Clark C60-75L Forklift Service Repair Manual.pdf

Technical
Publications
Lexington, KY 40510
www.Clarkmhc.com
SM-751
C60-80 D
C60-75L
Service Manual
December 2007

Truck Models Covered by this Manual
This manual consists of “base” module that pertains
to all C60-80 models and other modules that pertain
only to specific models. Manuals shipped with the
truck contain the base module and the modules spe-
cific to the purchased truck.
You may, however, purchase specific modules and
expand your manual to fully cover multiple models.
To do so, order the desired modules as you would
any other Clark part.
Arrangement and Use of this Manual
Clark arranges parts and service procedures by stan-
dardized Groups. In this manual, Groups are similar
to “chapters”. Groups are listed in the indexes on the
next page.
Each Group begins with a table of contents that
shows the Sections contained within the Group.
Lengthy Sections also begin with a table of contents.
Each Group and Section has an identifying name and
number, or “ID”.
Each page also has a unique ID. The page ID con-
sists of three numbers separated by hyphens. The
three numbers represent the Group number, the Sec-
tion number, and the page number. For example,
“00-1-2” on the lower corner of the page indicates
Group 00, Section 1, page 2.
The Group number sometimes has a letter or letters
added to it in parentheses if one or more variations of
the Group exist. For example, if the truck has a stan-
dard transaxle, Group 06 is expressed as “06(S)”; if
the truck has a hydrostatic transmission, Group 06 is
expressed as “06(H)”.
You can quickly locate a specific point in the manual
by using the headers and footers that appear on every
Section page. The following illustration points out
these areas.
This manual is intended for the use of trained service
personnel. Please read Group SA, “Safe Mainte-
nance”, and the Operator’s Manual before working
on or operating the truck.

CONTENTS
SM 751, Nov ’06 CONTENTS-1
CONTENTS
Contents of this Manual
Group Index
Group SA. Safe Maintenance
Group PS. Periodic Service
Group 00. Engine
Group 01. Engine Cooling System
Group 03. Air Induction and Exhaust System
Group 06. Transaxle
Group 13. Electrical system
Group 20. Drive Axle
Group 22. Wheels and Tires
Group 23. Brake System
Group 25. Steering Column and Gear
Group 26. Steer Axle
Group 29. Hydraulic Sump, Filters, and Pump
Group 30. Hydraulic Control Valve/Lift Circuit
Group 32. Tilt Cylinders
Group 34. Uprights
Group 38. Counterweight and Chassis
Group 40. Specifications
Group 34. Upright
Group 32.Tilt Cylinders
Group 13. Instrument Pod
Group 03. Air Induction System
Group 00. Engines
Group 01. Cooling System
Group 25. Steering Column and
Gear
Group 38. Counterweight,
Sheet Metal, & Chassis
Group 06.Transmission
Group 23. Brake/Inching System
Group 30. Hydraulic Control Valve/
Lift Circuit
Group 29. Hydraulic Pump, Sump,
and Filters
Group 02. Fuel System
Group 22.Wheels and Tires
Group 26. Steer Axle

GROUP SA
SM 751, Oct ’06 Group SA, Safe Maintenance
GROUP SA
SAFE MAINTENANCE
Safety ................................................................... Section 1
Lifting, Jacking, and Blocking the Truck ....... Section 2
Towing................................................................. Section 3

Group SA, Safe Maintenance
SM 751, Oct ’06 Safety • SA-1-1
Safety Signs and Messages
Safety signs and messages in this manual and on the lift
truck provide instructions and identify specific areas
where potential hazards exist and special precautions
should be taken. Be sure you know and understand the
meaning of these instructions, signs, and messages. Dam-
age to the truck, death, or serious injury to you or other
persons may result if these messages are not followed.
NOTE
This message is used when special informa-
tion, instructions or identification is re-
quired relating to procedures, equipment,
tools, pressures, capacities, and other spe-cial
data.
IMPORTANT
This message is used when special precau-
tions should be taken to ensure a correct
action or to avoid damage to, or malfunc-tion
of, the truck or a component.
CAUTION
!
This message is used as a reminder of safety
hazards that can result in personal injury if
proper precautions are not taken.
WARNING
!
This message is used when a hazard exists
that can result in injury or death if proper
precautions are not taken.
DANGER
!
This message is used when an extreme haz-
ard exists that can result in injury or death or
serious injury if proper precautions are not
taken.
The above terms have been adopted by Clark Material
Handling Company. The same terms may be used in dif-
ferent context in service literature supplied directly or
indirectly by vendors of truck components.
Safe Maintenance Practices
The following instructions have been prepared from cur-
rent industry and government safety standards applicble to
industrial truck operation and maintenance. These recom-
mended procedures specify conditions, methods, and
accepted practices that aid in the safe maintenance of
industrial trucks. They are listed here for the reference and
safety of all workers during maintenance operations.
Carefully read and understand these instructions and the
specific maintenance procedures before attempting to do
any repair work.
When in doubt of any maintenance procedure, please con-
tact your local Clark dealer.
1. Powered industrial trucks can become hazardous if
maintenance is neglected. Therefore, suitable mainte-
nance facilities, trained personnel, and procedures
must be provided.
2. Maintenance and inspection of all powered industrial
trucks shall be done in conformance with the manu-
facturer’s recommendations.
3. A scheduled planned maintenance, lubrication, and
inspection program shall be followed.
4. Only trained and authorized personnel shall be per-
mit-ted to maintain, repair, adjust, and inspect indus-
trial trucks. Work should be performed in accordance
with the manufacturer’s specifications.
5. Properly ventilate work area, vent exhaust fumes,
and keep shop clean and floor dry.
6. Avoid fire hazards and have fire protection equip-
ment present in the work area. Do not use an open
flame to check for level or leakage of fuel, electro-
lyte, oil, or coolant. Do not use open pans of fuel or
flammable cleaning fluids for cleaning parts.
7. Before starting work on truck:
a. Raise drive wheels off of floor and use blocks or
other positive truck positioning devices.
b. Disconnect battery before working on the electri-
cal system.
8. Before working on engine fuel system of gasoline- or
diesel-powered trucks, be sure the fuel shut-off valve
is closed.
Section 1
Safety

SA-1-2 • Safety SM 751, May ’07 ①
9. Operation of the truck to check performance must be
conducted in an authorized, safe, clear area.
10. Before starting to drive truck:
a. Be in operating position.
b. Be sure parking brake is engaged.
c. Put direction control in neutral.
d. Start engine.
e. Check functioning of direction and speed con-
trols, steering, brakes, warning devices, and any
load handling attachments.
11. Before leaving truck
a. Stop truck.
b. Put directional control in neutral.
c. Apply the parking brake.
d. Stop the engine by turning off the ignition circuit.
e. Put blocks at the wheels if truck is on an incline.
12. Brakes, steering mechanisms, control mechanisms,
warning devices, lights, governors, guards, safety
devices, and frame members must be carefully and
regularly inspected and maintained in a safe operat-
ing condition.
13. Special trucks or devices designed and approved for
hazardous area operation must receive special atten-
tion to ensure that maintenance preserves the origi-
nal, approved, safe-operating features.
14. Fuel systems must be checked for leaks and condi-
tion of parts. Extra special consideration must be
given in the case of a leak in the fuel system. Action
must be taken to prevent the use of the truck until the
leak has been corrected.
15. The truck manufacturer’s capacity, operation, and
maintenance instruction plates, tags, or decals must
be maintained in legible condition.
16. Batteries, motors, controllers, limit switches, protec-
tive devices, electrical conductors, and connections
must be inspected and maintained in conformance
with good practice. Special attention must be paid to
the condition of electrical insulation.
17. To avoid injury to personnel or damage to the equip-
ment, consult the manufacturer’s procedures in
replacing contacts on any battery connection.
18. Industrial trucks must be kept in a clean condition to
minimize fire hazards and help in the detection of
loose or defective parts.
19. Modifications and additions that affect capacity and
safe truck operation must not be done without the
manufacturer’s prior written approval. Capacity,
operation and maintenance instruction plates, tags, or
decals must be changed accordingly. This is an
OSHA requirement.
20. Care must be taken to assure that all replacement
parts, including tires, are interchangeable with the
original parts and of a quality at least equal to that
provided in the original equipment. Parts, including
tires, are to be installed per the manufacturer’s proce-
dures. Always use genuine CLARK or CLARK-
approved parts.
21. Use special care when removing heavy components
from the truck, such as counterweight, seat deck,
upright, etc. Be sure that lifting and handling equip-
ment is of the correct capacity and in good condition.
Also, this removal may upset the stability of the
truck. The frame must always be safely blocked for
major component removal.
NOTE
You should also be familiar with additional
operating and maintenance safety instruc-
tions contained in the following publica-
tions:
ANSI / ITSDF B56.1 : Operator Control-Industrial Tow
Tractors (Safety Standard For Powered Industrial Trucks).
NFPA 505: Fire Safety Standard for Powered Indus-trial
Trucks: Type Designations, Areas of Use, Mainte-nance
and Operation. Available from: National Fire Protection
Assoc., Inc., Batterymarch Park, Quincy, MA 02269.
General Industrial Standards, OSHA 2206: OSHA Safety
and Health Standards (29 CFR 1910), Subpart N-Mater
als Handling and Storage, Section 1910.178 Powered
Industrial Trucks. For sale by: Superintendent of Docu-
ments, U.S. Government Printing Office, Washington, DC
20402.

SM 751, Oct ’06 Lifting, Jacking, and Blocking the Truck • SA-2-1
WARNING
!
Lifting or jacking any large piece of equipment such as your fork truck presents obvious haz-
ards. It must be done with great care and forethought. Consult the truck weight tabulations
in Group 40, “Specifications” to ensure that your lifting equipment is of adequate capacity.
Section 2
Lifting, Jacking, and Blocking the Truck

SA-2-2 • Lifting, Jacking, and Blocking the Truck SM 751, Oct ’06
Safe Parking
Before working on truck:
1. Park truck on a hard, level, and solid surface, such as
a concrete floor with no gaps or breaks.
2. Put upright in vertical position and fully lower the
forks or attachment.
3. Put all controls in neutral. Turn key switch OFF and
remove key.
4. Apply the parking brake and block the wheels.
WARNING
!
Defective equipment can cause accidents. All
tools and lifting equipment must be in good
condition, meet the load capacity require-
ments and have OSHA labels when required.
Tools with defects can have failures causing
severe injury or death.
Lifting, Blocking, and Jacking Points
Use the following illustration to locate general lifting,
blocking, and jacking points on the truck. Read the proce-
dures for raising, blocking, or jacking specific compo-
nents of the truck to make sure you understand the correct,
safe procedures
WARNING
!
Do not attempt to lift the truck by the over-
head guard or the counterweight. Severe
injury may result and the truck can be dam-
aged.
Raising Drive Wheels Off Floor
This procedure uses the upright as a lever to lift the drive
wheels off the floor and prevent accidents due to inadvert-
ent powering of the drive wheels.
1. Park truck safely as described in “Safe Parking.”
Block steer wheels.
2. Be sure upright trunnion bolts are tight. Bolt torques
must be 75-80 N⋅m (55-59 ft-lb).
3. Start the engine. Tilt the upright fully back. Adjust
upright height as necessary to put blocking under-
neath the lower end of the upright.
4. Put a solid 100 x 100 mm (4 x 4 in) hardwood block
under the front section of each upright rail. Put a 3-6
mm (.125-.250 in) steel plate on top of each block.
5. Tilt upright fully forward. This raises the drive
wheels off the floor. Release the tilt control lever and
turn engine OFF.
On Tie Bars
of Upright
Under Upright
Under Frame
Under
Steer
Axle Frame Mount
Block
Steel
Plate

6. Insert blocking under the frame behind the drive
wheels or slip wheel cradles under the drive wheels.
If using blocking, check for safe clearance between
drive wheels and floor and blocks.
NOTE
When forks are raised as in illustration
above, use shop rags, paper, or bright tape on
fork tips to signal the danger of tripping.
7. Check for stable condition of the truck. Be sure that
the blocks are located securely under the truck frame
before operating the drive or working on truck.
8. Lower the drive wheels to the floor and remove the
blocks by reversing the above procedure.
Raising Truck with A Hoist
When suitable equipment is available, the front of the
truck may be raised by means of a hoist, with wheel cra-
dles placed under the wheels or blocking placed under the
frame.
CAUTION
!
When lifting the front of the truck watch
truck for signs of lateral instability. It may
tip sideways. You may have to support or
guide the side of the truck or overhead guard
to prevent tipping.
Block rear steer wheels.
2. Check trunnion bolts to make sure they are tightened
to correct torque. Bolt torques must be 75-80 N⋅m
(55-59 ft-lb).
3. To raise the front of the truck using the upright,
spread two chains on the outer rail tiebar of the
upright.
WARNING
!
Chain and hoist used to lift truck should be
checked to make sure they are of safe lifting
capacity. See the truck data plate for infor-
mation.
4. Slowly lift truck and lower drive wheels onto the cra-
dles or place blocking under frame prop points.
5. When maintenance work is completed, lower the
truck to the floor by reversing the lifting procedure.
Check to be sure no tools or equipment are under the
truck or wheels.
Rag
Place
chains
here

Blocking the Upright In Raised
Position
This procedure is used to safely provide clearance for
access from the front of truck to components on or near
the drive axle. Illustrations show upright with forks
removed however, fork removal is not necessary
2. Put blocks in front of and behind drive wheels.
3. Put wooden support blocks conveniently near upright
rails before raising the upright. Use two 100 x 100
mm (4 x 4 in) hardwood blocks or equal, of about
300 x 300 mm (12 in) and 600 x 600 mm (24 in)
length.
NOTE
For standard uprights, block may need
length cut to suit. For triple stage uprights,
the carriage may be blocked up, as shown.
4. Start engine and raise the upright carriage.
5. Hold the taller block against inner rail and lower the
upright until carriage rests on block.
6. Hold the shorter block against the outer rail and
lower the upright until inner rail rests on the block.
7. Reverse the procedure to remove blocking.
Raising Rear of Truck
The truck may be raised at the rear by jacking and block-
ing under the center of the frame member at either the
front or rear steer axle mounting, or under the center sec-
tion of the steer axle.
Refer to truck data plate for truck weights.
WARNING
!
An incorrectly installed counterweight can
move or fall unexpectedly. Never lift or block
a truck using the counterweight. Failure to
follow procedures outlined in this manual can
result in injury or death.
1. Park truck safely as described in “Safe Parking.” Put
blocks at front and rear of drive wheels.
Carriage
Outer Rail
Tall Block
Inner Rail
Carriage
Outer Rail
Short Block
Inner Rail

2. Put a floor jack under the steer axle mounting frame
member, centered between the two wheels.
WARNING
!
Never lift the truck by the counterweight.
NOTE
If there is insufficient clearance under frame
for your jack, the truck may first be driven
onto shims, such as 25 x 150 x 300 mm (1 x 6
x 12 in) pieces of board, to increase the truck
frame underclearance.
3. Raise the truck only as high as necessary to perform
the maintenance work.
4. Put blocks at both sides of the truck, fully under the
frame main side structure. Put the blocks in front of
but close to the counterweight and steer wheels for
best truck stability.
Put an equal amount of blocks under each side of the truck
to provide a level working position.
5. Lower the truck onto the blocks and remove the jack.
CAUTION
!
Before performing any maintenance work,
check the truck for stable condition on the
blocking.
6. When maintenance work is completed, lower the rear
of truck to the floor by reversing the above procedure
and lowering each side of the truck 50 mm (2 in) at a
time:
• Put jack under frame and raise truck.
• Carefully remove blocks and lower truck.
• Remove jack and blocks from drive wheels.
Raising Entire Truck
Refer to truck data plate for truck weights.
Lower upright fully.
2. If necessary, drive truck onto boards to increase
underclearance.
WARNING
!
SIDE-TO-SIDE TIPOVER. When jacking
side of truck, be sure upright is lowered fully
and do not raise one side of the truck more
than about 50 mm (2 in) higher than the
other, to avoid tipping truck over laterally.
END-TO-END TIPOVER. If the upright and
transaxle are removed while the truck is
blocked up, the truck will tip backwards due
to the heavy counterweight. Both upright and
counterweight must be removed before
attempting to raise the truck for transaxle
removal. The back of the truck must be sup-
ported by blocking under the steer axle to
prevent movement.
The reverse is also true. If the counterweight
is removed while the truck is up on blocks,
the weight of the upright and transaxle will
cause the truck to tip on the front blocks and
fall forward.

3. Put the jack under side frame near the center of the
truck.
IMPORTANT
Be sure to put the jack squarely and fully
under the main side structure of the frame.
Do not put the jack under the outer covers
which enclose the fuel and hydraulic sump
tanks.
4. Carefully raise the truck one side at a time, only as
high as necessary to do the maintenance work and
not more than a maximum of 150 mm (6 in) total.
5. Put blocks under the side frame, at each side of the
jack. Spread the blocks close to the steer and drive
wheels for maximum stability.
6. If using one jack, lower the truck onto the blocks and
move the jack to the opposite side. Repeat the lifting
procedure.
7. Put the same size blocks under each side of the truck
so it will be level.
CAUTION
!
Before performing any maintenance work,
check the truck for stable condition on the
blocking.
8. When maintenance work is completed, lower the
entire truck to the floor by reversing the lifting proce-
dure. Lower the truck one side at a time, while care-
fully removing the blocks. Check to be sure no tools
or equipment are under the truck or wheels.
NOTE
Depending on jack height, shims under the
tires may be needed for clearance to allow
removal of jack.
Shipping Tie-Down Instructions
1. Front of Truck
a. With Upright and Carriage Installed
• Lower the carriage fully.
• Put a tie down (e.g., chain) between the carriage
fork bars.
b. Without an Upright and Carriage Installed
• Put a chain across the truck floor plate. Protect
truck from chain damage by using covered chain
or protective material under the chain at contact
points.
2. Rear of Truck
• Attach the tie down to pocket in bottom of coun-
terweight.
Jack truck
here

SM 751, Oct ’06 Towing • SA-3-1
If your truck is disabled but can be moved freely on its
own wheels without further damage, use the following
procedures to tow the truck safely to a repair area.
WARNING
!
It is important for your safety and to the care
of your lift truck to use the proper equipment
and carefully follow these recommendations
for safe towing.
Do not tow a lift truck if there is a problem
with the brakes or tires, or if the steering
cannot be operated.
Do not tow the disabled truck up or down
ramps or steep inclines.
Do not attempt to tow the disabled truck if
traction or weather conditions are poor.
1. Be sure to apply the parking brake or block the drive
wheels on the disabled truck while working around
it.
2. When possible, raise the carriage (forks) on the dis-
abled truck 300 mm (12 in) from the floor or ground.
Secure the carriage on the upright with a chain.
3. Use a truck for towing that is of equal or larger
capacity than the disabled truck. Carry a partial load
on the tow truck for improved traction.
4. Check that the counterweight bolts on both trucks are
in place and properly torqued to 440-490 N⋅m (325-
361 ft-lb). These bolts are made of special, high-ten-
sile steel and are not commercially available. When
necessary, replace these bolts only with a genuine
Clark replacement part.
5. Use an approved, solid metal tow bar with towing
couplers that connect to the towing pins in the coun-
terweights.
NOTE
DOT-approved towing equipment is available
from your Clark dealer.
6. Release the parking brake on the towed vehicle.
Place directional control lever in neutral.
7. Tow the disabled truck backwards. An operator must
be on the disabled truck.
CAUTION
!
The power steering will not operate on the
disabled truck when the engine is not run-
ning. The steering handwheel will be difficult
to turn.
8. Tow the truck slowly. Careful towing is necessary to
prevent injury to personnel or damage to the disabled
truck. The truck should be towed at a speed of less
than 8 kph (5 mph, or a moderate walking speed)
with a driver in place and steering the disabled truck.
Direction of towing for distances of
300 meters (325 yards) or less.
Solid-metal
tow bar
Disabled truck with
driver in place to steer.
Tow truck moving at 8 kilome-
ters-per-hour (5 mph) or less.
Partial
load
Section 3
Towing

SA-3-2 • Towing SM 751, Oct ’06
IMPORTANT
Do not lift the disabled truck or any wheels
off the floor while the truck is being towed.
9. Park the disabled truck in authorized areas only.
Fully lower the forks on the floor, leave the direc-
tional control in neutral, turn the ignition switch to
OFF, and engage the parking brake. Remove the igni-
tion key and, when necessary, block the wheels to
prevent the truck from rolling.
WARNING
!
Always engage the parking brake when park-
ing a lift truck. The truck can roll and cause
injury or death to personnel near it.
LIFT TRUCK PARKING
P

GROUP PS
SM 751, Oct ’06 Group PS, Periodic Service
GROUP PS
PERIODIC SERVICE
Maintenance Schedules ............................ Section 1
The Planned Maintenance Program ....... Section 2

Group PS, Periodic Service
SM 751, Oct ’06 Maintenance Schedules • PS-1-1
“Periodic Service” and “Planned
Maintenance”
The term “periodic service” includes all maintenance
tasks that should be performed on a regularly scheduled
basis.
The term “Planned Maintenance” indicates a formalized
program of basic inspections, adjustments, and lubrica-
tions that the Clark service organization provides custom-
ers at a prescribed interval, usually 50-250 hours. The
recommended basic “Planned Maintenance” procedure is
given in Section 2 of this Group.
The current Section,“Maintenance Schedules,” specifies
all maintenance tasks—including Planned Maintenance
tasks—that should be performed periodically, and sug-
gests intervals at which they should be performed.
Determining Maintenance Intervals
Time intervals on the charts on the next four pages and
elsewhere in this manual relate to truck operating hours as
recorded on the hourmeter, and are based on experience
Clark has found to be convenient and suitable under nor-
mal operation. Standard operating condition classifica-
tions are:
Normal Operation: Eight-hour material handling, mostly
in buildings or in clean, open air on clean, paved surfaces.
Severe Operation: Prolonged operating hours or constant
usage.
Extreme Operation:
• In sandy or dusty locations, such as cement plants,
lumber mills, and coal dust or stone crushing sites.
• High-temperature locations, such as steel mills and
foundries.
• Sudden temperature changes, such as constant trips
from buildings into the open air, or in refrigeration
plants.
If the lift truck is used in severe or extreme operating con-
ditions, the maintenance intervals should be shortened
accordingly.
IMPORTANT
MAINTENANCE INTERVALS. If the lift
truck is used in severe or extreme operating
conditions, the maintenance intervals should
be shortened accordingly.
Since the operating environments of lift
trucks vary widely, the above descriptions
are highly generalized and should be applied
as actual conditions dictate.
Section 1
Maintenance Schedules

PS-1-2 • Maintenance Schedules SM 751, Oct ’06
Service Chart/Lubrication Points
A decal, similar to the illustration below, is located on the
underside of the truck’s engine cover. This decal is a basic
guide to periodic maintenance intervals and tasks. A more
detailed chart is supplied on the next page.
F-Hydraulic Oil
Clark # 2776239
Lift Chains
Upright Rollers
Every 8-10 Hours or daily
Every 2000 Hours or every year
Every 900-1000 Hours or every 6 months
Every 450-500 Hours or every 3 months
Every 50-250 Hours or monthly
Tilt Cylinder Pins
Lub
Axle Mounting
& Fasteners
Overhead Guard
Mounting Bolts
Transmission
Fluid (Diesel)
Engine Oil
LPG
V-Belts
Engine Oil Filter
Diesel
Radiator Coolant
and Core
Steer Axle
Linkage
Check/Lubricate Check/Replace Clean/Air Clean
Check
Drain/Flush
Counterweight
Fasteners
Monitor indicator on A/cleaner
and Service as Required
A-Diesel Engine Oil : 15W40 C-Engine Coolant
50/50 Mixture
D-EP2 Grease
NLGI #2
E-Transaxle Fluid
Clark #2776236 used in
standard transaxle
B-Hydraulic Oil
Clark # 2776239
LPG Engine Oil : 10W30
API,MORE THAN A CLASS SJ GRADE
Overall Visual
Check
Steer Axle Wheel
Bearings
Fuel Filter
LPG
Fuel Filter
Diesel
Transmission Fluid
(LPG)
All Wheel Lugs
Battery
Brake Discs
Brake Fluid
Brake Operation
Intervals refer to elapsed hour meter time and based on Clark's experience found to be suitable and convenient
under normal operating conditions.
Service and Maintain as per Service and Operator Manuals. Special or harsh conditions may need additional intervals.
Clark Material Handling Asia
Air Cleaner
Transmission Fluid
Filter (Diesel)
Transmission Fluid
Filter (LPG)
Diesel Eng-oil
Hydraulic oil
Hydraulic oil
Filter

Recommended Periodic Service Schedule
This chart lists maintenance tasks that should be done
periodically, the suggested time intervals, and the service
manual Group in which the task is covered.
Apply as appropriate for diesel, gas, and LPG trucks.
Refer to Operator’s Manual for Daily Checks.
TASKS 1st 50 Hours
Every
50-250 Hours
Every 450-
500 Hours
(or 3 months)
Every 900-
1000 Hours
(or 6 months)
Every 2000
Hours
(or 1 year)
Group PS - Periodic Maintenance
Perform Planned Maintenance
inspections, lubrications, and
adjustments
•
Group 00 - Engine
Exhaust smoke from gas engine -
inspect (blue-oil ; black-fuel)
•
Idle/governed rpm - check/adjust •
Mounts/brackets - inspect/tighten •
Oil change - drain/fill* • •
Oil filter cap & seal - clean/check •
Oil filter - replace • •
Oil level/condition - check • •
Stall rpm - check on standard
transaxle truck
•
Tune up - determine if needed by stall
check and/or functional test
•
Valve tappet adjustment - diesel engine •
Group 01 - Cooling System
Coolant level/condition - check/sample •
Coolant protection level - hydrometer test •
Coolant change - drain & flush •
Coolant hoses - inspect/replace • •
Fan blades - inspect loose/damaged •
Fan belt(s) - check tension, wear • •
Radiator cap - inspect/test • •
Thermostat - test/replace •
Water pump - check leaks/wear •
Group 02 - Fuel System
Carburetor idle/air - check/adjust •
CO level - check/adjust •
Diesel injectors/lines - clean/inspect •
Filler cap/screen - clean/inspect •
Fuel filter, diesel - replace •
Fuel filter, gas - replace •
LPG lock-off valve filter - inspect/replace •
LPG tank mounting/guard - inspect •
LPG tank shut-off valve - inspect/test •
LPG vaporizer/regulator/hoses - inspect •
Throttle linkage - check/adjust •
* Oil change interval may be determined by laboratory analysis

PS-1-4 • Maintenance Schedules SM 751, Oct ’06
Group 03 - Air Intake & Exhaust
Air filter element - replace • (Diesel) • (Gas/LPG)
Air hoses/clamps - inspect •
Exhaust pipe/muffler - inspect •
Group 06 - Transaxle
Air vent - inspect, clean or replace on
standard transaxle
•
Axle end lube - clean/repack During brake repairs
Axle mounting bolts - inspect/tighten •
Charging pump - stall test standard
transaxle
•
Clutch pack operation - stall test standard
transaxle
•
Pressure checks •
Fluid change - drain/fill • •
Fluid filter - replace • •
Fluid level/condition - check/sample • •
Inching operation - check/test •
Oil cooler/lines - inspect •
Transmission strainer - clean on standard
transaxle
•
Group 12 - Ignition System
Diesel cold starting plug - test •
Distributor cap/rotor - inspect •
Electronic ignition - test •
Ignition timing - check/adjust •
Ignition wiring - inspect •
Neutral start - check •
Parking brake interlock - check •
Spark plugs - regap/replace •
Starter motor - inspect/test •
Starter solenoid - inspect/test •
Group 13 - Electrical System
Hourmeter - check •
Lamp check - at start-up •
Wiring harness - inspect •
Group 22 - Wheels And Tires
Wheel mounting bolts - tighten • •
Tire pressure/condition - check • •
Group 23 - Brake System
Operation - check •
Service brake - check wear •
Brake lines - check • •
Parking brake - check/adjust • •
TASKS 1st 50 Hours
Every
50-250 Hours
Every 450-
500 Hours
(or 3 months)
Every 900-
1000 Hours
(or 6 months)
Every 2000
Hours
(or 1 year)

Group 26 - Steer Axle and Lines
Power steering relief pressure - check •
Steer axle mounting - inspect •
Steer wheel bearings - check •
Steer wheel bearings - lubricate/adjust •
Steering cylinder seals - check leakage •
Steering linkage - lubricate •
Group 29 - Hydraulic Pump, Sump, and Filter
Hydraulic fluid level/condition -
check/sample
•
Hydraulic fluid change - drain/fill •
Hydraulic suction screen - clean •
Hydraulic fluid filter - replace • •
Hydraulic tank breather - clean/replace •
Group 30 - Hydraulic Valve & Linkage
Hydraulic system relief pressure -
test/adjust
•
Group 32 - Tilt Cylinders
Tilt cylinder adjustment - check/adjust •
Tilt cylinder drift - test •
Tilt cylinder mounting - check/tighten •
Tilt cylinder rod ends -
check/tighten/lubricate
•
Tilt cylinder rod/seals - check for leaks •
Group 34 - Upright, Lift Cylinder, Carriage, Forks
Carriage and lift chain - lubircate •
Carriage chain condition - inspect/adjust •
Forks, latches, stop pin -
inspect/check wear
•
Lift chain condition - inspect/adjust •
Load backrest •
Upright lift cylinder downdrift-test •
Upright rollers - check •
Upright trunnion bolts - tighten •
TASKS 1st 50 Hours
Every
50-250 Hours
Every 450-
500 Hours
(or 3 months)
Every 900-
1000 Hours
(or 6 months)
Every 2000
Hours
(or 1 year)

SM 751, Oct ’06 The Planned Maintenance Program • PS-2-1
This Section defines a set of basic service procedures, known as the “Planned
Maintenance Program”, and describes systematic approach for performing
them.
Section 2
The Planned Maintenance Program

PS-2-2 • The Planned Maintenance Program SM 751, Oct ’06
Introduction to Planned Maintenance
A program of regular, routine inspections, lubrication, and
other service tasks is important for the long life and trou-
ble-free operation of the lift truck.
The Clark service organization offers customers a formal-
ized program—called Planned Maintenance, or PM—for
performing these tasks.
PM Intervals
The PM inspections, adjustments, and lubrications are
typically performed on each covered truck at 50-250 hour
intervals. (See Section 1, in this Group about defining ser-
vice intervals.)
The PM Form
As an aid to service technicians performing and docu-
menting PM inspections, Clark has prepared a “Gas, LPG
or Diesel Planned Maintenance Report” form. A black-
and-white copy of this form is inserted in Section 3 of this
Group.
We recommend that you use this form as a checklist and
to make a record of your inspection and truck condition.
This record can be used to inform the owner of needed
repairs and help establish the optimal PM intervals.
When you have finished the PM inspections, be sure to
give a copy of the report to the person responsible for lift
truck maintenance.
The Basic PM Procedures
The chart on the next page lists the basic PM tasks. The
actual PM program may be modified to meet the specific
needs of the truck application.
The procedures beginning on page 4 outline a systematic
approach to performing the PM tasks. These procedures
consist of:
• External visual checks you make as you walk
around the truck with it turned off.
• Operational checks you make while operating the
truck.
• Tests, adjustments, and lubrication you perform
with the covers removed.
CAUTION
!
• Do not make repairs or adjustments unless
authorized to do so.
• Disconnect the battery ground cable (-) from
the engine or frame before working on electrical
components.
• Always wear safety glasses.
• Wear a safety (hard) hat in industrial plants
and in special areas where protection is neces-
sary or required.
• Remove all jewelry (watch, rings, bracelets,
etc.) before working on the truck.

The Recommended PM Task Chart
Listed by Service Manual Group
Group PS - The Basic PM Procedures Alternator - inspect/test
Visual inspection Alternator dirve belts - inspect/adjust
Functional performance check - test dirve Alternator output - test
Air cleaning of truck Battery condition - performance load test
Lubrication, filters, and fluid levels checks Battery electrolyte level - check/add
Critical fasteners torque check Battery terminals/cables - clean/tighten
Group 00 - Engine Neutral start - check
Exhaust smoke (blue-oil ; black-fuel) Starter cranking voltage - test
Idle RPM - check/adjust Group 22 - Wheels And Tires
Max no-load gov’d RPM - check/adjust Tire pressure/condition - check
Mounts/brackets - inspect/tighten Group 23 - Brake System
Oil filler cap & seal - clean/check Brake lines - check
Oil level/condition - check Check operation
Stall RPM - check Parking brake - check/adjust
Group 01 - Cooling System Service brake - check wear
Coolant hoses - inspect/replace Group 26 - Steer Axle & Lines
Coolant level/condition - check/sample Operation - check
Coolant protection level - hydrometer test Steer axle mounting - inspect
Fan belt(s) - check tension, wear Steer wheel bearings - check
Fan blades - inspect loose/damaged Steering cylinder seals - check leakage
Fan speed control - inspect Steering valve - check leakage
Group 02 - Fuel System & Exhaust Group 29 - Hydraulic Pump, Sump and Filter
Air hoses/clamps - inspect Hydraulic fluid level/condition - check/sample
Exhaust pipe/muffler - inspect Lines - check for leakage
LPG tank mounting/guard - inspect Group 30 - Hydraulic Valve & Linkage
LPG tank shut-off valve - inspect/test Hydraulic system relief pressure - test/adjust
LPG vaporizer/regulator/hoses - inspect Linkage and control handle operation - check
Throttle linkage - check/adjust Group 32 - Tilt Cylinders
Group 06 - Transaxle Tilt cylinder mounting - check/tighten
Charging pump - stall test standard transaxle Tilt cylinder rod ends - check/tighten
Clutch pack - stall test standard transaxle Tilt cylinder rod/seals - check condition
Fluid level/condition - check/sample Group 34 - Upright, Lift Cylinders,
Carriage, Forks
Inching operation - check/test
Oil cooler/lines - inspect Carriage/lift chain - lubricate
Group 12 - Ignition System Carriage chain condition - inspect/adjust
Distributor cap/rotor - inspect Forks, latches, stop pin - inspect/check wear
Ignition wiring - inspect Lift chain condition - inspect/adjust
Parking brake interlock - test Load backrest - inspect
Group 13 - Electrical System Operation of lift and tilt cylinder - check
Hourmeter - check Racking - check for
Indicator lights - check Upright trunnion bolts - tighten
Wiring harness - inspect

Visual Inspection
First, perform a visual inspection of the lift truck and its
components. Walk around the truck and take note of any
obvious damage and maintenance problems.
Decals, Fasteners, and Leaks
Check for loose fasteners and fittings.
Check to be sure all capacity, safety, and warning plates
and decals are attached and legible.
NOTE
Do not operate a lift truck with damaged or
missing decals and nameplates. Replace them
immediately. They contain important infor-
mation. See Group 40 for decal locations.
Inspect the truck before and after starting engine for any
signs of external leakage: fuel, engine oil or coolant,
transmission fluid, etc.
Check for hydraulic oil leaks and loose fittings. DO NOT
USE BARE HANDS TO CHECK.
CAUTION
!
Hydraulic Fluid Pressure. Do not use your
hands to check for hydraulic leakage. Oil
may be hot or under pressure. Fluid under
pressure can penetrate your skin and cause
serious injury.
Overhead Guard
Be sure that the overhead guard and any other safety
devices are in place, undamaged, and attached securely.
Inspect welds and structural members for cracks or other
damage. Also check for loose or missing fasteners.
Carriage, Load Backrest, and Upright
(See Group 34 for detailed inspection procedure.)
Inspect the welds on the carriage, load backrest, and
upright for cracks. Be sure that the mounting fasteners are
in place and tight.
Inspect the upright assembly: rails, carriage rollers, car-
riage fork bars, lift chains, and lift and tilt cylinders. Look
for obvious wear and maintenance problems and damaged
or missing parts. Check for any loose parts or fittings.
Check for leaks, any damaged or loose rollers and rail
wear (metal flaking). Carefully check the lift chains for
wear, rust and corrosion, cracked or broken links, stretch-
ing, etc. Check that the lift and carriage chains are cor-
rectly adjusted to have equal tension. Check that the lift
chain anchor fasteners and locking means are in place and
tight.
Be sure all safety guards and chain retainers are in place
and not damaged. Inspect the carriage stops and cylinder
retainer bolts. Check all welded connections.
Inspect all lift line hydraulic connections for leaks. Check
the lift cylinder rods for wear marks, grooves and
scratches. Check the cylinder seals for leaks.
Forks
Inspect the load forks for cracks, breaks, bending and
wear as described in Group 34.
WARNING
!
HEEL WEAR. If the fork blade at the heel is
worn down by more than 10 percent, the load
capacity is reduced and the fork must be
replaced. See Group 34 for inspection proce-
dures.
Overhead Guard
Upright
Carriage
Fork

Inspect the fork latches to ensure that they are in good
condition, operate freely, and lock correctly.
Wheels and Tires
Check the condition of the drive and steer wheels and
tires. Remove objects that are embedded in the tread.
Inspect the tires for excessive wear or breaks or "chunking
out.
Check all wheel lug nuts or bolts to be sure none are loose
or missing. Have missing bolts or lug nuts replaced and
tightened to correct torque as explained in Group 22.
WARNING
!
Check tire pressure from a position facing
the tread of the tire, not the side. Use a long-
handled gauge to keep your body away. If
tires are low, the tire may require removal
and repair. Incorrect (low) tire pressure can
reduce truck stability. See “Specifications” in
Group 22 for proper inflation pressure.
Brake and Inching Pedal Freeplay
There should be no inching and 4~6mm braking pedal
freeplay. Both pedals should be at same the height. Adjust
as described in Group 23.
Functional Tests
Be sure that:
• Parking brake is applied
• Directional control is in "N" (neutral).
Test the horn, lights, and all other safety equipment. Be
sure they are properly mounted and working correctly.
Test all controls to ensure that they operate freely and
return to neutral properly.
Now prepare to start the truck and test its operation.
Starting System
A 3-position starter switch is standard equipment.
Check the neutral start function by placing the direction
control lever in forward or reverse and turning key switch
to “start” position. The starter must not engage until the
direction control lever is moved to “neutral” position.
As you start the engine, check the instrument display. All
indicator lights should come on for a 2-second lamp
check. The seat belt prompt light should remain on for 4
seconds, accompanied by a buzzer sound. The parking
brake light should remain on if the brake is set. If the truck
has a diesel engine, the glow plug preheat light should
remain on for 6 seconds. If the lights do not operate as
described, refer to Group 13 to diagnose the problem.
Engine Shut Down Mode
If the truck’s fault protection system detects low engine oil
pressure, excessive transmission oil temperature, or exces-
sive engine coolant temperature, the truck will go into
“shutdown mode”—a buzzer will sound for 30 seconds,
after which the truck will shut itself off. The truck may be
restarted, but if the fault condition still exists, the engine
will again shutdown in 30 seconds.
Parking Brake Interlock
The transmission should disengage when the parking brake
is on and reengage when the parking brake is released.
1. Apply the parking brake.
2. Start the engine, if it is not already running.
3. Place the direction control in forward or reverse.
Make sure the path is clear in the chosen direction.
OFF
ON
Start

4. Accelerate briefly. The truck should not move or put
any strain on the parking brake if the interlock sys-
tem is OK.
5. Release the parking brake (and service brake). Truck
should move slowly in selected direction. (On hydro-
static truck, depress accelerator pedal slightly.)
Accelerator, Brake/Inching System, Direction
Control, and Parking Brake
WARNING
!
Fasten your seat belt before driving the
truck.
Make sure that you on a level surface, the travel area is
clear in front of the truck, the parking brake is release, and
the truck is running.
1. Push the brake (right) pedal down fully and hold. The
brakes should apply before the pedal reaches the
floorplate. If the pedal continues to creep downward,
report the failure immediately. Do not operate the
truck until the brakes are repaired.
2. Move the direction control lever from neutral to for-
ward.
3. For standard transaxle trucks: Release the brake
pedal and let the truck travel slowly forward. Then
push down on the brake pedal to stop the truck. The
brakes should apply smoothly and equally.
4. For hydrostatic transmission trucks:
a. Release the brake pedal. The transmission should
not engage and the truck should not move.
b. Accelerate briefly, then release the accelerator
pedal. Do not depress the brake pedal. The truck
should decelerate to a stop briefly after the accel-
erator pedal is released.
c. Depress the brake pedal and depress the accelera-
tor pedal slightly, the truck should not move.
5. Be sure the travel area is clear behind the truck.
Repeat steps 2 through 4 in the reverse direction.
6. Drive the truck and check that it accelerates and
decelerates smoothly and stops properly.
7. Depress the inching (left) pedal and depress the
accelerator to see if the transmission disengages
properly.
8. Check the function of the parking brake. Park the
truck on a grade and apply the parking brake. The
parking brake should hold a lift truck with rated load
on a 15% grade.
CAUTION
!
If the service brake, parking brake, or inter-
lock is not operating properly, take the truck
out of service until it is repaired.
Steering System
Check the steering system by moving the steering hand-
wheel in a full right turn and then in a full left turn. Return
the steer wheels to the straight-ahead position. The steer-
ing system components should operate smoothly when the
steering handwheel is turned. Hard steering, excessive
play(looseness), or unusual sounds when turning or
maneuvering indicates a need for inspection or servicing.
If the truck has a steering system fault, take the truck out
of service until it is repaired.
Operator’s Controls. Standard arrangment shown.
Lift Lever
Tilt Lever
Aux. Lever
Brake Pedal
Accelerater Pedal
Directional
Control
Inching Pedal

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Lift Mechanisms and Controls
(See Group 34 for detailed test procedure.)
1. Check the function of the lift system and controls
with the engine running.
2. Pull back on the tilt control lever and hold until the
upright reaches the full back tilt position. Push for-
ward on the lever to return the upright to the vertical
position. Release the lever.
If there is excessive play between rails and channels,
upright adjustment is required. If there is racking,
adjustment of the cylinder rod yokes is required.
CAUTION
!
Be sure that there is adequate overhead
clearance before raising the upright.
3. Pull back on the lift control lever and raise the fork
carriage to full height. Watch the upright assembly as
it rises. All movements of the upright, fork carriage,
and lift chains must be even and smooth, without
binding or jerking. Watch for chain wobble or loose-
ness; the chains should have equal tension and move
smoothly without noticeable wobble. Release the
lever.
If the maximum fork height cannot be reached, this
indicates there is low oil level in the hydraulic sump
or severe binding within the upright.
4. Push forward on the lift control lever. Watch the
upright as it lowers. If you suspect a problem with
lifting or lowering speeds, refer to Group 34 to diag-
nose the problem.
Auxiliary Controls
If the truck is equipped with an attachment, test the con-
trol lever for correct function and operate the attachment
to check its function
When you have completed the operational tests, park and
leave truck according to standard shutdown procedures.
Be sure to make a record of all maintenance and operating
problems you find.
Air Cleaning the Truck
CAUTION
!
Wear suitable eye protection and protective
clothing.
Open the hood and remove the floorplate. Then air clean
the following: upright assembly, drive axle, radiator from
both counterweight and engine sides, engine and accesso-
ries, driveline and related components, and steer axle and
steer cylinder.
Use an air hose with special adapter or extension that has
a control valve and nozzle to direct the air properly. Use
clean, dry, low-pressure compressed air. Restrict air pres-
sure to 30 psi (207 kPa), maximum. (OSHA requirement).
It is important to maintain a lift truck in a clean condition.
Do not allow dirt, dust, lint or other contaminants to accu-
mulate on the truck. Keep the truck free from leaking oil
and grease. Wipe up all oil or fuel spills. Keep the controls
and floorboards clean, dry, and safe. A clean truck makes
it easier to see leakage, loose, missing, or damaged parts,
and will help prevent fires. A clean truck will run cooler.
The environment in which a lift truck operates determines
how often and to what extent cleaning is necessary. For
example, trucks operating in manufacturing plants which
have a high level of dirt, dust or lint, (e.g. cotton fibers,
paper dust, etc.) in the air or on the floor or ground,
require more frequent cleaning. The radiator, especially,
may require daily air cleaning to ensure correct cooling. If
air pressure does not remove heavy deposits of grease, oil,
etc., it may be necessary to use steam or liquid spray
cleaner.

Truck Chassis Inspection and Lubrication
Lubrication requirements are given in the “Service Chart/
Lubrication Points” chart in Section 1 of this Group. Also
see Lubricants and Shop Supplies” in Group 40 for parts
information, and “General Specifications” in Group 40 for
lubricant specifications.
Lubrication and inspection of truck chassis components
includes steer wheels, steer axle linkages, and steer wheel
bearings, and drive wheel bearings. To check these items,
the truck must be properly raised and blocked as described
in “Lifting, Jacking, and Blocking” in Group SA.
Check for play in wheel bearings by attempting to move
the wheel side to side and up and down, by hand.
Inspect the steering cylinder piston rods, seal, and fasten-
ers for damage and leaks, and looseness.
Check linkages by observing whether the steer wheels lag
when you turn the handwheel.
Lubricate the steer axle linkage rod ends and pivot points.
Be sure to clean the grease fittings before lubricating.
Remove the excess grease from all points after lubricat-
ing. Lubricate miscellaneous linkage as needed.
Upright and Tilt Cylinder Lubrication
Clean the fittings and lubricate the tilt cylinder rod end
bushings (forward end). Clean the fittings and lubricate
the tilt cylinder base rod end bushings (rear end). Clean
and lubricate the upright trunnion bushings.
Lift Chain Lubrication
Lubricate the lift chains as described in Group 34.
Under-the-Hood Inspection
General Checks
Check all fluid levels and make sure that the following
items are clean, secure, and in good condition:
• Hoses, lines, clamps, and fittings
• Wires, cables, and connectors
• Distributor, distributor cap, and rotor, coil, and
plug wires (gas/LPG engine only)
• Control linkages, pedals, and levers
• Engine mounts
• Fan and fan belts
• Oil filler cap
• Steering gear (check for leaks).
CAUTION
!
To avoid the possibility of personal injury,
never work in engine compartment with
engine running except when absolutely nec-
essary to check or make adjustments. Take
extreme care to keep face, hands, tools, loose
clothing, etc., away from fan and drive belts.
Also, remove watches, bracelets, and rings.
Do not smoke.
Engine Air Cleaner
Do not open the air cleaner to check the filter element.
The filter element should be replaced only at the specified
service interval or when the air filter light indicates that it
is dirty.
Fluid Checks
Battery
Inspect the battery for any damage, cracks, leaking condi-
tion, etc. If the terminals are corroded, clean and protect
them with CLARK Battery Saver (available from your
Clark dealer). If the battery has removable cell caps, check
to be sure the cells are all filled. If necessary, refill with
distilled water.

Engine Cooling System
Check coolant level in the coolant recovery bottle and in
the radiator as described in Group 01.
CAUTION
!
STEAM. Do not remove the radiator cap
when the radiator is hot. Steam from the
radiator will cause severe burns.
Coolant should be checked on a daily basis in high-cycle
applications.
Engine Oil
Oil Level: With the truck level and the engine shutdown
for at least 5 minutes, check the engine oil level.
Locate the engine oil dipstick. Pull the dipstick out, wipe
it with a clean wiper and reinsert it fully into the dipstick
tube. Remove the dipstick and check oil level.
It is normal to add some oil between oil changes. Keep the
oil level above the ADD mark on the dipstick by adding
oil as required. Use only the oil specified in Group 00.
Oil Change: Change oil as described in Group 00.
Diesel Engine Oil Filter:Replace as described in Group
00.
Hydraulic Fluid Level
Check the hydraulic sump tank fluid level as described in
Group 29. Correct fluid level is important for proper sys-
tem operation. Low fluid level can cause pump damage.
Overfilling can cause fluid leakage.
Hydraulic fluid expands as its temperature rises. There-
fore, it is preferable to check the fluid level at operating
temperature (after approximately 30 minutes of truck
operation).
Fill the oil level above the LOW mark on the dipstick by
adding only the hydraulic fluid prescribed in Group 29.
DO NOT OVERFILL.
Transaxle Fluid Level
Check the transaxle fluid level with the engine running, as
explained in Group 06.
Fill to the FULL mark on the dipstick, using the transaxle
fluid specified in Group 06.
Stall Test
On standard transaxle trucks, perform the stall test
described in Group 00 to determine engine and transaxle
condition.
Cranking Voltage Test
To determine battery condition, check the cranking volt-
age as described in Group 14.
Critical Fastener Torque Checks
For safety it is important that the correct torque be main-
tained on all critical fasteners of components which
directly support, handle or control the load and protect the
operator.
Check torque of critical items, including:
• Drive axle mounting
• Drive and steer wheel mounting
• Counterweight mounting
• Overhead guard mounting
• Operator’s cell mounting
• Tilt cylinder mounting and yokes
• Upright mounting and components.
Critical fastener torque specifications are given in the gen-
eral specifications Section of Group 40.
ADD
FULL
Low Full

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