General
Section 2 Servicing and Maintenance Work
Section 3 Removing and Installing
Section 4 Special Tools
GROUP 00(L) ENGINE (GM V6 4.3L)
Section 1 ENGINE REMOVAL AND REPLACEMENT
Section 2 4.3 LITER V6 ENGINE REPAIR PROCEDURES
Section 3 COOLING SYSTEM
GROUP 01 ENGINE COOLING SYSTEM
Section 1 Engine Cooling System Specifications and Description
Section 2 Engine Cooling System Troubleshooting
Section 3 Engine Cooling System Testing and Maintenance
Section 4 Radiator Removal and Replacemant
GROUP 02 (LP-TIER3) MI-07 LP SYSTEM (GM V6 4.3)
Section 0 REGULATORY COMPLIANCE
Section 1 LPG SYSTEM OVERVIEW
Section 2 SPECIFICATIONS
Section 3 RECOMMENDED MAINTENANCE
Section 4 INSTALLATION PROCEDURES
Section 5 TESTS AND ADJUSTMENTS
Section 6 BASIC TROUBLESHOOTING
Section 7 ADVANCED DIAGNOSTICS
Section 8 PARTS DESCRIPTION
GROUP 02 (GM-TIER4) PSI FUEL SYSTEM (GM V6 4.3)
Section 1 General Information
Section 2 Maintenance
Section 3 LPG Fuel System
Section 4 GASOLINE Fuel System
Section 5 Fuel System Diagnosis
Section 6 Electrical Section
Section 7 Definitions
GROUP 03 INTAKE AND EXHAUST SYSTEM
Section 1 Intake and Exhaust Systems Specifications and Description
Section 2 Intake System Troubleshooting
Section 3 Intake System Service
Section 4 Exhaust Systems
GROUP 07 TRANSMISSION – Model : 3WG-94EC (for Diesel truck)
Section 1 LAYOUT 3WG-94EC
Section 2 Measuring Points And Connections
Section 3 Disassembly
Section 4 Reassembly
Section 5 Transmission Removal and Installation
Section 6 AEB Setting of T/M Controller Clutch & Inching Calibration
Section 7 Troubleshooting
GROUP 08 TRANSMISSION (T12313 MODEL) (FOR LPG TRUCK)
Section 1 DISASSEMBLY
Section 2 DISASSEMBLY AND REASSEMBLY OF 1st AND 2nd CLUTCH
Section 3 DISASSEMBLY AND REASSEMBLY OF 3rd CLUTCH
Section 4 DISASSEMBLY AND REASSEMBLY OF FORWARD AND REVERSE CLUTCHES
Section 5 REGULATOR VALVE DISASSEMBLY AND REASSEMBLY
Section 6 CLEANING AND INSPECTION
Section 7 TROUBLESHOOTING PROCEDURES
Section 8 TRANSMISSION CONTROLLER
Section 9 TRANSMISSION REMOVAL AND INSTALLATION
GROUP 13 ELECTRICAL SYSTEM
Section 1 Cautions for working on the electrical system
Section 2 Electrical system Specifications and features
Section 3 Electrical Circuit Diagram & Electrical Parts Arrangement
Section 4 Instrument Pod
Section 5 Air Conditioning System (Option)
GROUP 20 (D) DRIVE AXLE (for Diesel truck)
Section 1 System Operation
Section 2 Differential Carrier Assy
Section 3 Drive Axle
Section 4 Problem and Cause
Section 5 Drive Axle Disassembly and Reassembly
Section 6 Transmission Removal and Installation
GROUP 21 (L) DRIVE AXLE (for LPG truck)
Section 1 System Operation
Section 2 Differential Carrier Assy
Section 3 Drive Axle
Section 4 Problem and Cause
Section 5 Disassembly and Reassembly of Drive Axle
Section 6 Transmission Removal and Installation
GROUP 22 WHEELS AND TIRES
Section 1 Wheels and Tires Specifications and Description
Section 2 Pneumatic Wheels and Tires
GROUP 23 BRAKE SYSTEM
Section 1 Braking / Inching System Specifications and Description
Section 2 Service Brake Troubleshooting
Section 3 Brake/Inching Pedals and Linkages Adjustments
Section 4 Brake System Bleeding
Section 5 Brake Valve Service
Section 6 Parking Brake Service
GROUP 25 STEERING COLUMN AND GEAR
Section 1 Steering System Specifications and Description
Section 2 Steering System Troubleshooting
Section 3 Steering Column and Component Removal and Replacement
Section 4 Steering System Relief Pressure Check and Adjustment
Section 5 Steering Gear Overhaul
GROUP 26 STEER AXLE
Section 1 Steer Axle Specifications and Description
Section 2 Steer Axle Wheel Bearing Maintenance and Adjustment
Section 3 Steer Axle Removal and Replacement
Section 4 Steer Axle Overhaul
Section 5 Steer Cylinder Removal and Replacement
Section 6 Steer Cylinder Overhaul
GROUP 29 HYDRAULIC SUMP, FILTERS, AND PUMP
Section 1 Main Hydraulic Sump, Filters, and Pump Specifications and Description
Section 2 Main Hydraulic Pump Troubleshooting
Section 3 Main Hydraulic Removal and Installation
GROUP 31 HYDRAULIC CONTROL VALVE
Section 1 Operation of Hydraulic Control Valve
Section 2 Hydraulic Circuit
Section 3 Disassembling Hydraulic Valve
Section 4 Assembling Hydraulic Control Valve
Section 5 Hydraulic System Pressure Checks and Adjustments
Section 6 Hydraulic Control Valve Removal and Replacement
Section 7 Testing Hydraulic Valve
Section 8 EHL Valve Disassembly and Assembly
GROUP 32 TILT CYLINDERS
Section 1 Tilt Cylinder Specifications and Description
Section 2 Tilt Cylinder Checks and Adjustments
Section 3 Tilt Cylinder Removal and Replacement
Section 4 Tilt Cylinder Overhaul
GROUP 34 UPRIGHTS
Section 1 Upright Specifications and Description
Section 2 Troubleshooting
Section 3 Upright Inspection
Section 4 Carriage and Upright Roller Clearance Checks and Shim Adjustments
Section 5 Cylinder Removal, Shimming, Overhaul, and Replacement
Section 6 Upright Chain Inspection, Adjustment, and Replacement
Section 7 Fork and Carriage Removal and Replacement
Section 8 Upright Removal and Replacement
GROUP 38 COUNTERWEIGHT AND CHASSIS
Section 1 Counterweight Specifications and Description
Section 2 Counterweight Removal and Replacement
Section 3 Overhead Guard/Operator’s Cell Removal and Replacement
Section 4 Floorboard, Cowls, and Seat Deck Removal and Replacement
Section 5 Operator’s Seat Removal and Replacement
GROUP 40 SPECIFICATIONS
Section 1 Nameplates and Decals
Section 2 General Specifications
Section 3 Hydraulic Fitting Tightening Procedure

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