Service Manual c60 c80 Compressed

C60-80 D
SERVICE MANUAL
RATED CAPACITY: 6000– 8000kg
Part No. 8051043

Book No. SM-751
Jan. 2007
700 Enterprise Drive

Lexington, KY
Copyrighted Material 40510
Intended for CLARK dealers only
Do not sell or distribute
Truck Models Covered by this Manual
This manual consists of “base” module that pertains You may, however, purchase specific modules and
to all C60-80 models and other modules that pertain expand your manual to fully cover multiple models.
only to specific models. Manuals shipped with the To do so, order the desired modules as you would
truck contain the base module and the modules spe- any other Clark part.
cific to the purchased truck.
Arrangement and Use of this Manual

Clark arranges parts and service procedures by stan- You can quickly locate a specific point in the manual
dardized Groups. In this manual, Groups are similar by using the headers and footers that appear on every
to “chapters”. Groups are listed in the indexes on the Section page. The following illustration points out
next page. these areas.
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 This manual is intended for the use of trained service
Group 00, Section 1, page 2. personnel. Please read Group SA, “Safe Mainte-
The Group number sometimes has a letter or letters nance”, and the Operator’s Manual before working
added to it in parentheses if one or more variations of on or operating the truck.
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)”.
Copyrighted Material
NOTE :
Copyrighted Material SM751, Dec ’06

CONTENTS
CONTENTS
Contents of this Manual
Group Index
Group SA. Safe Maintenance Group 23. Brake System
Group PS. Periodic Service Group 25. Steering Column and Gear
Group 00. Engine Group 26. Steer Axle
Group 01. Engine Cooling System Group 29. Hydraulic Sump, Filters, and Pump
Group 03. Air Induction and Exhaust System Group 30. Hydraulic Control Valve/Lift Circuit
Group 06. Transaxle Group 32. Tilt Cylinders
Group 13. Electrical system Group 34. Uprights
Group 20. Drive Axle Group 38. Counterweight and Chassis
Group 22. Wheels and Tires Group 40. Specifications
Group 34. Uprights

Group 06. Transaxl
Group 32. Tilt Cylinders

Group 23. Brake System
Group 20. Drive Axle

Group 25. Steering Column and
Gear
Group 30. Hydraulic Control Valve/
Lift Circuit
Group 13. Electrical system
Group 29. Hydraulic Sump, Filters,
and Pump
Group 03. Air Induction and
Exhaust System
Group 00. Engine
Group 01. Engine Cooling System
Group 22. Wheels and Tires
Group 38. Counterweight Group 26. Steer Axle

and Chassis
SM 751, Nov ’06 Copyrighted Material CONTENTS-1

NOTE :
CONTENTS Copyrighted Material SM751, Nov ’06

REVISION HISTORY
When new or revised information is published to Dec. 2006

update this manual the action to be taken with the Mark Indication Action required
pages is indicated in the table. ❍ Page to be newly added Add
Pages not marked are not currently revised, but are ● Page to be replaced Replace
included for page numbering continuity.
( ) Page to be deleted Discard
Mark Page Revision Mark Page Revision Mark Page Revision Mark Page Revision
number number number number
SA-1-1 00(D)-3-3 00(D)-3-41 00(D)-4-28
SA-1-2 00(D)-3-4 00(D)-3-42 00(D)-4-29
SA-2-1 00(D)-3-5 00(D)-3-43 00(D)-4-30
SA-2-2 00(D)-3-6 00(D)-3-44 00(D)-4-31
SA-2-3 00(D)-3-7 00(D)-3-45 00(D)-4-32
SA-2-4 00(D)-3-8 00(D)-3-46 00(D)-4-33
SA-2-5 00(D)-3-9 00(D)-3-47 00(D)-4-34
SA-2-6 00(D)-3-10 00(D)-3-48 00(D)-4-35
SA-3-1 00(D)-3-11 00(D)-3-49 00(D)-5-1
SA-3-2 00(D)-3-12 00(D)-3-50 00(D)-5-2
00(D)-3-13 00(D)-3-51 00(D)-5-3
PS-1-1 00(D)-3-14 00(D)-4-1 00(D)-5-4
PS-1-2 00(D)-3-15 00(D)-4-2 00(D)-5-5
PS-1-3 00(D)-3-16 00(D)-4-3 00(D)-5-6
PS-1-4 00(D)-3-17 00(D)-4-4 00(D)-5-7
PS-1-5 00(D)-3-18 00(D)-4-5 00(D)-5-8
PS-2-1 00(D)-3-19 00(D)-4-6 00(D)-6-1
PS-2-2 00(D)-3-20 00(D)-4-7 00(D)-6-2
PS-2-3 00(D)-3-21 00(D)-4-8
PS-2-4 00(D)-3-22 00(D)-4-9 01-1-1
PS-2-5 00(D)-3-23 00(D)-4-10 01-2-1
PS-2-6 00(D)-3-24 00(D)-4-11 01-3-1
PS-2-7 00(D)-3-25 00(D)-4-12 01-3-2
PS-2-8 00(D)-3-26 00(D)-4-13 01-3-3
PS-2-9 00(D)-3-27 00(D)-4-14 01-3-4
PS-2-10 00(D)-3-28 00(D)-4-15 01-3-5
00(D)-3-29 00(D)-4-16 01-3-6
00(D)-1-1 00(D)-3-30 00(D)-4-17 01-4-1
00(D)-1-2 00(D)-3-31 00(D)-4-18 01-4-2
00(D)-1-3 00(D)-3-32 00(D)-4-19
00(D)-1-4 00(D)-3-33 00(D)-4-20 03-1-1
00(D)-2-1 00(D)-3-34 00(D)-4-21 03-2-1
00(D)-2-2 00(D)-3-35 00(D)-4-22 03-3-1
00(D)-2-3 00(D)-3-36 00(D)-4-23 03-3-2
00(D)-2-4 00(D)-3-37 00(D)-4-24 03-4-1
00(D)-2-5 00(D)-3-38 00(D)-4-25 03-4-2
00(D)-3-1 00(D)-3-39 00(D)-4-26
00(D)-3-2 00(D)-3-40 00(D)-4-27 06-1-1
SM 751, Nov ’06 Copyrighted Material REVISION HISTORY - 1

REVISION HISTORY
Revision Revision Revision Revision

Mark Page number Mark Page number Mark Page number Mark Page number
06-1-2 06-5-1 13-4-15 23(S)-3-1
06-1-3 06-5-2 13-4-16 23(S)-3-2
06-1-4 06-5-3 13-4-17 23(S)-4-1
06-1-5 06-5-4 13-4-18 23(S)-5-1
06-2-1 06-5-5 13-4-19 23(S)-5-2
06-2-2 06-5-6 13-4-20 23(S)-5-3
06-2-3 06-5-7 13-4-21
06-2-4 06-5-8 13-4-22 25-1-1
06-2-5 06-5-9 13-4-23 25-1-2
06-2-6 06-5-10 25-2-1
06-2-7 06-5-11 20-1-1 25-2-2
06-2-8 06-5-12 20-1-2 25-3-1
06-2-9 06-5-13 20-2-1 25-3-2
06-2-10 06-5-14 20-2-2 25-3-3
06-2-11 20-2-3 25-3-4
06-2-12 13-1-1 20-2-4 25-4-1
06-2-13 13-2-1 20-3-1 25-4-2
06-3-1 13-3-1 20-3-2 25-4-3
06-3-2 13-3-2 20-3-3 25-4-4
06-3-3 13-3-3 20-3-4 25-5-1
06-3-4 13-3-4 20-3-5 25-5-2
06-3-5 13-3-5 20-3-6 25-5-3
06-3-6 13-3-6 20-3-7 25-5-4
06-3-7 13-3-7 20-3-8 25-5-5
06-3-8 13-3-8 20-3-9 25-5-6
06-3-9 13-3-9 20-3-10 25-5-7
06-3-10 13-3-10 20-3-11
06-3-11 13-3-11 20-4-1 26-1-1
06-3-12 13-3-12 26-1-2
06-3-13 13-3-13 22-1-1 26-2-1
06-3-14 13-3-14 22-2-1 26-2-2
06-3-15 13-3-15 22-2-2 26-2-3
06-3-16 13-4-1 22-2-3 26-2-4
06-3-17 13-4-2 22-2-4 26-3-1
06-3-18 13-4-3 22-2-5 26-3-2
06-3-19 13-4-4 22-2-6 26-3-3
06-3-20 13-4-5 22-2-7 26-3-4
06-3-21 13-4-6 22-2-8 26-4-1
06-3-22 13-4-7 22-2-9 26-4-2
06-3-23 13-4-8 22-2-10 26-4-3
06-4-1 13-4-9 22-2-11 26-5-1
06-4-2 13-4-10 26-5-2
06-4-3 13-4-11 23(S)-1-1 26-6-1
06-4-4 13-4-12 23(S)-1-2 26-6-2
06-4-5 13-4-13 23(S)-2-1 26-6-3
06-4-6 13-4-14 23(S)-2-2 26-6-4
2 - REVISION HISTORY Copyrighted Material SM 751, Nov ’06

REVISION HISTORY
Revision Revision Revision Revision

Mark Page number Mark Page number Mark Page number Mark Page number
34-1-5 34-8-3
29-1-1 34-1-6 34-8-4
29-1-2 34-2-1
29-1-3 34-2-2 38-1-1
29-1-4 34-2-3 38-2-1
29-1-5 34-2-4 38-2-2
29-1-6 34-3-1 38-3-1
29-2-1 34-3-2 38-3-2
29-2-2 34-3-3 38-4-1
29-2-3 34-3-4 38-4-2
29-3-1 34-3-5 38-5-1
29-3-2 34-3-6 38-5-2
29-3-3 34-3-7
34-3-8 40-1-1
30-1-1 34-3-9 40-1-2
30-1-2 34-3-10 40-1-3
30-2-1 34-4-1 40-1-4
30-3-1 34-4-2 40-2-1
30-3-2 34-4-3 40-2-2
30-4-1 34-4-4 40-2-3
30-4-2 34-4-5 40-2-4
30-5-1 34-4-6 40-2-5
30-5-2 34-4-7 40-2-6
30-5-3 34-4-8 40-2-7
30-5-4 34-4-9 40-3-1
30-6-1 34-5-1
30-6-2 34-5-2
30-6-3 34-5-3
30-6-4 34-5-4
34-5-5
32-1-1 34-5-6
32-2-1 34-6-1
32-2-2 34-6-2
32-2-3 34-6-3
32-3-1 34-6-4
32-3-2 34-6-5
32-3-3 34-6-6
32-3-4 34-6-7
32-4-1 34-6-8
32-4-2 34-6-9
32-4-3 34-7-1
34-7-2
34-1-1 34-7-3
34-1-2 34-7-4
34-1-3 34-8-1
34-1-4 34-8-2
SM 751, Nov ’06 Copyrighted Material REVISION HISTORY - 3

NOTE :
REVISION HISTORY Copyrighted Material SM 751, Nov ’06

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

NOTE :
Group SA, Safe Maintenance Copyrighted Material SM 751, Oct ’06

Group SA, Safe Maintenance
Section 1
Safety
Safety Signs and Messages Safe Maintenance Practices

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

9. Operation of the truck to check performance must be 19. Modifications and additions that affect capacity and
conducted in an authorized, safe, clear area. safe truck operation must not be done without the
manufacturer’s prior written approval. Capacity,
10. Before starting to drive truck:
operation and maintenance instruction plates, tags, or
a. Be in operating position.
decals must be changed accordingly. This is an
b. Be sure parking brake is engaged.
OSHA requirement.
c. Put direction control in neutral.
d. Start engine. 20. Care must be taken to assure that all replacement
e. Check functioning of direction and speed con- parts, including tires, are interchangeable with the
trols, steering, brakes, warning devices, and any original parts and of a quality at least equal to that
load handling attachments. provided in the original equipment. Parts, including
tires, are to be installed per the manufacturer’s proce-
11. Before leaving truck
dures. Always use genuine CLARK or CLARK-
a. Stop truck.
approved parts.
b. Put directional control in neutral.
c. Apply the parking brake. 21. Use special care when removing heavy components
d. Stop the engine by turning off the ignition circuit. from the truck, such as counterweight, seat deck,
e. Put blocks at the wheels if truck is on an incline. upright, etc. Be sure that lifting and handling equip-
ment is of the correct capacity and in good condition.
12. Brakes, steering mechanisms, control mechanisms,
Also, this removal may upset the stability of the
warning devices, lights, governors, guards, safety
truck. The frame must always be safely blocked for
devices, and frame members must be carefully and
major component removal.
regularly inspected and maintained in a safe operat-
ing condition.
NOTE
13. Special trucks or devices designed and approved for
hazardous area operation must receive special atten- You should also be familiar with additional
tion to ensure that maintenance preserves the origi- operating and maintenance safety instruc-
nal, approved, safe-operating features. tions contained in the following publica-
tions:
14. Fuel systems must be checked for leaks and condi-
tion of parts. Extra special consideration must be ASME B56.1 - : Operator Control-Industrial Tow Tractors
given in the case of a leak in the fuel system. Action (Safety Standard For Powered Industrial Trucks). Pub-
must be taken to prevent the use of the truck until the lished by: American Society of Mechanical Engineers,
leak has been corrected. Three Park Avenue, New York, NY 10016.
15. The truck manufacturer’s capacity, operation, and NFPA 505: Fire Safety Standard for Powered Indus-trial
maintenance instruction plates, tags, or decals must Trucks: Type Designations, Areas of Use, Mainte-nance
be maintained in legible condition. and Operation. Available from: National Fire Protection
16. Batteries, motors, controllers, limit switches, protec- Assoc., Inc., Batterymarch Park, Quincy, MA 02269.
tive devices, electrical conductors, and connections General Industrial Standards, OSHA 2206: OSHA Safety
must be inspected and maintained in conformance and Health Standards (29 CFR 1910), Subpart N-Mater
with good practice. Special attention must be paid to als Handling and Storage, Section 1910.178 Powered
the condition of electrical insulation. Industrial Trucks. For sale by: Superintendent of Docu-
17. To avoid injury to personnel or damage to the equip- ments, U.S. Government Printing Office, Washington, DC
ment, consult the manufacturer’s procedures in 20402.
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.
SA-1-2 • Safety Copyrighted Material SM 751, Oct ’06

Section 2
Lifting, Jacking, and Blocking the Truck
! 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.
SM 751, Oct ’06 Lifting, Jacking, and Blocking the Truck • SA-2-1
Safe Parking Raising Drive Wheels Off Floor

Before working on truck: This procedure uses the upright as a lever to lift the drive
wheels off the floor and prevent accidents due to inadvert-
1. Park truck on a hard, level, and solid surface, such as
ent powering of the drive wheels.
a concrete floor with no gaps or breaks.
1. Park truck safely as described in “Safe Parking.”
2. Put upright in vertical position and fully lower the
Block steer wheels.
forks or attachment.
2. Be sure upright trunnion bolts are tight. Bolt torques
3. Put all controls in neutral. Turn key switch OFF and
must be 75-80 N⋅m (55-59 ft-lb).
remove key.
3. Start the engine. Tilt the upright fully back. Adjust
4. Apply the parking brake and block the wheels.
upright height as necessary to put blocking under-
neath the lower end of the upright.
! WARNING
4. Put a solid 100 x 100 mm (4 x 4 in) hardwood block
Defective equipment can cause accidents. All under the front section of each upright rail. Put a 3-6
tools and lifting equipment must be in good mm (.125-.250 in) steel plate on top of each block.
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 Steel

Plate
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, Block
safe procedures
On Tie Bars
of Upright 5. Tilt upright fully forward. This raises the drive
wheels off the floor. Release the tilt control lever and
turn engine OFF.
Under Under Frame Under Upright

Steer
Axle Frame Mount
! 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.
SA-2-2 • Lifting, Jacking, and Blocking the Truck

Copyrighted Material SM 751, Oct ’06
6. Insert blocking under the frame behind the drive 3. To raise the front of the truck using the upright,
wheels or slip wheel cradles under the drive wheels. spread two chains on the outer rail tiebar of the
If using blocking, check for safe clearance between upright.
drive wheels and floor and blocks.
Place
chains
here
Rag
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 ! WARNING

the blocks are located securely under the truck frame Chain and hoist used to lift truck should be
before operating the drive or working on truck. checked to make sure they are of safe lifting
8. Lower the drive wheels to the floor and remove the capacity. See the truck data plate for infor-
blocks by reversing the above procedure. mation.
4. Slowly lift truck and lower drive wheels onto the cra-
dles or place blocking under frame prop points.
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.
1. Park truck safely as described in “Safe Parking.” 5. When maintenance work is completed, lower the
Block rear steer wheels. truck to the floor by reversing the lifting procedure.
Check to be sure no tools or equipment are under the
2. Check trunnion bolts to make sure they are tightened
truck or wheels.
to correct torque. Bolt torques must be 75-80 N⋅m
(55-59 ft-lb).
Blocking the Upright In Raised

Position
Carriage
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 Inner Rail
mm (4 x 4 in) hardwood blocks or equal, of about
300 x 300 mm (12 in) and 600 x 600 mm (24 in) Outer Rail
length.
NOTE Short Block
For standard uprights, block may need

length cut to suit. For triple stage uprights, 7. Reverse the procedure to remove blocking.
the carriage may be blocked up, as shown.
4. Start engine and raise the upright carriage. Raising Rear of Truck
5. Hold the taller block against inner rail and lower the The truck may be raised at the rear by jacking and block-
upright until carriage rests on 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
Carriage
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.
Inner Rail
Outer Rail
Tall Block
6. Hold the shorter block against the outer rail and

lower the upright until inner rail rests on the block.

2. Put a floor jack under the steer axle mounting frame 6. When maintenance work is completed, lower the rear
member, centered between the two wheels. of truck to the floor by reversing the above procedure
and lowering each side of the truck 50 mm (2 in) at a
! WARNING time:
• Put jack under frame and raise truck.
Never lift the truck by the counterweight. • 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.
NOTE
If there is insufficient clearance under frame
! WARNING
for your jack, the truck may first be driven SIDE-TO-SIDE TIPOVER. When jacking
onto shims, such as 25 x 150 x 300 mm (1 x 6 side of truck, be sure upright is lowered fully
x 12 in) pieces of board, to increase the truck and do not raise one side of the truck more
frame underclearance. than about 50 mm (2 in) higher than the
other, to avoid tipping truck over laterally.
3. Raise the truck only as high as necessary to perform
the maintenance work. END-TO-END TIPOVER. If the upright and
transaxle are removed while the truck is
4. Put blocks at both sides of the truck, fully under the blocked up, the truck will tip backwards due
frame main side structure. Put the blocks in front of to the heavy counterweight. Both upright and
but close to the counterweight and steer wheels for counterweight must be removed before
best truck stability. 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.
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.
3. Put the jack under side frame near the center of the
truck. ! 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
Jack truck Depending on jack height, shims under the
here tires may be needed for clearance to allow
removal of jack.
IMPORTANT
Be sure to put the jack squarely and fully
under the main side structure of the frame. Shipping Tie-Down Instructions
Do not put the jack under the outer covers 1. Front of Truck
which enclose the fuel and hydraulic sump a. With Upright and Carriage Installed
tanks. • Lower the carriage fully.
• Put a tie down (e.g., chain) between the carriage
4. Carefully raise the truck one side at a time, only as fork bars.
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.
b. Without an Upright and Carriage Installed

• Put a chain across the truck floor plate. Protect
6. If using one jack, lower the truck onto the blocks and
move the jack to the opposite side. Repeat the lifting
truck from chain damage by using covered chain
procedure. or protective material under the chain at contact
points.
7. Put the same size blocks under each side of the truck
so it will be level. 2. Rear of Truck
• Attach the tie down to pocket in bottom of coun-
terweight.

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

IMPORTANT
Do not lift the disabled truck or any wheels
! WARNING
off the floor while the truck is being towed. Always engage the parking brake when park-
ing a lift truck. The truck can roll and cause
9. Park the disabled truck in authorized areas only. injury or death to personnel near it.
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.
LIFT TRUCK PARKING
SA-3-2 • Towing Copyrighted Material SM 751, Oct ’06

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

NOTE :
Group PS, Periodic Service Copyrighted Material SM 751, Oct ’06

Group PS, Periodic Service
Section 1
Maintenance Schedules
“Periodic Service” and “Planned Determining Maintenance Intervals

Maintenance” Time intervals on the charts on the next four pages and
The term “periodic service” includes all maintenance elsewhere in this manual relate to truck operating hours as
tasks that should be performed on a regularly scheduled recorded on the hourmeter, and are based on experience
basis. Clark has found to be convenient and suitable under nor-
mal operation. Standard operating condition classifica-
The term “Planned Maintenance” indicates a formalized tions are:
program of basic inspections, adjustments, and lubrica-
tions that the Clark service organization provides custom- Normal Operation: Eight-hour material handling, mostly
ers at a prescribed interval, usually 50-250 hours. The in buildings or in clean, open air on clean, paved surfaces.
recommended basic “Planned Maintenance” procedure is Severe Operation: Prolonged operating hours or constant
given in Section 2 of this Group. usage.
The current Section,“Maintenance Schedules,” specifies Extreme Operation:
all maintenance tasks—including Planned Maintenance
tasks—that should be performed periodically, and sug- • In sandy or dusty locations, such as cement plants,
gests intervals at which they should be performed. 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.
SM 751, Oct ’06 Copyrighted Material Maintenance Schedules • PS-1-1

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
API,CF Clark # 2776239
API,MORE THAN A CLASS SJ GRADE
PS-1-2 • Maintenance Schedules Copyrighted Material SM 751, Oct ’06

Recommended Periodic Service Schedule

This chart lists maintenance tasks that should be done Apply as appropriate for diesel, gas, and LPG trucks.
periodically, the suggested time intervals, and the service Refer to Operator’s Manual for Daily Checks.
manual Group in which the task is covered.
Every 450- Every 900- Every 2000

Every
TASKS 1st 50 Hours 500 Hours 1000 Hours Hours
50-250 Hours
(or 3 months) (or 6 months) (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


Every
50-250 Hours
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 • •
PS-1-4 • Maintenance Schedules Copyrighted Material SM 751, Oct ’06


Every
50-250 Hours
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 •

NOTE :
Group PS, Periodic Service Copyrighted Material SM 751, Oct ’06

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

Introduction to Planned Maintenance The Basic PM Procedures

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

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

Inspect the fork latches to ensure that they are in good Functional Tests
condition, operate freely, and lock correctly.
Be sure that:
Wheels and Tires • Parking brake is applied
Check the condition of the drive and steer wheels and • Directional control is in "N" (neutral).
tires. Remove objects that are embedded in the tread.
Inspect the tires for excessive wear or breaks or "chunking Test the horn, lights, and all other safety equipment. Be
out. 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.
Check all wheel lug nuts or bolts to be sure none are loose
or missing. Have missing bolts or lug nuts replaced and As you start the engine, check the instrument display. All
tightened to correct torque as explained in Group 22. 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.
ON
OFF
Start
Engine Shut Down Mode

If the truck’s fault protection system detects low engine oil
! WARNING pressure, excessive transmission oil temperature, or exces-
sive engine coolant temperature, the truck will go into
Check tire pressure from a position facing “shutdown mode”—a buzzer will sound for 30 seconds,
the tread of the tire, not the side. Use a long- after which the truck will shut itself off. The truck may be
handled gauge to keep your body away. If restarted, but if the fault condition still exists, the engine
tires are low, the tire may require removal will again shutdown in 30 seconds.
and repair. Incorrect (low) tire pressure can
reduce truck stability. See “Specifications” in Parking Brake Interlock
Group 22 for proper inflation pressure.
The transmission should disengage when the parking brake
Brake and Inching Pedal Freeplay is on and reengage when the parking brake is released.
There should be no inching and 4~6mm braking pedal 1. Apply the parking brake.
freeplay. Both pedals should be at same the height. Adjust 2. Start the engine, if it is not already running.
as described in Group 23.
3. Place the direction control in forward or reverse.
Make sure the path is clear in the chosen direction.

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

Lift Mechanisms and Controls Auxiliary Controls

(See Group 34 for detailed test procedure.) If the truck is equipped with an attachment, test the con-
trol lever for correct function and operate the attachment
1. Check the function of the lift system and controls
to check its function
with the engine running.
When you have completed the operational tests, park and
2. Pull back on the tilt control lever and hold until the
leave truck according to standard shutdown procedures.
upright reaches the full back tilt position. Push for-
Be sure to make a record of all maintenance and operating
ward on the lever to return the upright to the vertical
problems you find.
position. Release the lever.
If there is excessive play between rails and channels,
upright adjustment is required. If there is racking, Air Cleaning the Truck
adjustment of the cylinder rod yokes is required.
! CAUTION
! CAUTION
Wear suitable eye protection and protective
Be sure that there is adequate overhead clothing.
clearance before raising the upright.
Open the hood and remove the floorplate. Then air clean
3. Pull back on the lift control lever and raise the fork the following: upright assembly, drive axle, radiator from
carriage to full height. Watch the upright assembly as both counterweight and engine sides, engine and accesso-
it rises. All movements of the upright, fork carriage, ries, driveline and related components, and steer axle and
and lift chains must be even and smooth, without steer cylinder.
binding or jerking. Watch for chain wobble or loose-
ness; the chains should have equal tension and move Use an air hose with special adapter or extension that has
smoothly without noticeable wobble. Release the a control valve and nozzle to direct the air properly. Use
lever. 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.
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.

Truck Chassis Inspection and Lubrication Under-the-Hood Inspection

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

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 Fill the oil level above the LOW mark on the dipstick by
adding only the hydraulic fluid prescribed in Group 29.
Check coolant level in the coolant recovery bottle and in
DO NOT OVERFILL.
the radiator as described in Group 01.
! CAUTION
Low Full
STEAM. Do not remove the radiator cap

when the radiator is hot. Steam from the
radiator will cause severe burns.
Transaxle Fluid Level
Coolant should be checked on a daily basis in high-cycle Check the transaxle fluid level with the engine running, as
applications. explained in Group 06.
Engine Oil Fill to the FULL mark on the dipstick, using the transaxle
fluid specified in Group 06.
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.
FULL
Stall Test
ADD
On standard transaxle trucks, perform the stall test
described in Group 00 to determine engine and transaxle
condition.
Cranking Voltage Test

It is normal to add some oil between oil changes. Keep the To determine battery condition, check the cranking volt-
oil level above the ADD mark on the dipstick by adding age as described in Group 14.
oil as required. Use only the oil specified in Group 00.
Oil Change: Change oil as described in Group 00. Critical Fastener Torque Checks
Diesel Engine Oil Filter:Replace as described in Group
For safety it is important that the correct torque be main-
00.
tained on all critical fasteners of components which
directly support, handle or control the load and protect the
Hydraulic Fluid Level
operator.
Check the hydraulic sump tank fluid level as described in
Check torque of critical items, including:
Group 29. Correct fluid level is important for proper sys-
tem operation. Low fluid level can cause pump damage. • Drive axle mounting
Overfilling can cause fluid leakage. • Drive and steer wheel mounting
Hydraulic fluid expands as its temperature rises. There- • Counterweight mounting
fore, it is preferable to check the fluid level at operating • Overhead guard mounting
temperature (after approximately 30 minutes of truck
• Operator’s cell mounting
operation).
• Tilt cylinder mounting and yokes
• Upright mounting and components.
Critical fastener torque specifications are given in the gen-
eral specifications Section of Group 40.

PS-2-10 • The Planned Maintenance Program Copyrighted Material SM 751, Oct ’06
GROUP 00(D)
GROUP 00(D)
ENGINE
(N45-MNS)
General specifications .............................. Section 1
Fuel .............................................................Section 2
Duty - Industrial applications

Mechanical injection Engines ...................Section 3
Overhaul and technical specifications ......Section 4
Tools.............................................................Section 5
Engine Replacement...................................Section 6
PREFACE TO USER’S GUIDELINE MANUAL

Section 1 describes the NEF engine illustrating its features and working in general.
Section 2 describes the type of fuel feed.
Section 3 relates to the specific duty and is divided in four separate parts:
1. Mechanical part, related to the engine overhaul, limited to those components with different characteristics based
on the relating specific duty.
2. Electrical part, concerning wiring harness, electrical and electronic equipment with different characteristics
based on the relating specific duty.
3. Maintenance planning and specific overhaul.
4. Troubleshooting part dedicated to the operators who, being entitled to provide technical assistance, shall have
simple and direct instructions to identify the cause of the major inconveniences.
Sections 4 and 5 illustrate the overhaul operations of the engine overhaul on stand and the necessary equipment to execute
such operations.
SM 751, Dec ’06 Copyrighted Material Group 00(D), ENGINE

NOTE :
Group 00(D), ENGINE Copyrighted Material SM 751, Dec ’06

Group 00(D), Engine(IVECO)
Section 1
GENERAL SPECIFICATIONS
LUBRICATION From the pan, the lubrication oil flows to the driving shaft,
to the camshaft and to the valve drive.
Lubrication by forced circulation is achieved through oil
rotary expansion pump, placed in the front part of the Lubrication involves the heat exchanger (2,3), the turbob-
basement, driven by the straight-tooth gear splined to the lower for turbocompressed versions, and for any com-
shaft’s bar hold. pressed air system.
All these components may often vary according to the
specific duty.
Routing of oil under pressure

Routing of oil return by gravity
to sump
Introduction of oil
3 4
LUBRICATION SYSTEM LAYOUT (4 cyl. engines)

1. Lubrication oil pipe to supercharger - 2. Heat exchanger body - 3. Heat exchanger - 4. Oil rotary expansion pump -
5. Oil filter
SM 751, Dec ’06 Copyrighted Material GENERAL SPECIFICATIONS • 00(D)-1-1

OIL VAPOUR RECIRCULATING The remaining non-condensed vapours shall be properly

SYSTEM conveyed through the breather pipe (2), by suction as an
example (connection towards these vapours shall be
On the tappet cap (3) there is a valve (1) whose duty is to designed by the Engineer).
condense oil vapour inducing these to fall down because
of gravity, to the Tappet cap underneath.
00(D)-1-2 • GENERAL SPECIFICATIONS Copyrighted Material SM 751, Dec ’06

COOLING SYSTEM −Visc pusher fan, having the duty to increase the heat
dissipating power of the radiator. This component as
The engine cooling system, closed circuit forced circula- well will be specifically equipped based on the
tion type, generally incorporates the following compo- engine’s development.
nents: −Heat exchanger to cool the lubrication oil: even this
−Expansion tank; placement, shape and dimensions are component is part of the engine’s specific equipment.
subject to change according to the engine’s equipment. −Centrifugal water pump, placed in the front part of the
−Radiator, which has the duty to dissipate the heat sub- engine block.
tracted to the engine by the cooling liquid. Also this −Thermostat regulating the circulation of the cooling
component will have specific peculiarities based on liquid.
the equipment developed, both for what concerns the −The circuit may eventually be extended to the com-
placement and the dimensions. pressor, if this is included in the equipment.
Figure 4
TO RADI ATO R
FROM RADIATOR
W ater comingout from thermostat

003241t
W ater recirculating in engine
W ater coming into pump
COOLIN G SYSTEM LAYOU T (4 cyl. engines)
SM 751, Dec ’06 Copyrighted Material GENERAL SPECIFICATIONS • 00(D)-1-3

AIR INDUCTION BOOST DIAGRAM The above mentioned air is then cooled by the radiator and
flown through the piston induction collector.
Description The turbocharger is equipped with a transforming valve to

regulate the pressure , that is located on the exhaust col-
The turbocharger is composed by the following main lector before the turbine and connected by piping to the
parts: induction collector.
one turbine, one transforming valve to regulate the boost It’s duty is to choke the exhaust of the emissions , releas-
feeding pressure , one main body and one compressor. ing part of them directly to the exhaust tube when the
boost feeding pressure, over the compressor, reaches the
During engine working process, the exhaust emission
prescribed bar value.
flow through the body of the turbine, provoking the tur-
bine disk wheel’s rotation. The cooling process and the lubrication of the turbo-
charger and of the bearings is made by the oil of the
The compressor rotor, being connected by shaft to the tur-
engine.
bine disk wheel, rotates as long as this last one rotates,
compressing the sucked air through the air filter.
Figure 6
AIR FILTER TU RBO CHARGE R
EX HAUST
RADI ATO R
74195
00(D)-1-4 • GENERAL SPECIFICATIONS Copyrighted Material SM 751, Dec ’06

Section 2
Fuel
INJECTION FEED SYSTEM BY −- Fuel pre-filter (if available, it is usually placed close
to the engine on the machine frame)
MECHANICAL ROTARY PUMP −Priming pump, assembled to the engine and driven by
the camshaft
4 cylinder engines General information −Fuel filter (assembled to the engine in different posi-
tions according to equipment application and duty)
Fuel feed system is composed by: −Fuel feed rotary pump
−Fuel tank (placed on the machine) −Injector feed pipeline (from fuel feed pump to injec-
−Fuel delivery and back-flow to tank tors)
−Injectors.
SM 751, Dec ’06 Copyrighted Material Fuel • 00(D)-2-1

Description of working principles Transfer pump is placed inside the feed pump, and is
bladed type; its duty is to increase fuel pressure in corre-
Fuel is sucked from the fuel tank by the priming pump. spondence with the increase of the number of revolutions.
This last one is placed on the engine basement and is
driven by the camshaft. The fuel arrives therefore to the valve gauging the pres-
sure inside feed pump.
Throughout the filter/s, the fuel is piped to the union fit-
ting vacuum chamber of the transfer pump. (For applica- The distribution plunger further increases this pressure
tions to be equipped in cold climate areas, the fuel filter is and delivers fuel throughout the delivery pipe fitting to the
provided with heater). injectors.
The fuel drawing from the injectors is recovered and
delivered to the tank again.
00(D)-2-2 • Fuel Copyrighted Material SM 751, Dec ’06

FEED PUMP E = Pump dimensions

4= 4 cylinders engine
The rotary type pump is driven by a gear mating the cam- 12 = Distribution plunger in mm.
shaft’s one. 1150 = No. of pump revolutions per minute
LV = Left direction of rotation
Example of identification
V= Distribution rotary plunger

PRIMING PUMP assembled to the engine basement and driven by the cam-
shaft.
This pump has the specific duty to prime the fuel available
in the tank and convey it to the feed pump inlet. It is
00(D)-2-4 • Fuel Copyrighted Material SM 751, Dec ’06

FUEL FILTER On the filter cartridge base there is a water dump screw,
throughout which it is possible to provide regular drain-
The filter is assembled close to the feed and priming pump age; on the bearing for those equipment applications
and has the specific duty to provide barrier to the impuri- requiring it (cold climate areas), there can be a heater
ties and separation of water from fuel. assembled to and a temperature sensor. On some versions,
a water presence sensor is present at filtering cartridge
base.

NOTE :
Group 00(D), Engine(IVECO) Copyrighted Material SM 751, Dec ’06

Section 3
DUTY - INDUSTRIAL APPLICATION
GENERAL INFORMATION ter will follow and comply with all

installation prescriptions provided by Iveco
Motors.
Version equipped with mechanical feed pump Furthermore, the expanders assembled by
the Setter must always comply with couple,
NEF engines have been designed and developed by Iveco
power and number of revolutions based on
Motors specifically for transportation by land and farming
which the engine has been designed.
equipment in general.
They are characteristed by diesel cycle 4 stroke atmo- The section herein described is composed or four directo-
spheric or supercharged 4 and 6 cylinders each with 2 ries:
valves.
−directory of mechanical overhaul prescribed in accor-
Feed is provided by rotary mechanical pump or on line dance to the engine’s specific duty, illustrating all nec-
according to the equipment application. essary operations to remove and assembly the external
components of the engine, including cylinder heads,
It differs from other applications because of the provision
gearbox of the timing system and of the front part
of different power, power take-off for the different collec-
cover;
tor configuration, priming pump, oil pan and boost tur-
−electrical directory, describing the connections of the
bine.
different components, of the pre-post heating gearbox
NOTE (only for some versions) and of the sensors assembled
The picture shows application designed for 4 to the engine;
cylinders version, 2 valves per cylinder, hav- −troubleshooting directory;
ing fuel feed mechanical pump. −directory of preventive and regular maintenance opera-
tions, providing instructions for the execution of the
NOTE main operations.
Data, technical specifications and perfor-
mances granted shall be valid only if the Set-
SM 751, Dec ’06 Copyrighted MaterialDUTY - INDUSTRIAL APPLICATION • 00(D)-3-1

Clearance data - 4 cyl.
NOTE Furthermore, the users assembled by the set-

Data, features and performances are valid ter shall always be in conformance to couple,
only if the setter fully complies with all the power and number of turns based on which
installation prescriptions provided by Iveco the engine has been designed.
Motors.
00(D)-3-2 • DUTY - INDUSTRIAL APPLICATIONCopyrighted Material SM 751, Dec ’06

OVERHAUL OF THE 4 CYLINDER NOTE

ENGINE PROVIDEDWITH For some versions, the oil filter (3) is directly
assembled on to the heat exchanger:in such
MECHANICAL ROTARY PUMP case it shall be disassembled using tool
99360076.
Preface Warning: the oil filter contains inside aprx. 1
kg. of engine oil. Provide for oil recovery and
Part of the operations illustrated within this section can be disposal in compliance with the law and regu-
partially executed while the engine is assembled on the lations in force.
vehicle, depending on the room available for access to the
engine and on the equipment application as well.
NOTE
With regard to the engine disassembly opera-
tions, please apply for information consulting
the specific manual. All operations of engine
disassembly operations as well as overhaul
operations must be executed by qualified
engineers provided with the specific tooling
and equipment required.
The following information relate to the engine overhaul

operations only for what concerns the different compo-
nents customising the engine, according to its specific
duties. Only for turbocompressed versions
NOTE −disassemble lubrication oil exhaust pipe from the

For specific application exigencies, some turbo-blower:
units can be assembled to the engine in dif- Underneath the turbo-blower loosen the two screws
ferent positions. (2), loosen the screw (3) fixing the pipe throughout the
stop collar (4) fixing the block; finally loosen and
Within ”General overhaul” section, all the operations of remove the union (5) fromthe block; plug the pipe
engine block overhaul have been contemplated. Therefore ends and the exhaust of the turbo-blower.
the abovementioned section is to be considered as follow-
ing the part hereby described.
Engine setting operations for the assem-

bly on turning stand
Figure relevant to turbocompressed versions
In order to apply the brackets 99361037 to the engine
block to fix it on to the stand 99322205 for the overhaul, it
is necessary to perform the following operations:
On the right hand side:
−disassemble pipes (1) from the union (2) fitting the
lubrication oil filter (assembled on the opposite side):
unlock the nuts fixing the pipes (1) and remove them
from the union (2); drain the oil eventually still inside
the pipes and plug them properly in order to avoid
impurity inlet.

−Disassemble the starter; −Assemble the second bracket 99361037 throughout the
Properly hold the starter (1) and loosen the two fixing screw-threaded ports (1).
screws (2); assemble the bracket bearing 99361037 −Lift the engine using the rocker arm 99360595 and put
using the four screw threaded ports (3). −Drain the oil through the cap underneath the plug.
NOTE
Warning: avoid contact of engine oil with the
skin:
in case of skin contamination, rinse in run-
ning water. Engine oil is highly pollutant:
provide for disposal in compliance with the
law and regulations in force.
On the left hand side:

−Disassemble oil filter (1) and bracket aswell (for ver-
sions with engine oil filter not directly assembled on to
the exchanger);
Using tool 99360076 operate on oil filter;
Loosen the screws (3) removing the bracket together
with the filter bearing (4 and 5).
NOTE
Warning: the oil filter contains inside aprx. 1
kg. of engine oil. Disassembly of application components
Provide tank with sufficient capacity to con-
For turbocompressed versions
tain the liquid.
Warning: avoid contact of engine oil with the proceed disassembling the supercharger:
skin: in case of skin contamination rinse in
−loosen the fixing nut (1) and remove the lubrication
running water.
pipe from the supercharger. Analogously carry out the
Engine oil is highly pollutant: provide for dis-
same operation on the other end of the pipe and
posal in compliance with the law and regula-
remove it from the upper part of the heat exchanger.
tions in force.
−Loosen the screw nuts fixing the supercharger on the
exhaust manifold.
−Remove the oil level rod together with guide pipe (2);
−Hold up the supercharger and after lifting it remove
(loosen the guide pipe disassembling from the block);
the gasket.
properly pipe the screw-threaded port to avoid inlet of
foreign matters.

−Place a container under the fuel filter and screw out −Disconnect the LDA pipe (1) from the head and from
the condense drain faucet underneath said filter. Carry the feed pump. Pipe the ends of the pipelines as well as
out complete drainage of the fuel contained therein. the feed pump and the engine head.
−Screw out completely the faucet and, using equipment
99360076 disassemble oil filter (1).
−Disconnect fuel pipelines (2 and 3) respectively from
priming pump to filter bearing and from this last one
to the feed pump.
−Remove the fuel filter bearing (4) from the bracket
fixed to the engine head.
NOTE
To disconnect fuel pipelines (2 and 3, Figure
8), in low pressure from the relating pipe fit-
tings, it is Necessary to press the locking fas-
tener (1) as shown in picture B.
After having disconnected the pipeline, reset
the locking fastener (1) in lock position as
shown in. picture A, to avoid any possible
deformation of the fastener itself.

−Disconnect the pipelines (1) and (2) that provide feed −Loosen the two fixing screws and disassemble priming
and fuel recovery between pump and injectors; screw pump.
out the nuts fixing the pipes to the pumping elements;
loosen the fuel recovery pipe collar on the injection
pump; operate on the nuts assembled to the injectors
and loosen the screws fixing the fuel recovery pipe-
line; loosen the screws holding the fixing brackets of
such pipelines (1,6, and 7, Figure 11); pipe the pipe-
line ends.
−Disassemble the injectors and remove them from their
slot: remove the gaskets.

−Remove tappet caps: −Disassemble rocker arm bearings; loosen the two fix-
Loosen the four fixing screws (1) and lift the caps (2); ing screws (2) and remove the complete rocker arm-
remove the gaskets. bearing; withdraw tappet rods. Repeat the operation
for all the remaining rocker arm bearings.
NOTE
−Disassemble water temperature transmitter (1).
In the picture, the front cap has already been
removed.
On the central cap there is a blow-by valve
for the lubrication oil vapours.
All the gaskets shall always be replaced dur-
ing assembly.
For applications with automatic belt stretcher

−Remove the belt tightener(2).
−Remove the belt (4) of the ancillary members by act-
ing on the alternator fixing bracket (1).
−Remove the alternator (3), the water pump (6), the fan
pulley (5) and the jockey pulley (7).
−Remove the pulley support (8).
−Remove the engine block cooling system connector
(3).
−Disassemble suction and exhaust manifolds: loosen

the 8 screws (1) fixing the suction manifold plate to
the cylinder head (two of them have already been
screwed-out since fixing the pipe brackets to the injec-
tors); from the exhaust manifold side;
loosen the (2) fixing screws; remove the gaskets.

−Remove belt tensioner (3). −Disassemble thermostat unit; loosen the three fixing
−Remove belt (5) for auxiliary members operating on screws (1) and disassemble the thermostat unit (2)
bracket (1) securing the alternator. together with the bracket (3); remove the gasket (4)
−Remove alternator (2), water pump (4), fan pulley (7) and the thermostat (5).
and guide pulleys (6). −Assemble the bracket in the original position fixing
−take support off pulley (8). itwith the screws of the thermostat unit.
−Properly hold the alternator (1) separating it from its

bearing by loosening the screw (2); remove screw nut
For applications with traditional belt stretcher and washer.
−Loosen screw (1) and relevant nut on belt stretcher

bracket (3).
−Loosen screw (2, Figure 20) in order to slide out
POLY-V belt (2).
−Remove the belt stretcher bracket (3).
−Disassemble the driven pulleys and the guide rollers.

−Loosen the screws (1) and withdraw the alternator −Disassemble cylinder head;
bearing (2). loosen the screws (1) and (2) fixing the cylinder head
(3); hook the brackets with metal ropes and, through-
NOTE
out a hoist withdraw cylinder head from the block.
The shape and the dimensions of the support
of the alternator vary according to the use of
the engine. The relevant pictures provide a
general trace of the intervention that is to be
carried out. The procedures described are
always applicable.
−Use the tool 99360339 (2) to operate on the flywheel

cover box (1) in order to block flywheel rotation (3).
(Utilise starter holding down studs and fixing screw-
nuts).
−Loosen the flywheel fixing screws (4) to engine drive
−Loosen the screws (4) and disassemble the oil pres- shaft.
sure/temperature sensor (3) (if fitted).
−Loosen the screws (1) and disassemble the oil filter/ NOTE
heat exchanger bearing (2), interlayer plate (6) and In some versions there is provided 99360351
relating gaskets. tool checking the flywheel.
−Disassemble oil level sensor (5) (whether provided).
−Disassemble injection pump (see specific procedure)
and the power take-off underneath.

−- Loosen the screws (1) and disassemble the pulley (2). −Using the specially provided tie rod (3) for the tool
99363204 and the lever (4), withdraw the external
holding ring (2) from the front cover (1).
−Loosen the screws (1) and remove the front cover (2).
−Remove the engine drive shaft fixing ring from the
front cover. Use the tool 99340055 (4) to operate on NOTE
the front tang (2) of the engine drive shaft. Throughout Take note of the screw (1) assembly position,
the tool guide ports, drill the internal holding ring (1) since the screws have different length.
using Ø 3,5 mm drill for a 5mm depth. Fix the tool to
the ring tightening the 6 screws specially provided.
Proceed withdrawing the ring (1) tightening the screw
(3).
−Loosen the screws (1) and remove oil pump (2).
00(D)-3-10 • DUTY - INDUSTRIAL APPLICATION

Copyrighted Material SM 751, Dec ’06
−Screw out the opposite screws (1) fromthe portswhere −Remove the flywheel cover box fixing ring using the
the withdrawal pins shall be introduced (see picture tool 99340056 (3) to operate on the back tang (5) of
following). the engine drive shaft. Throughout the tool guide
−Loosen remaining flywheel fixing screws (3) to the ports, drill the internal holding ring using Ø 3,5 mm
engine drive shaft (4). drill for a 5mm depth.
−Remove the flywheel block tool (2). −Fix the tool 99340056 (3) to the ring (1) tightening the
6 screws specially provided (4).
−Proceed with drawing the ring (1) tightening the screw
(2).
−Using the specially provided tie rod (3) for the tool
99363204 and the lever (4), withdraw the external
holding ring of the flywheel cover box.
−Screw up two medium length screws in the ports (4) to

sling the flywheel with a hoist.
Throughout two guide pins (2) previously screwed up
into the engine drive shaft ports (3) control the engine
flywheel withdrawal by means of a hoist.
−Loosen the screws (2) and remove the flywheel cover

box (1).
NOTE
Take note of the screw (1) assembly position,
since the screws have different length.
SM 751, Dec ’06 DUTY - INDUSTRIAL APPLICATION • 00(D)-3-11

−Turn the engine upside-down. Version with suction rose type B

−Loosen the screws (2), disassemble the plate (3) and
−Remove the screws (1) and (4) and disassembled the
remove the oil pan (1).
suction rose (5).
NOTE −Remove the screws (2) and disassemble the stiffening
The shape and dimensions of the pan and of plate (3)
the rose pipe may vary according to the
engine application. The relating illustrations
provide general guidelines of the operation to
be performed. The procedures described are
applicable anyway.
By means of pin (1) lock the additional masses (2) in the

P.M.S. Loosen the fixing screws (3) and remove the addi-
tional masses (2).
Version with suction rose type A

−Loosen the screws (1) and disassemble the oil suction
rose pipe (3).
−Loosen the screws (2) and remove the stiffening plate
(4).

−Loosen the screws (1) and disassemble the gear Version with reduced distribution
fromthe camshaft (2).
−Loosen the screws (2) and remove the flywheel cover
box (1).
NOTE
−Remove the gear (1) transmitting motion to the igni-

tion pump and the relevant support.
−Loosen the screws (2) and disassemble the timing

gearbox (1).
NOTE

−Remove the screws (1) and disassemble the gears (3) −Reassemble to box (1) to the engine block.
and (4) from the camshaft (2). −Tighten the fixing screws in the same position as found
out during disassembly and fix the screws to the lock-
ing couples listed here below, following the order as
shown in the picture.
Screws M12 ........................ 65~89 Nm
Screws M8 ......................... 20~28 Nm
Screws M10 ....................... 42~52 Nm
NOTE
Before assembly, always check that the
threads of the ports and of the screws have no
evidence of tear and wear nor dirt.
Installation of rear components

−Accurately clean the timing gearbox (1) and the
engine block.
NOTE
It is necessary and essential to clean the sur-
face to be sealed in order to achieve excellent
tight seal.
Apply sealing LOCTITE 5205 on the box in
order to form a kerbstone of a few mm.
Diameter.
It must be uniform (no crumbs), with no air
blisters, thinner or irregular zones.
Any eventual imperfection shall be correct as
soon as possible.
Avoid using material in excess to seal the
joint. Too much sealing material would drop
out on both sides of the joint and obstruct −With a penmarker,mark the tooth (1) of the driving
lubricant passages. gear assembled to the engine drive shaft with (2) ()
timing notch.
Couplings must be assembled within 10 min-
utes after completing the sealing operation. NOTE
Screw up two pins to facilitate operation of
engine drive shaft rotation.

−Orient engine drive shaft (3) and camshaft (4) taking −- Tighten the screws (1) fixing the gear to the camshaft
care that in phase of assembly of the driving gear (2) (3) and lock them to the prescribed couple.
to the camshaft, the notches marked on the gears (1
and 2) shall match.
−Position comparator (1) on timing system gear (2) and

check that the clearance between gears (2) and (3) is
within 0.076 0.280 mm range.

NOTE NOTE
It is necessary and essential to clean the sur- Before assembly, always check that the
face to be sealed in order to achieve excellent threads of the ports and of the screws have no
tight seal. evidence of tear and wear nor dirt.
Diameter. It must be uniform (no crumbs),
with no air blisters, thinner or irregular
zones.
Any eventual imperfection shall be correct as
soon as possible.
out on both sides of the joint and obstruct
lubricant passages.
Couplings must be assembled within 10 min-
utes after completing the sealing operation.
−Apply to engine drive shaft rear tang (6), the detail (5)
of the tool 99346252, fix it tightening the screws (4)
and key the new holding ring on it (3).
−Place detail (1) on detail (5), tighten the screw nut (2)
until complete assembly of the fixing ring (3) into the
flywheel cover box (7).
−Reassemble the box (1) to the engine block, tighten the

fixing screws in the same position as found out during
disassembly and fix the screws to the locking couples
listed here below, following the order as shown in the
picture.
Screws M12 ....................... 75 ~ 95 Nm
Screws M10 ....................... 44 ~ 53 Nm
NOTE
In case of engine coupling with mechanical
gears in presence of friction, verify surface
status of the flywheel and eventually work it
out to maintain rated engine flywheel thick-
ness, which is 49,6 ± 0,13 mm.

−- Check the conditions of the rim tooth (2). Whether on the latter, the marks printed on the gears (1 and 2)
tooth break or excessive wear is detected, disassemble coincide.
the rim from the engine flywheel using a commonwil-
low and replace with a new one, previously heated to
150 ℃ degrees for 15 ~ 20; seconds; bevelling must be
made towards engine flywheel direction.
−Place the dial gauge (1) on the timing gear (2) and
check that the slack between the gears (2) and (3) is
included in the range between 0,076 ~ 0,280 mm.
Installation of rear components with reduced

distribution
−With a penmarker,mark the tooth (1) of the driving
gear assembled to the engine drive shaft with (2) ()
timing notch.
NOTE
Screw up two pins to facilitate operation of
engine drive shaft rotation.
−Fit the screws (1) fastening the gears (2) to the cam-
shaft (3) and tighten them to the prescribed pair.
−Orient the engine drive shaft (3) and the camshaft (4)
ensuring that while assembling the conveyed gear (1)

−Spline the gear (1) transferring motion to the ignition Couplings must be assembled within 10 min-
pump. utes after completing the sealing operation.
−Fit the power take-off gear (2) (if available) into the
specially provided housing and fasten the screws (1), −Re-assemble the box (1) to the engine basement.
−Tighten the fastening screws (2) to the same position
detected before disassembly.
NOTE
NOTE
It is necessary and essential to clean the sur-
face to be sealed in order to achieve excellent
tight seal.
Diameter. It must be uniform (no crumbs),
with no air blisters, thinner or irregular −Apply to the rear tongs hold (3) of the engine drive
zones. shaft the part (6) of the tool 99346253, fix it with the
Any eventual imperfection shall be correct as screws (1) and spline the new tight ring to it (2).
soon as possible.
out on both sides of the joint and obstruct
lubricant passages.

−Place the part (5) on the part (6), tighten the nut (4) on the flywheel cover box (1) to block engine flywheel
until tight ring assembly (2) into the flywheel box is rotation.
completed.
Tighten the engine flywheel (1) fixing screws (2) in two

phases:
−1st phase; tightening by means of dynamometric
wrench to couple 30 ± 4 Nm;
−2nd phase, 60 ° ± 5 ° angle dwell
Flywheel installation
NOTE
−Screw up two hooks or trail rings in the flywheel (1) Angle dwell shall always be performed using
threaded ports (4) for handling . 99395216 tool.
−Using a hoist, handle the flywheel to place it in its Before assembly, always check that the
housing inside the flywheel cover box. threads of the ports and of the screws have no
−Screw up to pins (2) having appropriate length, in the evidence of tear and wear nor dirt..
shaft ports (3) and using them as guide, assemble the
engine flywheel (1) properly placing it inside the fly-
wheel cover box.
Installation of front components

−Tighten the screws (4) fixing the engine flywheel (3) −Assemble oil pump (1).
to the engine shaft. Use tool 99360339 (2) to operate

−Tighten fixing screws (2) and lock themto the pre- −Remove the fixing ring (2) from the front cover (1),
scribed couple. accurately clean the plug surface.
Fi
gure54
70220
−Accurately clean the contact surface of engine block
−Apply to the water pump (1) a new fixing ring (2). and apply sealing LOCTITE 5205 on it in order to
form a uniform and continuous kerbstone with no
crumbs.
−Assemble the water pump (1).

−Tighten the screws (2) and lock them to the prescribed
couple. −Assemble the front cover (2) to the block and tighten
the screws (1) fixing them to the prescribed couple.

−Apply on engine drive shaft front tang (6) the detail −Assemble the plate (3), the suction rose (5) and tighten
(4) of the tool 99346252, fix it with the screws (5) and the fixing screws (1, 2 and 4) to the prescribed torque.
key the new holding ring on it (7).
−Place the detail (2) on the detail (4), screw-up the
threaded nut until carrying out the complete assembly
of the holding ring (7) to the front cover.
−Assemble the plate (1), the rose pipe (2), tighten the
fixing screws (3) and fix them to the prescribed cou-
ple.

Assembly of additional masses

Fit the additional masses (2) and tighten the screws (3) on
the engine block.
Remove the lock pin (1) of the additional masses.
Timing of additional masses

Version with reduced distribution
Match the signs (A) engraved on the gears for timing,
insert the pin in the hole (B) on the balancing mass.

−Provide for newgasket replacement (1) of the oil pan −Assemble the pulley (1) to the engine drive shaft , and
(2). the distance ring (3).
−Tighten the fixing screws (2) and lock them to the 68
NOTE
± 7 Nm couple.
The pictures illustrating the pan and of the
rose pipe may not correspond to the ones of
your model. However the procedures
described are applicable anyway.
−Assemble oil pan (1), apply the plate over it (2).

Tighten the screws (2) and lock them to the prescribed
couple.
NOTE
threads of the ports and of the screws have no −Assemble the following elements to the block: new
evidence of tear and wear nor dirt. gasket (1), heat exchanger (2), new gasket (3), oil filter
bearing (4).
Tighten the screws (5) and lock them to the prescribed
couple.
NOTE

−- Lubricate the fixing ring (2) using engine oil and NOTE
place it on the oil filter (3). Before assembly, always check that the
−- Manually start the oil filter (3) on the bearing union threads of the ports and of the screws have no
(1) until counter-boring, further screw up the oil filter evidence of tear and wear nor dirt.
(3) by 3/4 turn.
−- Place a new fixing ring on the block housing (6).
−- Apply, (if needed) new fixing ring on the oil temper-
ature/pressure sensor (4) and assemble it to the bearing
(1) tightening the fixing screws to the prescribed cou-
ple.
NOTE
In some applications, the bearing of the
exchanger shall be assembled to a screw
threaded union connected to the filter on the
opposite side of the engine, throughout two
pipelines (see picture 2).
−Connect the alternator (1) to the support.

−Tighten the screw without locking it (2).
NOTE
The shape and the dimensions of the alterna-
tor support vary according to the use of the
engine. Therefore the relevant pictures pro-
vide a general guideline of the intervention −Place the gasket (1) over the block.
that is to be carried out. However the proce- The choice of the gasket’s thickness shall be made in
dures described are applicable. consideration of the cylinder protrusion measured with
respect to the block’s upper surface.
−- Assemble the alternator bearing (1) ensuring that the
NOTE
pins (3 and 4) are against the engine block.
−- Tighten the screws (2) and lock them to the pre- Verify that the engine block stand is clean.
scribed couple. Do not grease the gasket. It is recommended
to keep the gasket inside packaging until
assembly to the cylinder head.
Gasket assembly shall be made following the
direction of wording printed on the gasket

itself so that this will be readable as indicated M12 x 180 ...............70 Nm + 180 deg’s
in the picture.
−Carry out the assembly of the rocker arms after previ-

ous check of the components..
−Place the head (3) over the block and insert screws (1)
and (2).
NOTE
If the valves have been removed from the
head, it is necessary to assemble them before
assembling the head itself on the engine
block.
Check the coupling surfaces of bearing and shaft: no evi-

dence of excessive wear shall be detected or damages.
Replace if necessary.
−Lubricate cylinder head bolts and install to head.

−Bolts must be torqued using stitching pattern starting
with the centre bolts and moving out. Bolts to be
torqued in stages: all bolts torqued to snug torque, then
90 degrees rotation for all bolts. Then a further 90
degrees for the M12 x 140 and M12 x 180.
M12 x 70 .................50 Nm + 90 deg’s
M12 x 140 ...............40 Nm + 180 deg’s

If unscrewed, check adjustment quota. −Tighten the screws (2) to the prescribed couple and
Tighten the screw-threaded nut (1) to the i 0.4 - 0.6 Nm assemble water temperature sensor (1).
couple.
Before executing assembly, check the Rocker Arm driving

rods: these shall not be deformed; the spherical ends in
contact with the Rocker Armadjustment screw and with Adjust the slack between rocker arms and valves using
the tappet (arrows) shall not present evidence of seizure socket wrench (1), point wrench (3) and feeler gauge (2).
orwear: in case of detection proceed replacing them. Correct slack is:
The rods driving the suction and exhaust valves are identi- −suction valves 0.25 ± 0.05 mm
cal and therefore interchangeable. −exhaust valves 0.50 ± 0.05 mm.
NOTE
In order carry out a quicker adjustment of
the working slack between rocker arms and
valves, proceed as following: Rotate the
engine drive shaft, balance the valves of cyl-
inder 1 and adjust the valves identified by
star symbol, as indicated in the following
table:
−Insert the tappet driving rods and the Rocker Arm unit. NOTE
Before using the fixing screws again,measure Rotate the engine drive shaft., balance the
themtwice as indicated in the picture, checking D1 and valves of cylinder 4 and adjust the valves
D2 diameters:
if D1 - D2 < 0,1 mm the screw can be utilised again;
if D1 - D2 > 0,1 mm the screw must be replaced;

identified by star symbol, as indicated in the In such case provide for replacement with
following table: new nods.
Cylinder No. 1 2 3 4
Suction * * - -
Exhaust * - * -
−Assemble injectors after having replaced the sealing

gasket (1).
NOTE
During assembly of injectors, verify that the
injector sphere is correctly positioned on the
head housing.
−Assemble exhaust manifold (1) providing new gaskets

(2).
NOTE
The illustration of exhaust manifold may be
not matching your model. Anyhow,
described procedure is applicable.
−Assemble cylinder covers (2) with the respective gas-

kets;
−Fit the seal nods and tighten the screws fixing them to
the prescribed couple.
NOTE
Always replace the gaskets using new ones.
Check the threads of the fixing screws: there
shall be no evidence of wear or dirt deposit. −Assemble thermostat unit (2) including thermostat (5)
Seal nods shall have no visible deformation. and gasket (4).

−Tighten the screws to the prescribed couple. For applications with traditional belt stretcher
NOTE −In order to connect the POLY-V belt carry out the
The screws (1) have been have been utilised operations described on page 8 vice versa.
to fix the bracket (3).
NOTE
Disassemble the bracket and reassemble
For belt stretching turn the alternator as
components from 1 to 5 as shown in the pic-
ture. indicated in the figure, tighten screw (1) and
The gasket must be new. the bolt that fixes the alternator to the sup-
port.
NOTE
If the old belt is to be reassembled examine it
carefully in order to see if there may be inci-
sions or evident signs of yielding.
−Assemble the pulley fan bearing tightening the screws

to the prescribed couple.
−Assemble the alternator tensioning bracket.
−Mount pulley (3) and secure it to support through
screws (2).
−Assemble the transmission pulley (1).
For applications with automatic belt tensioner
Assemble belt Poli-V (4) on the pulley (5) of the engine
shaft, on the jockey pulley (2), on the water pump (6) and
on the alternator (3), tighten (syn.: tension) the belt by
means of the automatic belt tensioner.

−Mount Poly-V belt (4) on pulley (7), engine shaft pul- −Also assemble the brackets (1) fixing the fuel pipe-
ley (5), guide pulleys (6), water pump (3) and alterna- lines to the injectors: use the same screws (2) fixing
tor (1); stretch the belt by operating on automatic belt the manifold plate as shown in the picture.
tensioner (2).
−Apply on the surface joining the suction manifold

plate (1) a sufficient coat of Loctite 5999 and provide.
fixing the screws to the prescribed couple.
−If the pipe (6) of the suction manifold plate (1) has
been removed, reassemble it after having fit a new
gasket (5).
−Tighten the screws (7) to the prescribed couple. −Assemble priming pump (1) providing new gasket and
tighten the screws (2) to the prescribed couple.
NOTE −Also assemble feed pump (see specific procedure) and
For the versions provided with heater, also the power take-off underneath.
assemble components (3) and (4).
NOTE
Pump mounting requires specific procedure
contained in this section.

−Assemble the pipes (1) and (2) providing fuel feed and −Fix the LDA pipeline (1) to the engine head and to the
recovery between pump and injectors; feed pump.
Screw up the locking nuts and tighten the screws fix-
ing the fuel recovery manifold; fix the pipes to the
injectors throughout the brackets previously assem-
bled.
−- Assemble the fuel filter bearing (4) to the bracket

fixed to the engine head.
−- Connect the fuel pipelines (2 and 3) respectively
from priming pump to filter bearing and from this last
one to feed pump.
−- Using 99360076 equipment assemble fuel filter (1).

NOTE −- Tighten the lubrication pipe fixing ring. Operate in

The filter shall be priory filled with fuel to the same way on the other end of the pipe. Connect it
facilitate feed system bleed operations. to the upper part of the heat exchanger.
To complete engine assembly it is necessary to remove it
from the turning stand.
−- Using rocker arm 99360595 hold the engine and
loosen the screws fixing the brackets to the turning
stand 99322205.
−- Disassemble the brackets from the engine after hav-
ing properly put it on a wooden bearing.
NOTE
To connect fuel pipelines (2 and 3, Figure 96)
in low pressure from the relating connection
unions it is necessary to press the locking fas-
tener (1) as shown in picture B.
After having connected the pipeline, reset the
fastener (1) into block position as shown in
picture A. Completion of the engine
On the right hand side:
−reassemble the pipes (1) from the union (2) to the
lubrication oil filter (placed on the opposite side):
tighten the pipe rings (1) and connect them to the
union
NOTE
In some cases, the oil filter (3) is directly
placed on the heat exchanger: in this case it
shall be assembled using tool 99360076.
For turbocompressed versions

proceed assembling the turbocharger:
−- Hold the turbocharger and place it on the exhaust
manifold after having interposed the gasket.
−- Screw up the fixing nuts of the turbocharger to the
exhaust manifold tightening them to the prescribed
couple.

For turbocompressed versions On the left hand side:

−Reassemble the lubrication oil exhaust pipeline (1) −Assemble oil filter (1) together with bracket (for the
from the turbocharger: from underneath the turbo- versions with engine oil filter not directly assembled to
charger tighten the two screws (2); tighten the screw the exchanger); tighten the screws (3) assembling the
(3) fixing the pipeline to the block throughout the fix- bracket (4) including filter bearing (5).
ing collar (4) to the block; finally tighten the union (5) Using tool 99360076 screw up oil filter;
to the block. −Assemble oil level rod togetherwith guide pipe (2).Fill
up engine oil.
−Install the engine on the machine (for installation
operations please apply to specific issue).
−Reassemble the starter; properly hold the starter (1)

and tighten the fixing screws to the prescribed couple.

Rotary feed pump disassembly and assembly The following procedure analyses this second hypothesis
since it is the more complex.
procedure
NOTE
This procedure prescribes that:
− The fuel pipelines (from pumping ele-
ments to injectors, bleeding recovery
pipes from injectors to pump, LDA pipe-
line and feed provided by priming pump)
shall all be disassembled.
− Electrical connection to feed pump shall
be disconnected.
− Accelerator cable shall be disconnected.
Engine versions with tool (99360330)
Disassemble the starter fromthe flywheel box and use tool
99360330 (2) to rotate the flywheel.
Find the top dead centre with the tool (99395097) -
False injector
Remove the rocker covers of the 1st cylinder; remove the
1st injector and place the tool (1) to set the 1st cylinder top
dead centre position (end-of-compression phase). Pre-
load the gauge.
The searched condition is obtained by rotating the engine
shaft properly until you find the maximum value on the
comparator and then checking that the intake and exhaust
valves are both closed.
Once PMS has been obtained, lock the flywheel by means
of tool 99360339 (Figure 104).
Engine versions with tool (99360339)

Disassemble the starter from the flywheel box (1) and use
tool 99360339 (2) to rotate the flywheel.
In case feed pump replacement is necessary, this shall be
supplied pre-set already as spare part.
On the other hand, in case the pump shall be disassembled
and reassembled later on without being repaired it will be
necessary to pr-set it while it is still assembled to the
engine and disassemble it only afterwards.
−Unscrew the side screw that locks the pump shaft par-
tially (1) and remove spacer (2). This must be kept on

a side (we recommend to fix it on the pump with a NOTE

wire or a clip). Hold the pump driving gear to avoid interfer-
−Tighten the lateral screw (1) blocking rotation of the ence or crawling during timing gear rotation.
pump shaft.
−Assemble the pump pre-set in its housing on the

−From timing side, remove the cover (2) loosening the engine, fitting the shaft into the gear port (not provided
screws (1) in order to have access to the union fixing with wrench).
nut (3) to the pump driving gear. −Tighten the fixing nuts (1) locking the pump flange in
−Loosen the fixing nut (3) and remove the relating the slot centre.
washer. NOTE
The gasket removed during pump disassem-
bly shall not be utilised again.
Always use original spare parts.
−From the pump side, loosen the fixing nuts (1) without
removing them in order to enable moving the pump
backwards using 99340035 extractor.
−Assemble the 99340035 extractor throughout the two
threaded ports (4, Figure 107) and withdraw the gear
from the pump shaft.
−Properly hold the feed pump and loosen completely
the fixing nuts.
−Withdraw the pump from the studs, together with the
gasket.
When the supply pump is to be assembled on the engine
the P.M.S. conditions at compression end stage cylinder
No. 1 must be carried out.

−On the timing side, throughout the specially appointed −With the injection pump inserted in relating seat and
port, fit the washer and screw up the fixing nut (3) to securing screws loosened, mount comparator
the pump shaft. Lock the nut to the 90-95 Nm couple. 99395603 (2) and 99395100 gauge tool (1), preloading
the rod by 2.5 mm.
−Rotate the engine derive shaft to shift from the condi-
tion of the first cylinder to TDC end of compression
phase. Reset the dial gauges and rotate the engine
drive shaft condition of the 1st cylinder to TDC in
phase of compression (see Figure 105).
From this position on the comparator applied on the
pump it must be possible to read the value listed on the
pumping element pre-lift table. Section 4.
−Rotate the pump in anti-clockwise direction if the
stroke is shorter or in clockwise direction if the stroke
is longer, until obtaining the stroke prescribed.
−Checking these conditions, lock the pump by tighten-
ing the relevant nuts to the prescribed pair.
−Loosen screw (1) that prevents pump shaft rotation

and insert spacer (2). Tighten screw (1)so that it locks
spacer (2): in this way the supply pump shaft will be
able to rotate freely.
−Assemble the cover (2, Figure 110) including gasket
and tighten the screws (1, Figure 110).
−Disassemble the flywheel rotation/locking tool
99360339 or 99360330; arrange the starting motor in
its seat.
−Connect all pipelines (from pumping elements to
injectors, bleeding recovery pipes from injectors to
pump, LDA pipeline and feed provided by priming
pump).
−Connect electrical connections to electro-magnets on
the hydraulic head and on KSB.
NOTE
In case pump removal has been carried out
while the engine was assembled, connect
acceleration cable.
Ignition pump control and timing

Feed system bleed procedure Power take-off disassembly and assem-

Version with A type fuel filter bly procedure
In case any operation has been executed on the compo- Where designed, there is a power take-off able to transmit
nents of the feed circuit, it is necessary to execute bleed- motion to different auxiliary parts.
ing of air within the system. Disassembly of such mechanism shall be executed as fol-
−Loosen the bleeder vent screw (3) on the fuel filter (1) lowing:
and keep working on the bleed lever of the priming −Loosen the two screws (3) and after having removed
pump (2). the cover (1) with a specially provided extractor, with-
−Continue executing this operation until when fuel draw the power take-off (2).
drains from the bleeder vent screw. −The two gaskets (4) shall be replaced in phase of reas-
−Tighten the bleeder vent screw (3). semble.
−Vary out the assembly fitting the power take-off in its
housing, providing new gasket and checking the
sprocket gear meshing.
−Assemble cover and gasket and tighten the screws to
the prescribed couple.
Version with B type fuel filter

−Disconnect the fuel pipe (1) of the filter and repeat
working on the drain lever (2) of the priming pump.
−Continue the operation until when fuel outflows.
−Connect the (1) to the filter.

Checks and controls

NOTE
The following tests shall be made after engine
assembly to the vehicle.
Preventively check that the liquid levels have
been correctly restored.
Start the engine, let it run at revolution regimen slightly

higher than idling and wait that the cooling liquid temper-
ature reaches the value enabling thermostat opening, then
check that:
−There is no water bleeding from the manifolds con-
necting engine cooling circuit pipelines and cabin
internal heating, eventually providing to further
tighten the locking rings.
−Carefully check the fuel connection pipes to the
respective unions.
−There is no oil leakage from the lubrication circuit of
the various pipelines connecting cover and cylinder
head, oil pan and bearing, oil filter and heat exchanger
as well as relating housings.
−There is no fuel leakage from fuel pipelines.
−There is no blow-by from pneumatic pipes (if pro-
vided).
−Verify correct working of the lighting leds of the dash-
board containing the tools as well as of the equipment
that was disconnected during engine disconnection.
−Check and blow by with care the engine cooling sys-
tem, carrying out frequent drainage.

ELECTRICAL EQUIPMENT
ELECTRICAL COMPONET LAYOUT (4 CYL. ENGINESWITH ROTARY POMP)
Below there are listed the electric components which are 4. Electromagnets assembled to feed pump:
present on NEF F4BE04--- and F4GE04--- engines. (A) on hydraulic head unit
(B) on KSB;
1. Cooling liquid temperature sensor;
5. Fuel heater;
2. Starter;
6. Oil pressure sensor;
3. KSB Water temperature sensor;
7. Resistance for cold start up (where provided for);
8. Alternator;
Cooling liquid temperature sensor Bulb side on engine: .......-40 ~ +140 ℃

Working tensions: ...........6 ~ 28 V
It is a component integrating a temperature sensor. Settings:
It is assembled to the engine head close to the thermostat 80 ℃ ..........................0.304 ~ 0.342 ㏀
unit and its duty is to detect engine cooling liquid temper-
ature.
Specifications:
Range of working temperatures:
Connection side ...............-40 ~ +150 ℃ for < 10 min.
00(D)-3-38 • ELECTRICAL EQUIPMENT Copyrighted Material SM 751, Dec ’06

20 ℃ ........................... 2.262 ~ 2.760 ㏀ KSBWater temperature sensor

-10 ℃ .........................8.244 ~ 10.661 ㏀
It is assembled to the cylinder head on the engine left hand
side.
Specifications:
Working tensions: 12 ~ 24 V
Electrical Power load: 2.5 A (induction)
5.0 A (resistance)
Setting: 32 ± 2℃ Contact opening
upon increasing temperature
22 ± 2 ℃ Contact closure
upon decreasing temperature
Starter
Starter is usually driven by starting unit placed on the
vehicle dashboard and provides positive tension to the
tele-switch assembled to the starter itself.
Specifications: BOSCH 3 kW - 12V
Electromagnets assembled to feed pump
SM 751, Dec ’06 Copyrighted Material ELECTRICAL EQUIPMENT • 00(D)-3-39

Oil pressure sensor Alternator

It is assembled to the block on the engine’s left hand side. It is place front view on the right hand side of the engine,
and is driven by tooth belt.
Specifications:
Specifications:
Working tensions: ............................12 ~ 24 V
Working tension: ..................... 12 V
Contact closure Current delivered: .................... 90A (at 6000 rpm)
upon lower pressure: ........................0.2 bar Absorption in stand-by: ........... ≤ 1mA
Contact opening Sense of rotation: ..................... clockwices
upon higher pressure: .......................0.9 bar
Fuel filter Pre-post heating resistor

On the fuel filter bearing there is the temperature sensor
It is a resistor assembled to the suction collector and is uti-
and the fuel filter heating resistor connection.
lised to heat the air during pre-post heating operations.
It is fed by a tele-switch usually placed very close to the
engine.
Specifications:
Working tension: 12 V
Maximum possible
air flow: 2 cc / min
(pressure 138 kPa)
00(D)-3-40 • ELECTRICAL EQUIPMENT Copyrighted Material SM 751, Dec ’06

Pre-post heating unit Operating temperature: ..........................-40℃ ~ 85℃

Maximum current in the GH line: .........0.3A
Legend
F= Fuse
R= Pre-post heating resistance
T= Remote control switch
GHC = Pre-post heating unit
Electrical diagram pin out

PIN Description
1 “Cold start” warning indicator light output
2 Not connected
3 Feedback signal input from pre-post heating resis-
tance (FB)
4 Started engine signal input (D)
5 Start-up signal input (50)
6 Pre-post heating resistance supply remote control
switch output (GH)
7 Supply positive (15)
8 Supply negative (31)
9 Not connected
10 Temperature analogue signal input (NTC)
This unit operates, bymeans of the remote control switch,

the pre-post heating resistance according to the engine
coolant temperature.
Features:
Nominal voltage: ................................... 12 V
Operating voltage: ................................. 7 V ~ 16V
SM 751, Dec ’06 Copyrighted Material ELECTRICAL EQUIPMENT • 00(D)-3-41

TROUBLESHOOTING
ANOMALY POSSIBLE CAUSE REMEDY NOTE
The engine does not start Battery flat or faulty. Check and recharge battery.
Replace battery if necessary.
Connections to battery termi- Clean, examine and tighten the nuts

nals corroded or loose. on the battery terminals. Replace
the cable terminals and the nuts if
excessively corroded.
Incorrect timing of injection Check and correctly time the injec- See your Iveco dealer.
pump. tion pump.
Deposits or water in the fuel Disconnect the hoses and clean Drain feed system.
tank. them using a jet of compressed air.
Dismantle and clean the injection
pump.
Remove water from tank and
refuel.
No fuel in tank. Refuel.
No power supply. Overhaul or replace the fuel or

transfer pump.
Air bubbles in the fuel lines Check the hoses to ensure that air is
or injection pump. in fact present and also check the
fuel pump.
Eliminate the air from the injection
pump by unscrewing the cap and
working the fuel pump by hand.
Faulty starter motor. Repair or replace the starter motor.
The engine does not start Fuel system clogged with Replace the fuel with fuel suitable
at low temperatures paraffin crystals forming due for use at low temperatures.
to the use of unsuitable fuel. Replace the fuel filters.
K.S.B. device for cold spark Check or replace the injection See your Iveco dealer.
advance control operating pump.
incorrectly.
00(D)-3-42 • TROUBLESHOOTING Copyrighted Material SM 751, Dec ’06

The engine cuts out. Idle rpm too low. Adjust with adjustment screw.
Irregular flow of injection Adjust flow. See your Iveco dealer.

pump.
Impurities or water in the fuel Disconnect the hoses and clean Drain feed system.
lines. them using a jet of compressed air.
Dismantle and clean the injection
pump. Remove water from fuel
tank and refuel.
Clogged fuel filter. Dismantle and replace if necessary.
Presence of air in the fuel and Check that the hoses are not
injection system. cracked or the unions loose.
Replace worn parts, remove the air
from the hoses and deaerate the
injection pump and fuel filter by
unscrewing the caps and working
the primer pump by hand.
Broken injection pump con- Replace the faulty parts.

trols.
Abnormal clearance between Adjust clearance by replacing

camshaft cams and tappets. shims.
Burnt, corroded or chalky Replace the valves, rectify or

valves. replace the cylinder head seatings.
The engine overheats Faulty water pump. Check the unit and replace if neces-
sary. Replace the gasket.
Malfunctioning thermostat. Replace the thermostat.

Fouling in coolant openings Wash following the standards spec-
in the cylinder head and cyl- ified for the type of descaling prod-
inder groups. uct used.
Water pump drive belt slack. Check and adjust the tightness of On applications provided
the belt. with automatic tensioner,
check corret worching of
such device.
Coolant level too low. Top-up radiator with coolant.
Incorrect engine timing. Check timing and tune correctly.
Incorrect calibration of injec- Correct the delivery rate of the See your Iveco dealer.
tion pump. pump on a bench so that the injec-
tion is at the specified rate.
Dry air cleaner blocked. Clean the air filter or replace if nec-
essary.
SM 751, Dec ’06 Copyrighted Material TROUBLESHOOTING • 00(D)-3-43

Engine operation is irreg- Incorrect timing of injection Check timing and correctly set
ular and lacks power pump. pump.
K.S.B. automatic cold Check or replace injection pump.

advance device malfunction-
ing.
Excessive piston wear. Check or replace injection pump.
Incorrect calibration of speed Check and correctly calibrate the See your Iveco dealer.
regulator. regulator.
Engine operation is irreg- Partial blockage of nozzles or Clean the nozzles of the atomisers
ular and lacks power faulty operation of injectors. using the appropriate tools and
completely overhaul the injectors.
Impurities orwater in the fuel Carefully clean the system and If necessary drain feed
and injection system. refuel. system.
Incorrect play between cam- Check and correct play

shaft cams and tappets.
Faulty turbocharger. Replace complete unit.
Air cleaner blocked. Clean or replace air cleaner.
Faulty operation of L.D.A. Check that the diaphragm is not See your Iveco dealer.
device perforated, that the counter spring
is suitable and that it has the correct
loading (check on test bench).
Check that there is adequate air
pressure inside the intakemanifold
in relation to the engine rpm under
full-load conditions.
Tie rods between accelerator Adjust the tie-rods so that the com-
pedal and regulation lever mand lever can be moved to the full
incorrectly adjusted. delivery position.
Engine running with Faulty operation of injectors. Replace all injectors.

abnormal knocking
Fuel lines blocked. Dismantle the hoses, clean them
and replace those that are seriously
dented.
Incorrect set-up of injection Correct the set-up of the pump so See your Iveco dealer.
pump. that injection occurs at the speci-
fied angle.

Engine running with Knocking of crankshaft caus- Rectify the pins of the crankshaft
abnormal knocking ing excessive play on one or and install smaller bearings.
more main or rod bearings or Replace the thrust halfrings.
excessive play on shoulders.
Crankshaft unbalanced. Check alignment of crankshaft.
Loosening of screws securing Replace the loosened screws and

flywheel. tighten all the screws to the speci-
fied torque.
Misalignment of rods. Replace the rods.
Noise from piston journals Replace the piston journal and/or

due to excessive play of pis- the piston and rod bushing.
ton hubs and in the rod bush-
ing.
Loose bushings in the rod Replace with new bushings.
seatings.
Noisy timing. Adjust the play between camshaft

cams and tappets and check that
there are no broken springs, that
there is no excessive play between
the valve stems and the valve
guides, tappets and seatings.
The engine smokes abnor- Excessive maximum pump Disconnect the pump and adjust See your Iveco dealer.
mally. Black or dark grey output. delivery in accordance with the
smoke. data given in the calibration table.
K.S.B. device out of calibra- Check operation by a tester and

tion or malfunctioning. adjust correctly as described in the
manual.
There is an excessive delay Correct the set-up.

on the injection pump.
SM 751, Dec ’06 Copyrighted Material TROUBLESHOOTING • 00(D)-3-45

The engine smokes abnor- The injection pump has an Correct the set-up.
mally. Black or dark grey excessive advance.
smoke.
The holes in the atomisers (or Replace the injectors with a series
some of them) are partially or of new injectors or clean and rec-
entirely blocked. tify the original ones using suitable
equipment.
Air cleaner blocked or deteri- Clean or replace the filter element.

orated.
Loss of compression in the Overhaul the engine or limit the
engine due to: interventions to the relative parts.
stuck or worn flexible rings;
worn cylinder liners;
valves deteriorated or badly
adjusted.
Unsuitable injectors, differ- Replace or calibrate the injectors.

ent types of injectors or
incorrectly calibrated.
Injection hoses with an Check conditions of the end or

unsuitable internal diameter, unions and where necessary replace
end of hoses pinched due to the hoses.
repeated blocking.
Blue, grey-blue, grey Excessive delay in injection Correct the set-up of the pump. See your Iveco dealer.
smoke tending to white. pump.
K.S.B. automatic cold Check or replace injection pump. See your Iveco dealer.
advance device malfunction-
ing.
Faulty injector. Replace the injector.
Leaking of oil from the pis- Overhaul the engine.

ton rings caused by glued or
worn rings or wearing of cyl-
inder liner walls.
Engine oil passing through Recondition the cylinder head.

the intake guides-valves fol-
lowing wearing of guides or
valve stems.
Engine too cold (thermostat Replace the thermostat.

blocked or inefficient).

MAINTENANCE PLANNING
MAINTENANCE PLANNING
Recovery
To ensure optimisedworking conditions, in the following pageswe are providing instructions for the overhaul control
interventions, checks and setting operations that must be performed on the engine at due planned dates.
The frequency of themaintenance operations is just an indication since the use of the engine is the main characteristic to
determine and evaluate replacements and checks.
It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary
maintenance and controlling operations even if not being included in the ones listed here below but that may be suggested
by common sense and by the specific conditions in which the engine is run.
Planning of controls and periodical intervention

Controls and periodical intervention Frequency (hours)
Visual check of engine .................................................................................................. Daily
Check presence of water in fuel filter or pre-filter ........................................................ Daily
Check of belt wear status ............................................................................................. -
Check and setting of tappet clearance .......................................................................... 4000
Replacement of engine’s oil and filter .......................................................................... 500
Replacement of fuel pre-filter ....................................................................................... 1000
Replacement of fuel filter ............................................................................................. 500
Replacement of belt ...................................................................................................... 1500
NOTE
The frequency of the maintenance operations is just an indication since the use of the engine is the main
characteristic to determine and evaluate replacements and checks.
The maintenance operations are valid only if the setter fully complies with all the installation prescrip-
tions provided by Iveco Motors.
Furthermore, the users assembled by the setter shall always be in conformance to couple, power and
number of turns based on which the engine has been designed.
Checks not included in maintenance planning-daily checks

It is a good habit to execute, before engine start, a series of simple checks that might represent a valid warranty to avoid
inconveniences, even serious, during engine running. Such checks are usually up to the operators and to the vehicle’s
drivers.
− Level controls and checks of any eventual leakage from the fuel, cooling and lubricating circuits.
−Notify the maintenance if any inconvenience is detected of if any filling is necessary.
After engine start and while engine is running, proceed with the following checks and controls:
−check presence of any eventual leakage from the fuel, cooling and lubricating circuits.
−Verify absence of noise or unusual rattle during engine working.
−Verify, using the vehicle devices, the prescribed pressure temperature and other parameters.
−Visual check of fumes (colour of exhaust emissions)
−Visual check of cooling liquid level, in the expansion tank.
SM 751, Dec ’06 Copyrighted Material MAINTENANCE PLANNING • 00(D)-3-47

MAINTENANCE PROCEDURES full compliance with the law and regulations

in force.
Checks and controls

Engine oil level check.
The check must be executedwhen the engine is discon-
nected and possibly cool.
The check can be made using the specially provided flexi-
ble rod (1).
Draw off the rod fromits slot and check that the level is
within the etched tags of minimum and maximum level.
Whether it should be difficult tomake the evaluation, pro-
ceed cleaning the rod using a clean cloth with no rag
grinding and put it back in its slot. Draw it off again and
check the level.
In case the level results being close to the tag showing
minimum level, provide filling lubrication of the engine’s
components.
Check of fuel system

The check must be executed both when the engine discon-
nected and when it is running.
The check operation consists in examining the fuel pipe-
lines running from the tank to the pre-filter (if provided in
the specific equipment), to the filter, to the injection pump
and to the injectors.
Cooling system check

The check must be executed both when the engine discon-
nected and when it is running.
Check the pipelines from the engine to the radiator, from
the expansion tank and vice-versa. Find out any blow-by,
To provide filling, operate through the upper top (1) or
verify the status of the pipes specially close to the holding
through the lateral top (2). During filling operation, the
strips.
tops must be removed as well as the rod in order to make
the oil flow easier”. Verify that the radiator is clean, the correct working of the
fan flywheels, the presence of any leakage from the con-
Some applications are equipped with a level transmitter nectors, from the manifold and from the radiating unit.
alerting dashboard instruments in case of insufficient
lubrication oil within the pan. NOTE
Due to the high temperatures achieved by the
NOTE system, do not operate immediately after the
The engine oil is highly polluting and harm- engine’s disconnection, but wait for the time
ful. deemed necessary for the cooling.
In case of contact with the skin, rinse well Protect the eyes and the skin from any even-
with water and detergent. tual high pressure jet of cooling liquid.
Adequately protect the skin and the eyes,
operate in full compliance with safety regula-
tions.
Disposal must be carried out properly, and in
00(D)-3-48 • MAINTENANCE PLANNING Copyrighted Material SM 751, Dec ’06

The density of the cooling liquid must be checked any Some applications are equipped with an automatic ten-
how every year before winter season and be replaced in sioner that provides correcting belt tensioning.
any case every two year.
Check of belts tear and wear status
NOTE
Carefully verify the belts surface in order to detect any
In case of new filling, proceed bleeding sys- sign of incision, crack, excessive wear in correspondence
tem, through the bleeds on the engine. of toothing; check end and surface grinding.
If bleeding of the system is not carried out,
serious inconvenience might be caused to the
engine due to the presence of air pockets in
! DANGER
the engine’s head. Danger: if the engine is switched off but is
still hot, unexpected motion of the belt may
Lubricating system check occur.
Wait for engine temperature cooling as a pre-
The check must be executed both when the engine
caution in order to avoid serious danger
disconnected and when it is running. injury.
Verify the presence of any oil leakage or blow-by from the
head, from the engine pan of from the heat exchanger. Check and setting of tappet clearance
NOTE Adjust clearance between rockers and valves using set-
The engine oil is highly polluting and harm- screw wrench (1), box wrench (3) and feeler gauge (2).
ful.
Clearance shall be as follows:
In case of contact with the skin, rinse well
with water and detergent. −intake valves 0.25 0.05 mm
Adequately protect the skin and the eyes, −exhaust valves 0.50 0.05 mm.
operate in full compliance with safety regula-
tions.
Disposal must be carried out properly, and in
full compliance with the law and regulations
in force.
Check of water presence within fuel filter or pre-filter

NOTE
The components of the system can be dam-
aged very quickly in presence of water or
impurity within the fuel.
Timely proceed operating on the pre-filter
(not available on the engine block) to carry
out the drainage of the water within the feed
circuit. NOTE
Fuel filter is equipped with pump screw-valve to drain the In order to more quickly perform the operat-
water eventually mixed with fuel (some applications of 6 ing clearance adjustment for rocker arms —
cylinders engines will be equipped with two fuel filters, valves, proceed as follows:
both provided with drainage. rotate the drive shaft, balance cylinder 1
valves and adjust the valves marked by the
Place a container underneath the filter and slightly loosen
asterisk as shown in the table:
the screw. Drain the water eventually contained in the fil-
ter’s bottom.
cylinder n. 1 2 3 4
Lock the screw (max 0.5 Nm locking couple) as soon as
fuel starts bleeding. intake - - * *
exhaust - * - *
Check of drive belt tensioning

Rotate the drive shaft, balance cylinder 4 valves and −Check the level through the dipsick until when the fill-
adjust the valves marked by the asterisk as shown in the ing is next to the maximum level notch indicated on
table: the dipsick.
cylinder n. 1 2 3 4 Whereas you replace the lubrication oil, it is necessary to

intake * * - - replace the filter.
According to the application the filter can be located in
exhaust * - * -
different positions: the following procedure is a valid
guide for all applications.
Oil motor and filter replacement −The filter is composed by a support and a filtering car-
tridge. For the cartridge replacement use the 9936076-
! WARNING tool.
Warning: We recommend to wear proper
protections because of high motor service ! WARNING
temperature. Warning: the oil filter contains inside a quan-
The motor oil reaches very high tempera- tity of oil of about 1 kg.
ture: you must always wear protection Place properly a container for the liquid.
gloves. Warning: avoid the contact of skin with the
motor oil: in case of contact wash the skin
Due to the several applications, the pan shape and the oil with running water.
quantity can change slightly. However, the following The motor oil is very pollutant: it must be
operations are valid for all applications. disposed of according to the rules.
Werecommend to carry out the oil drainage when themo-
tor is hot. −Replace the filtering cartidge with a new one and
screw manually until when the gasket is in contact
−Place a proper container for the oil collecting under with the support.
the pan connected with the drain plug. −Tigthen by means of the 99360076-tool of three fourth
−Unscrew the plug and then take out the control dipsick turn.
and the inserting plug to ease the downflowof the −Operate the motor for some minutes and check the
lubrication oil. level through the dipsick again. If it is necessary, carry
NOTE out a topping up to compensate the quantity of oil used
for the filling of the filtering cartridge.
The oil motor is very pollutant and harmful.
In case of contact with the skin, wash with
much water and detergent. Fuel filter replacement
Protect properly skin and eyes: operate
according to safety rules. NOTE
Dispose of the residual properly following the During this operation don’t smoke and don’t
rules. use free flames.
Avoid to breathe the vapors coming from fil-
−After the complete drainage, screw the plug and carry ter.
out the clean oil filling.
NOTE
NOTE
After filters replacement the supply equip-
Use only the recommended oil or oil having
ment deaeration must be carried out.
the requested features for the corrrect motor
functioning.
According to the applications the filters position and the
In case of topping up, don’t mix oils having
quantity can change.
different features.
If you don’t complywith theses rules, the ser- However the following operations are valid for all applica-
vice warrantyis no more valid. tions.
00(D)-3-50 • MAINTENANCE PLANNING Copyrighted Material SM 751, Dec ’06

−Drain the fuel inside the filter by operating the water For applications with automatic belt stretcher
release screw. Collect the fuel in a container without
−Unscrew the screws which fix the belt guard (2) to the
impurities.
support and dismount it.
−Unscrew the cartridge by using the 99360076-tool.
−Operate on the tightener (1) and withdraw the belt (3)
−Collect the eventual fuel inside the filtering cartridge.
from the alternator and water pumps from pulleys and
−Clean the gasket seat on the support and oil slightly
from the returns pumps.
the gasket on the new filtering cartridge.
−Replace the worn belt with a new one.
−Screw manually the new filtering cartdrige until when
−Place the belt on the pulleys and the guide rollers.
the gasket is completely on its seat.
−Place the automatic tightener in order to key the belt in
−Tigthen through the 99360076-tool at 10-5 Nm torque.
the functioning position.
Alternator belt replacement
−Further adjustments are not required.
Due to several applications the belt run can change very-
much.
We describe the replacement of a belt mounted on a 4-cyl-
inders motor with traditional belt tension and a 6-cylin-
ders motor with an automatic screw coupling.
! WARNING
Warning: with switched off motor (but still
hot) the belt can operate without advance
notice.
Wait for the motor temperature lowering to
avoid very serious accidents.
For applications with traditional belt stretcher

−Loosen screw (1) and the relevant nut on belt stretch-
ing bracket (3).
−Loosen the bolt that fixes the alternator to the support.
−Fit the new belt on the pulleys and guide rollers.
−Stretch POLY-V belt (2).
−Lock screw (1) and the bolt that fixes the alternator to
the support
−Run the engine for a few hours and check proper belt
stretching.

NOTE :

Section 4
OVERHAUL AND TECHNICAL SPECIFICATIONS
SM 751, Dec ’06 OVERHAUL

Copyrighted AND TECHNICAL SPECIFICATIONS • 00(D)-4-1
Material
00(D)-4-2 • OVERHAUL AND TECHNICAL SPECIFICATIONS


Material


Material


Material
INJECTION PUMP PUMPING ELEMENT PRE-LIFT TABLE

Technical Code Commercial Code Pre-lift (mm)
4 CYLINDER ENGINES F4BE0454A*D601 1 ± 0.05
F4BE0454B*D601 1 ± 0.05
F4BE0454B*D602 1 ± 0.05
F4BE0484D*D608 1 ± 0.05
F4BE0484E*D601 1 ± 0.05
F4BE0484E*D602 1 ± 0.05
F4BE0484E*D605 1 ± 0.05
F4BE0484E*D607 1 ± 0.05
F4BE0484F*D606 1 ± 0.05
F4GE0404A*D6.. N45 MNA - MSA 1.15 ± 0.05
F4GE0404B*D6.. 1.15 ± 0.05
F4GE0454A*D6.. N45 MNS - MSS 1 ± 0.05
F4GE0454B*D6.. 1 ± 0.05
F4GE0454E*D6.. 1 ± 0.05
F4GE0454G*D6.. 1 ± 0.05
F4GE0454H*D6.. 1 ± 0.05
F4GE0484C*D650 1 ± 0.05
F4GE0484C*D6.. N45 MNT - MST 1 ± 0.05
F4GE0484G*D6.. N45 MST 1 ± 0.05
NOTE The following operations are relating to the 4 cylinders

INJECTION PUMP CALIBRATION engine but are analogously applicable for the 6 cylinders.
Overhaul and calibration interventions are Remove the screws (1) fastening the connecting rod caps
up to BOSCH assistance network. (2) and remove them.
The contract technical specification contain-
ing the data to calibrate thepump at the- Withdrawthe pistons including the connecting rods
benchis identified by the code shown on fromthe top of the engine block.
injection pump body and is available at NOTE
BOSCH technical assistance network.
Keep the half-bearings into their housings
Otherwise, refer to IVECO MOTORS Tech-
since in case of use they shall be fitted in the
nical Assistance Service.
same position found at removal.
ENGINE OVERHAUL
ENGINE REMOVAL AT THE BENCH

The following instructions are prescribed on the under-
standing that the engine has previously been placed on the
rotating bench and that removal of all specific components
of the equipment have been already removed as well. (See
Section 3 of the manual herein).
The section illustrates therefore all the most important
engine overhaul procedures.

Remove the screws (1) and the main bearing caps (2). Remove the main half-bearings (1).
Remove the screws (2) and remove the oil nozzles (3).
The second last main bearing cap (1) and the relevant sup-
port are fitted with shoulder half-bearing (2).
NOTE Remove the screws (1) and disconnect camshaft (3)
retaining plate (2).
Take note of lower and upper half-bearing
assembling positions since in case of reuse NOTE
they shall be fitted in the same position found Take note of plate (2) assembling position.
at removal.
Withdraw carefully the camshaft (1) from the engine

block.
Use tool 99360500 (1) and hoist to remove the output
shaft (2) from the block.

Material
Withdraw the tappets (1) from the engine block. Measurements shall be performed on each cylinder, at
three different heights in the barrel and on two planes per-
pendicular with each other: one parallel to the longitudinal
axis of the engine (A), and the other perpendicular (B).
Maximum wear is usually found on plane (B) in corre-
spondence with the first measurement.
Should ovalisation, taper or wear be found, bore and grind
the cylinder barrels. Cylinder barrel regrinding shall be
performed according to the spare piston diameter over-
sized by 0.5 mm and to the specified assembling clear-
ance.
REPAIR OPERATIONS(CYLINDER
UNIT)
Checks and measurements

Once engine is disassembled, clean accurately the cylin-
der-block assembly. s
Use the proper rings to handle the cylinder unit.

The engine block shall not show cracks.
Check operating plug conditions and replace them in case
of uncertain seal or if rusted.
Inspect cylinder barrel surfaces; they shall be free from-
seizing, scores, ovalisation, taper or excessive wear.
Inspection of cylinder barrel bore to check ovalisation,
taper and wear shall be performed using the bore dial
gauge (1) fitted with the dial gauge previously set to zero
on the ring gauge (2) of the cylinder barrel diameter.
NOTE
Should the ring gauge be not available, use a
micrometer for zero-setting.

NOTE Checking head supporting surface on

In case of regrinding, all barrels shall have cylinder unit
the same oversize (0.5 mm).
When finding the distortion areas, replace the cylinder
Check main bearing housings as follows: unit.
−fit the main bearings caps on the supports without Planarity error shall not exceed 0.075 mm.
bearings;
Check cylinder unit operating plug conditions, replace
−tighten the fastening screws to the specified torque;
−use the proper internal gauge to check whether the them in case of uncertain seal or if rusted.
housing diameter is falling within the specified value.
Replace if higher value is found.

Material
TIMING SYSTEM if they show any traces of seizing or scoring replace the
camshaft and the bushes.
Camshaft
Camshaft pin and cam surfaces shall be absolutely
smooth;
Checking cam lift and pin alignment BUSHES

Set the camshaft on the tailstock and using a 1/100 gauge Camshaft bushes (2) shall be pressed into their housings.
set on the central support, check whether the alignment Internal surfaces must not show seizing or wear.
error is not exceeding 0.04 mm, otherwise replace the Use bore dial gauge (3) to measure camshaft front and
camshaft. rear bush (2) and intermediate housing (1) diameter.
Measurements shall be performed on two perpendicular
Check camshaft (2) pin diameter using micrometer (1) on
axes.
two perpendicular axes.

Bush replacement Tappets

To replace front and rear bushes (1), remove and refit
them using the beater 99360362 (2) and the handgrip
99370006 (3).
NOTE
When refitting the bushes (1), direct them to
make the lubricating holes (2) coincide with
the holes on the block housings.

Material
Fitting tappets — camshaft Check camshaft end float (1).

It shall be 0.23 ± 0.13 mm.
Lubricate the tappets (1) and fit them into the relevant
housings on the engine block.
Fit nozzles (2) and tighten the fastening screws (1) to the
specified torque.
Lubricate the camshaft bushes and fit the camshaft (1)
taking care not to damage the bushes or the housings.
OUTPUT SHAFT
Set camshaft (3) retaining plate (1) with the slot facing the Measuring journals and crankpins
top of the engine block and the marking facing the opera-
tor, then tighten the screws (2) to the specified torque. Grind journals and crankpins if seizing, scoring or exces-
sive ovalisation are found. Before grinding the pins (2)
measure them with a micrometer (1) to decide the final
diameter to which the pins are to be ground.
NOTE
It is recommended to insert the found values
in the proper table.
See Figure 27.
Undersize classes are:

NOTE
Journals and crankpins shall always be
ground to the same undersize class.

Journals and crankpins undersize shall be For undersized crankpins and journals: let-
marked on the side of the crank arm No.1. ters MB
For undersized crankpins: letter M
For undersized journals: letter B

Material

Replacing oil pump control gear Finding journal clearance

Check that gear toothing (1) is not damaged or worn, oth- Refit the output shaft (2).
erwise remove it using the proper puller (3). Check the backlash between output shaft main journals
When fitting the new gear, heat it to 180℃ for 10 minutes and the relevant bearings as follows:
in an oven and then key it to the output shaft.
−clean accurately the parts and remove any trace of oil;

−position a piece of calibratedwire (3) on the output
shaft pins (4) so that it is parallel to the longitudinal
axis;
Fitting main bearings −fit caps (1), including the half bearings (2) on the rele-
vant supports.
NOTE
Refit the main bearings that have not been
replaced, in the same position found at
removal.
Main bearings (1) are supplied spare with 0.250 — 0.500

mm undersize on the internal diameter.
NOTE
Do not try to adapt the bearings.
Clean accurately the main half bearings (1) having the

lubricating hole and fit them into their housings.
The second last main half bearing (1) is fitted with shoul-
der half rings.

Material
Tighten the pre-lubricated screws (1) in the following −Remove caps from supports.
three successive stages: The backlash between the main bearings and the pins is
found by comparing the width of the calibrated wire (2) at
−1st stage, with dynamometric wrench to 50 ± 6 Nm.
−2nd stage, with dynamometric wrench to 80 ± 6 Nm. the narrowest point with the scale on the envelope (1) con-
taining the calibrated wire.
The numbers on the scale indicate the backlash in mm.
Replace the half bearings and repeat the check if a differ-
ent backlash value is found. Once the specified backlash
is obtained, lubricate the main bearings and fit the sup-
ports by tightening the fastening screws as previously
described.
−3rd stage, with tool 99395216 (1) set as shown in the

figure, tighten the screws (2) with 90 ° ± 5 ° angle.
Checking output shaft shoulder clearance

This check is performed by setting amagnetic-base dial
gauge (2) on the output shaft (3) as shown in the figure,
standard value is 0.068 to 0.41.
If higher value is found, replace main thrust half bearings
of the second last rear support (1) and repeat the clearance
check between output shaft pins and main half bearings.

CONNECTING ROD — PISTON Remove split rings (1) from piston (2) using pliers
99360183 (3).
ASSEMBLY
NOTE
Pistons are supplied spare with 0.5 mm over-
size.
Piston pin (1) split rings (2) are removed using a scriber
(3).

Material
Pistons(Measuring piston diameter) The clearance between the piston and the cylinder barrel
can be checked alsowith a feeler gauge (1) as shown in the
Using a micrometer (2), measure the diameter of the pis-
figure.
ton (1) to determine the assembly clearance.
NOTE
The diameter shall be measured at 12 mm
from the piston skirt.
FOR F4BE--- ENGINES
Application with Intercooler

Application without Intercooler
Piston pins Conditions for proper pin-piston coupling

To measure the piston pin (1) diameter use the micrometer Lubricate the pin (1) and its seat on piston hubs with
(2). engine oil; the pin shall be fitted into the piston with a
slight finger pressure and shall not be withdrawn by grav-
ity.

Material
Split rings In this position, use a feeler gauge to check the clearance
(X) between ring and slot: found value shall be the speci-
Use a micrometer (1) to check split ring (2) thickness. fied one.
Check the clearance between the sealing rings (3) of the

2nd and 3rd slot and the relevant housings on the piston
(2), using a feeler gauge (1).
Use feeler gauge (1) to measure the clearance between the
ends of the split rings (2) fitted into the cylinder barrel (3).
Since the first sealing ring section is trapezoidal, the clear- Connecting rods
ance between the slot and the ring shall be measured as
follows: make the piston (1) protrude from the engine
block so that the ring (2) protrudes half-way from the cyl-
inder barrel (3).

NOTE Material removal is not allowed.

The surface of connecting rod and rod cap
are knurled to ensure better coupling.
Therefore, it is recommended not to smooth
the knurls.
Bushes
Check that the bush in the connecting rod small end is free
from scoring or seizing and that it is not loosen. Otherwise
replace.
Removal and refitting shall be performed using the proper
beater.
When refitting take care to make coincide the oil holes set
NOTE on the bush with those set on the connecting rod small
Every connecting rod is marked as follows: end. Grind the bush to obtain the specified diameter.
−On body and cap with a number showing their cou-
pling and the corresponding cylinder. Checking connecting rods
In case of replacement it is therefore necessary to
mark the new connecting rod with the same num- Check that the axes of the connecting rods (1) are parallel
bers of the replaced one. using tool 99395363 (5) as follows:
−On body with a letter showing theweight of the con- −fit the connecting rod (1) on tool 99395363 (5) spindle
necting rod assembled at production: and lock it with screw (4);
• V, 1820 to 1860 (yellow marking);
• W, 1861 to 1900 (green marking);
• X, 1901 to 1940 (blue marking);
Spare connecting rods are of theWclass with green mark-
ing *.

Material
−set the spindle (3) on V-blocks by resting the connect- Checking bending
ing rod (1) on the stop bar (2).
Check connecting rod (5) bending by comparing two
points C andD of the pin (3) on the vertical plane of the
connecting rod axis.
Position the vertical support (1) of the dial gauge (2) to
rest the latter on pin (3), point C.
Move the connecting rod forwards and backwards to find
pin top position, then in this condition reset the dial gauge
(2).
Move the spindle with the connecting rod (5) and repeat
the check of the top point on the opposite side D of the pin
(3). The difference between point Cand pointDshall not
exceed 0.08 mm.
Checking torsion
Check connecting rod (5) torsion by comparing two points
(A and B) of pin (3) on the horizontal plane of the con-
necting rod axis.
Position the dial gauge (2) support (1) to obtain a preload
of approx. 0.5 mm on the pin (3) in point A and then set
the dial gauge (2) to zero. Move the spindle (4) with the
connecting rod (5) and compare any deviation on the
opposite side (B) of the pin (3): the difference between A
and B shall not exceed 0.08 mm.
Fitting connecting rod-piston assembly

Connecting rod-piston coupling
The piston crown is marked as follows:
1. Part number and design modification number;
2. Arrow showing piston assembling direction into cyl-
inder barrel, this arrow shall face the front key of the
engine block;
3. Marking showing 1st slot insert testing;

4. Manufacturing date. the cylinder barrel and the numbers (5) marked on the
connecting rod (5) are read as shown in the figure.
On piston crown, following references are printed:

1. Spare part number and design modification number;
2. Manufacturing date.
3. Writing indicating the mounting mark of the piston
in the cylinder barrel; this writing must face block
front side;
Position the piston (1) on the connecting rod according to

the diagram shown in the figure, fit the pin (3) and stop it
by the split rings (2).
Connect piston (2) to connecting rod (4) with pin (3) so

that the reference arrow (1) for fitting the piston (2) into
Fitting split rings

Use pliers 99360183 (3) to fit the split rings (1) on the pis-
ton (2).

Material
Split rings shall be fitted with the marking “TOP” facing Fitting connecting rod-piston assembly
upwards and their openings shall be displaced with each
into cylinder barrels
other by 120 ° .
Lubricate accurately the pistons, including the split rings
NOTE
and the cylinder barrel inside.
Split rings are supplied spare with the follow-
ing sizes: Use band 99360605 (2) to fit the connecting rod-piston
- standard, yellow marking; assembly (1) into the cylinder barrels and check the fol-
- 0.5 mm oversize, yellow/green marking; lowing:
−the number of each connecting rod shall correspond to
the cap coupling number.
Fit half bearings (1) on connecting rod and cap.

−- Split ring openings shall be displaced with each other
NOTE
by 120 ° ;
Refit the main bearings that have not been
−- connecting rod-piston assemblies shall have the same
replaced, in the same position found at
weight;
removal. Do not try to adapt the half bear-
−- the arrowmarked on the piston crown shall be facing
ings.
the front side of the engine block or the slot obtained
on the piston skirt shall be corresponding to the oil
nozzle position.

Finding crankpin clearance −Apply tool 99395216 (1) to the socket wrench and
tighten screws (2) of 60 ° .
To measure the clearance proceed as follows:
−- clean the parts accurately and remove any trace of
oil;
−- set a piece of calibrated wire (2) on the output shaft
pins (1);
−- fit the connecting rod caps (3) with the relevant half
bearings (4).
−Remove the cap and find the existing clearance by

comparing the calibrated wire width (1) with the scale
on the wire envelope (2).
−Lubricate the screws (1) with engine oil and then

tighten them to the specified torque using the dynamo-
metric wrench (2).
If a different clearance value is found, replace the half

bearings and repeat the check.
Once the specified clearance has been obtained, lubricate
the main half bearings and fit them by tightening the con-
necting rod cap fastening screws to the specified torque.
NOTE
Before the final fitting of the connecting rod
cap fastening screws, check that their diame-
ter measured at the centre of the thread
length is not < 0.1mmthan the diametermea-
sured at approx. 10 mm from screw end.

Material
Check manually that the connecting rods (1) are sliding CYLINDER HEAD
axially on the output shaft pins and that their end float,
measured with feeler gauge (2) is 0.250 to 0.275 mm.
Removing the valves
Intake (1) and exhaust (2) valves have heads with different
diameter.
NOTE
Should cylinder head valves be not replaced,
number them before removing in order to
refit them in the same position.
A = intake side
Checking piston protrusion

Once connecting rod-piston assemblies refitting is over,
use dial gauge 39395603 (1) fitted with base 99370415 (2)
to check piston (3) protrusion at T.D.C. with respect to the
top of the engine block.
Protrusion shall be 0.28 to 0.52 mm.
Valve removal shall be performed using tool 99360268 (1)

and pressing the cap (3) so that when compressing the
springs (4) the cotters (2) can be removed. Then remove
the cap (3) and the springs (4).
Repeat this operation for all the valves.
Overturn the cylinder head and withdraw the valves (5).
Sealing rings (1) for intake valves are yellow.

NOTE Distortion found along the whole cylinder head shall not
Sealing rings (2) for exhaust valves are green. exceed 0.20 mm.
Remove sealing rings (1 and 2) from the valve If higher values are found grind the cylinder head accord-
guide. ing to values and indications shown in the following fig-
ure.
The rated thickness A for the cylinder head is 95 ± 0.25
mm, max. metal removal shall not exceed thickness B by
1 mm.
NOTE
After grinding, check valve sinking. Regrind
the valve seats, if required, to obtain the spec-
ified.
Checking cylinder head wet seal

This check shall be performed using the proper tools.
Use a pump to fill with water heated to approx. 90℃ and 2
to 3 bar pressure.
Replace the cup plugs (1) if leaks are found, use the
proper beater for their removal/refitting.
NOTE
Before refitting, smear the plug surfaces with
water-repellent sealant.
Replace the cylinder head if leaks are found.
Checking cylinder head supporting surface

Material
VALVES Check the valve stem (1) using a micrometer (2), it shall
be 7.943 to 7.963.
Checking clearance between valve stem

and valve guide and valve centering
Use a magnetic base dial gauge (1) set as shown in the fig-
ure, the assembling clearance shall be 0.056 0.096 mm.
Removing carbon deposits, checking Turn the valve (2) and check that the centering error is not
and grinding valves exceeding 0.03 mm.
Remove carbon deposits from valves using the proper

metal brush.
Check that the valves show no signs of seizing, scoring or
cracking.
Regrind the valve seats, if required, using tool 99305018
and removing as less material as possible.

VALVE GUIDE VALVE SEATS

Use a bore dial gauge to measure the inside diameter of
the valve guides, the read value shall comply with the Regrinding — replacing the valve seats
value shown in the figure.
Check the valve seats (2). If slight scoring or burnout is
found, regrind seats using tool 99305014 (1) according to
the angle values shown in Figure 86.
Should valve seats be not reset just by regrinding, replace them with the spare ones. Use tool 99305019 (Figure 85) to
remove as much material as possible from the valve seats (take care not to damage the cylinder head) until they can be
extracted from the cylinder head using a punch.
Heat the cylinder head to 80℃- 100℃ and using the proper beater, fit the new valve seats, previously cooled, into the cyl-
inder head.
Use tool 99305019 to regrind the valve seats according to the values shown in Figure 86.

Material
After regrinding, check that valve (3) sinking value is the FITTING CYLINDER HEAD
specified one by using the base 99370415 (2) and the dial
gauge 99395603 (1). Lubricate the valve stems (1) and fit them into the relevant
valve guides according to the position marked at removal.
Fit the sealing rings (2 and 3) on the valve guide.
NOTE
Sealing rings (2) for intake valves are yellow
and sealing rings (3) for exhaust valves are
green.
VALVE SPRINGS
Before refitting use tool 99305047 to check spring flexi-
bility. Compare load and elastic deformation data with
those of the new springs shown in the following table.
Position on the cylinder head: the spring (4), the upper cap
(3); use tool 99360268 (1) to compress the spring (4) and
lock the parts to the valve (5) by the cotters (2).
Height Under a load of
H (free) 63.50 N
H1 49.02 329 Refitting the cylinder head

H2 38.20 641 Check cleanness of cylinder head and engine block cou-
pling surface.
75759 Take care not to foul the cylinder head gasket.
75751 Set the cylinder head gasket (1) with the marking “N. of
component” (1) facing the head.
Figure 89

The arrow shows the point where the gasket thickness is NOTE
given. Before re-utilising the fixing screws for the
cylinder head, verify there is no evidence of
wear or deformation and in that case replace
them.

Material


Material
NOTE :

Section 5
TOOLS
TOOLS
TOOL NO. DESCRIPTION
99305019 Kit for valve seat regrinding
99305047 Spring load tester
Revolving stand for overhauling units (700 daN/m capacity, 120

99322205 daN/m torque)
99340035 Injection pump gear extractor.
99340055 Tool to remove output shaft front gasket
99340056 Tool to remove output shaft rear gasket
SM 751, Dec ’06 Copyrighted Material TOOLS • 00(D)-5-1

TOOLS
99340205 Tool to remove injectors
99346252 Tool for fitting output shaft front gasket
99346253 Tool for fitting output shaft rear gasket
99360076 Tool to remove oil filter (engine)
99360183 Pliers for removing/refitting piston rings (65 . 110 mm)
99360268 Tool for removing/refitting engine valves
00(D)-5-2 • TOOLS Copyrighted Material SM 751, Dec ’06

TOOLS
99360330 Flywheel crank handle (*)
99360339 Tool for stopping the engine flywheel (**)
99360344 Adapter, cylinder compression test (use with 99395682)
99360351 Tool for flywheel holding (***)
99360362 Beater for removing/refitting camshaft bushes (to be used with

993700069)
99360500 Tool for lifting the output shaft

TOOLS
99360595 Lifting rig for engine removal/refitting
99360605 Band for fitting piston into cylinder barrel (60 . 125 mm)
99361037 Brackets for fastening engine to revolving stand 99322205
99363204 Tool to remove gaskets
99365195 Comparator holder tool for injection pump timing

(to be used with 99395604) (*****)
99367121 Tool to remove gaskets

TOOLS
9999370006 Interchangeable willow handgrip
99370415 Gauge base for different measurements (to be used with

99395603)
99395097 Tool to check top dead centre (use with 99395604)
99395100 Dial gauge holder for rotary injection pump timing (use with
99395603)
99395216 Pair of gauges with ½ ”and ¾ ”square head for angle

tightening
99395220 All-purpose goniometer/Inclinometer

TOOLS
99395363 Complete bush testing square
99395603 Dial gauge (0 . 5 mm)
99395604 Dial gauge (0 . 10 mm)
99395682 Diesel fuel engine cylinder compression control device

APPENDIX
SAFETY PRESCRIPTIONS Ensure that hands and feet are dry and execute work-
ing operations utilizing isolating foot-boards. Donot
Particular attention shall be drawn on some precautions carry out working operations if not trained for.
that must be followed absolutely in a standard working −Do not smoke nor light up flames close to batteries
area and whose non fulfillment will make any other mea- and to any fuel material.
sure useless or not sufficient to ensure safety to the per- −Put the dirty rags with oil, diesel fuel or solvents in
sonnel in-charge of maintenance. anti-fire specially provided containers.
Be informed and inform personnel as well of the laws in −Do not execute any intervention if not provided with
force regulating safety, providing information documenta- necessary instructions.
tion available for consultation. −Do not use any tool or equipment for any different
operation from the ones they’ve been designed and
−Keep working areas as clean as possible, ensuring ade- provided for: serious injury may occur.
quate aeration. −In case of test or calibration operations requiring
−Ensure that working areas are provided with emer- engine running, ensure that the area is sufficiently aer-
gency boxes, that must be clearly visible and always ated or utilize specific vacuum equipment to eliminate
provided with adequate sanitary equipment. exhaust gas. Danger: poisoning and death.
−Provide for adequate fire extinguishing means, prop-
erly indicated and always having free access. Their
efficiency must be checked on regular basis and the During maintenance
personnelmust be trained on intervention methods and −Never open filler cap of cooling circuit when the
priorities. engine is hot. Operating pressure would provoke high
−Organize and displace specific exit points to evacuate temperature with serious danger and risk of burn. Wait
the areas in case of emergency, providing for adequate unit the temperature decreases under 50C.
indications of the emergency exit lines. −Never top up an overheated engine with cooler and uti-
−Smoking in working areas subject to fire danger must lize only appropriate liquids.
be strictly prohibited. −Always operate when the engine is turned off: whether
−ProvideWarnings throughout adequate boards signal- particular circumstances require maintenance inter-
ing danger, prohibitions and indications to ensure easy vention on running engine, be aware of all risks
comprehension of the instructions even in case of involved with such operation.
emergency. −Be equipped with adequate and safe containers for
drainage operation of engine liquids and exhaust oil.
Prevention of injury −Keep the engine clean from oil tangles, diesel fuel and
or chemical solvents.
−Do not wear unsuitable cloths for work, with fluttering −Use of solvents or detergents during maintenance may
ends, nor jewels such as rings and chains when work- originate toxic vapors. Always keep working areas
ing close to engines and equipment in motion. aerated. Whenever necessary wear safety mask.
−Wear safety gloves and goggles when performing the −Do not leave rags impregnated with flammable sub-
following operations: stances close to the engine.
−filling inhibitors or anti-frost −Upon engine start after maintenance, undertake proper
−lubrication oil topping or replacement preventing actions to stop air suction in case of run-
−utilization of compressed air or liquids under pressure away speed rate.
(pressure allowed: ≤ 2 bar) −Do not utilize fast screw-tightening tools.
−Wear safety helmet when working close to hanging −Never disconnect batteries when the engine is running.
loads or equipment working at head height level. −Disconnect batteries before any intervention on the
−Always wear safety shoeswhen and cloths adhering to electrical system.
the body, better if provided with elastics at the ends. −Disconnect batteries from system aboard to load them
−Use protection cream for hands. with the battery loader.
−Change wet cloths as soon as possible −After every intervention, verify that battery clamp
−In presence of current tension exceeding 48-60 V ver- polarity is correct and that the clamps are tight and
ify efficiency of earth andmass electrical connections. safe from accidental short circuit and oxidation.
SM 751, Dec ’06 Copyrighted Material APPENDIX • 00(D)-5-7

−Do not disconnect and connect electrical connections be aerated, far from heat sources and not exposed to
in presence of electrical feed. fire danger.
−Before proceeding with pipelines disassembly (pneu- −Handle the batteries with care, storing them in aerated
matic, hydraulic, fuel pipes) verify presence of liquid environment and within anti-acid containers. Warning:
or air under pressure. Take all necessary precautions battery exhalation represent serious danger of intoxi-
bleeding and draining residual pressure or closing cation and environment contamination.
dump valves. Always wear adequate safety mask or
goggles.
Non fulfillment of these prescriptions may cause seri-
ous injury and poisoning.
−Avoid incorrect tightening or out of couple. Danger:
incorrect tightening may seriously damage engine’s
components, affecting engine’s duration.
−Avoid priming from fuel tanks made out of copper
alloys and/or with ducts not being provided with fil-
ters.
−Do not modify cable wires: their length shall not be
changed.
−Do not connect any user to the engine electrical equip-
ment unless specifically approved by Iveco.
−Do not modify fuel systems or hydraulic system unless
Iveco specific approval has been released. Any unau-
thorized modification will compromise warranty assis-
tance and furthermore may affect engine correct
working and duration. For engines equipped with elec-
tronic gearbox:
−Do not execute electric arc weldingwithout having pri-
ory removed electronic gearbox.
−Remove electronic gearbox in case of any intervention
requiring heating over 80ºC temperature.
−Do not paint the components and the electronic con-
nections.
−Do not vary or alter any data filed in the electronic
gearbox driving the engine. Any manipulation or alter-
ation of electronic components shall totally compro-
mise engine assistance warranty and furthermore may
affect engine correct working and duration.
Respect of the Environment

−Respect of the Environment shall be of primary impor-
tance: all necessary precautions to ensure personnel’s
safety and health shall be adopted.
−Be informed and inform the personnel as well of laws
in force regulating use and exhaust of liquids and
engine exhaust oil. Provide for adequate board indica-
tions and organize specific training courses to ensure
that personnel is fully aware of such law prescriptions
and of basic preventive safety measures.
−Collect exhaust oils in adequate specially provided
containers with hermetic sealing ensuring that storage
is made in specific, properly identified areas that shall
00(D)-5-8 • APPENDIX Copyrighted Material SM 751, Dec ’06

Section 6
Engine Replacement
Engine Replacement 6. Set the engine onto the mounting isolators. Set
mounting bolts in place but do not tighten. The
Before beginning engine replacement, make sure the truck engine may have to be shifted to line up with the
parked with the parking brake applied and wheels transmission.
chocked. To replace the engine:
1. Make sure the hoist and chains or engine stand you
are using is of adequate capacity to safely lift the
engine.
2. Hook the hoist chains to the engine lifting eyes.
7. Connect the engine to the transaxle (or hydrostatic

transmission pump) .
3. Slowly lift the engine and move it into place over the 8. Torque engine mounting bolts to 170-190 N⋅m (125-
truck frame. 140 ft-lb).
4. Make sure there are no wires, cables, hoses, or other 9. Align and connect the exhaust pipe to the engine ter-
equipment in the way of lowering the engine into the bocharge manifold using.
frame. V-type Clamp
5. Slowly begin lowering the engine into the frame.
Exhaust manifold
! WARNING
Never use your hands to move the engine in
the frame. Always use a pry bar to gently
shift or hold the engine in place. After the
engine is in place, keep the hoist chains
attached and keep slack out of the chains.
Remove the chains only when the engine is
securely mounted in the truck frame and
remounted with the transmission.
SM 751, Oct ’06 Copyrighted Material Engine Replacement • 00(D)-6-1

10. Reconnect the radiator hoses between the radiator 14. Check the engine air cleaner and hoses. See Group 3
and the water pump and the thermostat of the engine, for complete details. Set the aircleaner and hoses in
as described in Group 01. Before reinstallation, place and align before tightening clamps and mount-
check that hoses are in good condition with no drying nuts. Torque the base-mounting nuts to 20-25
ing, cracking, or splitting. N⋅m (14.8-18.5 ft-lb); torque hose-to-engine clamp
to 1.9-2.9 N⋅m (1.4-2.1 ft-lb).
11. Uncap and reconnect the fuel line at the fuel tank.
Make sure the hose is in good condition with no dry- 15. Check the battery and reconnect the cables to the bat-
ing, cracking, or splitting evident. Torque band tery posts and to the starter and ground.
clamp to 0.8-1.0 N⋅m (0.6-0.73 ft-lb).
Negative cable
grounded to frame
Battery cable
A Neg.
VIEW A Battery x2
Positive cable to
starter solenoid
To engine From battery Side

frame LH
Fuel hose
Bend clamp Engine starter

Battery cable positive
motor
12. Reconnect the wiring. See Group 13 for drawings

that show the wiring harness and component connec-
a. Torque the terminal nuts at the battery posts to
tion points on the engine.
14-20 N⋅m (10.3-14.8 ft-lb).
13. On the standard transaxle truck, reconnect the accel- b. Torque the nut on the starter terminal to 10-12
erator linkage and adjust length using the adjustment N⋅m (90-110 in-lb; 7.5-9.1 ft-lb).
nuts. See Group 02 for throttle linkage adjustments. c. Install covers over cable ends after assembly.
16. Assembly the rear hood according to the procedures
in Group 38.
17. Close engine drain valve and fill radiator according
to the prodedures presented in “Engine Cooling Sys-
tem Testing and Maintenance” in Group 01. Check
inlet and outlet hoses for leaks.
18. Restart the engine and check all truck electrical,
Accelerator hydraulic, and mechanical components for proper
Cable Bracket operation before returning the truck to service.
Throttle Lever
00(D)-6-2 • Engine Replacement Copyrighted Material SM 751, Oct ’06

GROUP 01
GROUP 01
ENGINE COOLING SYSTEM
Engine Cooling System

Specifications and Description .......................... Section 1
Engine Cooling System Troubleshooting ......... Section 2
Engine Cooling System Testing

and Maintenance..................................................Section 3
Radiator Removal and Replacement ............... Section 4
NOTE
Removal and replacement procedures for the water pump and
thermostat are covered in the Overhaul section of Group 00,
“Engines”.
SM 751, Nov ’06 Copyrighted Material Group 01, Engine Cooling System
NOTE :
Group 01, Engine Cooling System Copyrighted Material SM 751, Nov ’06
Group 01, Engine Cooling System
Section 1

Specifications and Description
Specifications Description
The engine cooling system is a conventional setup and
Service Intervals consists of the radiator, the fan and drive belt, the thermo-
stat, the water pump, and associated hoses. The radiator is
Coolant Level Check: Every 8-10 hours or daily. filled through the overflow bottle, a reservoir for extra
Coolant Change (drain and refill): Every year or 2000 coolant that allows for fluid expansion as the fluid gets
hours of operation. warmed in the engine. The transmission oil cooler is sepa-
rate from the engine cooling system, but is mounted
Coolant Hoses Inspection/Replacement: As needed and
every 50-250 hours or each PM and every year or 2000 directly below the radiator.
hours of operation. The radiators of the different models of the truck are not
Coolant Protection Check (hydrometer test): Every six the same, but the procedures for general service are the
months or 1000 hours of operation. same. Radiator repair is not covered in this manual. Radi-
ator service shops should be consulted if the radiator is
Radiator Core Air Cleaning: Every 50-250 hours or
clogged, cracked, or otherwise unserviceable. The compo-
monthly.
nents that can be serviced include the belts (gas and LPG
Radiator Cap Inspection and Test: Every year or 2000 engines have two belts), the thermostat, the water pump,
hours of operation. and hoses.
Thermostat Test/Replacement: Every 2000 hours or each
PM.
Fan Belt Tension Wear Inspection: After the first 50 hours
of operation, then every 50-250 hours or each PM.
Fan Inspection for Loose or Damaged Blades: Every 50-
250 hours or each PM.
SM 751, Nov ’06 Engine Cooling

Copyrighted System Specifications and Description • 01-1-1
Material
NOTE :
Section 2
Engine Cooling System Troubleshooting
Temperature gauge in red zone • Low engine oil pressure; check oil level and fill
and check for leaks.
• Radiator fins plugged; blow debris from radiator. • High coolant temperature; check “Engine over-
• Blockage in system; drain, flush, and refill system. heating” for symptoms and remedies.
Engine overheating Water pump leaks

• Loose fan belt; tighten to correct tension (see Sec- • Pump has a worn shaft and/or seal.
tion 4 for belt tensioning procedure). • Bad O-Ring.
• Low coolant level; refill and check for leaks. • Broken pump impeller.
• Radiator pressure cap is defective. Replace the seals and O-Rings or replace the pump.
• Inadequate air flow to the radiator; check that fan
blades have the coined imprinting facing the Water pump making noise
engine and are not installed backwards.
• Worn pump shaft or bearings loose or worn.
• Missing or damaged fan shroud or shields on radia-
tor. • Pump impeller broken.
• Radiator fins plugged; blow debris from radiator. • Loose fan belt.
• Radiator clogged; drain and flush radiator. • Bent or broken fan blade.
• Scale or deposits in cooling system; drain and flush • Fan hitting engine or shroud.
entire cooling system.
• Radiator defective; repair or replace the radiator. Engine runs cold, emits excessive blue/
• Thermostat incorrect or defective. white exhaust smoke or idles roughly
• Collapsed radiator hose(s) on suction side of cool- • Contaminated fuel.
ing system. • Coolant temperature below normal due to incorrect
• Water pump defective. or defective thermostat; replace the thermostat.
• Water passages in engine are clogged. • Defective temperature sender or indicator light;
• Air in cooling system; drain and flush. check and replace if necessary.
• Ignition timing misadjusted.
• Excessive exhaust system back pressure. Oil in coolant or coolant in crankcase
• Engine oil level is low or needs changing. • Leaking head gasket.
• Engine overloaded. • Cylinder head bolts not tight.
• Engine internal parts worn. • Cylinder head cracked.
• Leaking head gasket. • Engine cylinder block water jackets cracked.
• Defective temperature gauge.
Engine shuts down (automatic engine

shutdown sensor)
• High transmission temperature; check transmission
oil cooler components.
SM 751, Nov ’06 Engine Cooling System Troubleshooting • 01-2-1

NOTE :
NovGroup 01, Engine Cooling System
Section 3

Testing and Maintenance
! WARNING
2376150
The engine coolant fan, on all internal combustion engines, can cause
extensive injury and bodily harm. Keep hands, arms and clothing away
from a spinning fan. Also, don’t stand in line with a spinning fan.
SM 751, Nov ’06 Copyrighted Material Engine Cooling System • 01-3-1

1. Park the truck as described in “Safe Parking.”

! CAUTION
2. Open the engine cover and check the coolant level in
SAFE PARKING. Before working on truck: the reservoir:
• Park truck on a hard, level, and solid sur- • When at operating temperature, the coolant level
face, such as a concrete floor with no gaps must be within the hot range mark.
or breaks. • When cold, the coolant level must be within the
• Put upright in vertical position and fully cold range mark.
lower the forks or attachment.
• Put all controls in neutral. Turn key switch
OFF and remove key.
• Apply the parking brake and block the
wheels.
Engine Coolant Level Check

Hot range mark
! CAUTION Cold range mark
Use extreme care when removing the cap
from the radiator. Never remove the radiator
cap from a hot engine. It is a good safety 3. Remove the radiator cover. See Group 38 for instruc-
practice to use a shop cloth over the cap as tions.
shown if there is any possibility of pressure 4. Use a rag to cover the radiator cap and turn to the
being present. Turn cap to the first stop and first stop to release any steam. Let all pressure and
note if any steam is released. When you are steam run out of the radiator before removing the
sure all pressure has been released, press cap.
down on the cap with the cloth in place, turn
and remove the cap. Stand clear of the radia- 5. Check the coolant level in the radiator; coolant level
tor opening; hot coolant can splash out. should be to the bottom of the filler neck opening.
Steam or hot coolant can cause severe burns. 6. Fill the reservoir and radiator to the correct level of
Failure to follow these instructions could coolant and close tightly.
result in serious personal injury and/or dam-
age to the cooling system or engine. IMPORTANT
Do not overfill the system. If necessary, wait 4
hours or until the engine is completely cool
before adding coolant to the correct levels in
the reservoir and radiator.
The cooling system should be filled at all times with a

50% water and 50% glycol, permanent-type antifreeze
solution containing rust and corrosion inhibitors. Plain
water may be used in an emergency, but should be
replaced with specified coolant as soon as possible to
avoid damage to the system or engine. When only water is
used in the system, do not let the engine run hot.
NOTE
Heated coolant expands and is driven from the radiator Do not use alcohol or methanol antifreeze.
into the reservoir. The engine must be cooled for at least 4
hours before the coolant will flow back to the radiator. To Add coolant as required. If frequent refilling or as much as
check the coolant levels in the engine: a quart is required at one time, inspect cooling system for
leaks.
01-3-2 • Testing and Maintenance Copyrighted Material SM 751, Nov ’06

Adding Coolant 4. Check the planned maintenance time interval (oper-

ating hours), or the condition of the coolant to deter-
1. The coolant level should be at the cold mark on the mine if it needs to be changed (drained and replaced).
coolant reservoir when the engine is cold.
5. Inspect the radiator cap. Check condition of the
NOTE upper and lower seals. Check the seal holder and
Fork lift truck applications require also spring for correct movement and operation. The rub-
checking the coolant level directly in the radi- ber seal face should be clean and undamaged. Look
ator. Lift truck radiators will plug up and for nicks or cracks in the seals. Replace the cap if the
overheat which forces coolant into the over- seal is defective. Cap should have a pressure rating of
flow bottle and on out at the vent. This 90 kPa (13 psi) nominal and 83-109 kPa (12-16 psi)
results in a low coolant level which may cause limits. See “Cooling System Tests” in this Section for
overheating. procedures to test the radiator cap.
6. Inspect the radiator cap sealing surfaces located in
2. Coolant level in the radiator should be checked daily
the radiator filler neck. Look for nicks, deep
(or before each shift of operation) to make sure the
scratches, or damage which may cause radiator cap
radiator is full at all times. Radiator is full when
leakage.
coolant level is at the bottom edge of the filler neck
opening. 7. Inspect the overflow pipe and tubing for clogging,
damage, or wear. Clean the overflow pipe. Remove
! CAUTION any contaminants that can cause restriction. Replace
the tubing if it is faulty.
from the radiator. When checking coolant 8. Inspect and clean the overflow bottle (reservoir) as
level in the radiator, use a rag over the cap. needed.
Turn cap to the first stop and allow all pres- 9. Inspect the inlet and outlet hoses for damage, cracks,
sure and steam to be released. wear, or evidence of collapsing. Inspect hose clamps
to determine if they need to be replaced.
3. If the cooling system requires the addition of a large
quantity of coolant and the engine has been overheat- 10. Use a coolant tester to test the low temperature pro-
ing, perform the following cooling system inspec- tection level (the proportion of glycol to water) of the
tion. coolant solution. Add coolant solution (antifreeze or
water) to provide maximum protection (50/50 mix-
ture).
Cooling System Inspection

1. Check water pump, thermostat, radiator, and all
plumbing for leaks.
! CAUTION
from the radiator. When checking coolant
level in the radiator, use a rag over the cap.
Turn cap to the first stop and allow all pres-
sure and steam to be released before remov-
ing cap.
NOTE
2. Remove the radiator cap. See CAUTION above. A coolant solution containing 50% glycol
3. Inspect the condition of the coolant. Look for exces- provides freezing protection to -37° C (-34°
sive contamination, rust, oiliness, or gummy deposits F). Refer to Service Information Bulletin, SI-
in the coolant solution. The coolant should have a 01-207-78 for more information on the use of
clean appearance. antifreeze.
SM 751, Nov ’06 Copyrighted Material Testing and Maintenance • 01-3-3

11. If the engine has been requiring the addition of large 2. The gauge pressure reading should hold within the
amounts of coolant: specified limits of the cap relief pressure. Cap should
• Inspect the radiator for blockage of air flow have a pressure rating of 96 kPa (14 psi) nominal and
through the fins. Air clean the radiator. 83-109 kPa (12-16 psi) limits. If the test relief pres-
• Check the tailpipe. Be sure exhaust flow is not sure either exceeds or is below the specified limits,
blowing into the radiator. Make sure all baffles replace the cap with a new Clark part.
and shrouds are in place.
• Check fan belt and cooling fan.
• Check and make sure the fan is not installed
Testing Radiator and Cooling System
backward. The coined imprinting on the fan
blades should be facing the engine for correct 1. Pressure test the radiator and cooling system to deter-
operation. mine if it will hold the correct pressure without leaks
• Check engine oil to see if it contains coolant. or failure. Wet the rubber sealing surfaces and install
• Check the radiator cap to see that it has the cor- the tester cap tightly on the radiator fill neck. Apply
rect rating. pressure to the cooling system equal to the radiator
• Pressure test the radiator and cooling system. cap specified relief pressure of 90 kPa (13 psi) nomi-
See “Cooling System Tests” in this Section for nal and 83-109 kPa (12-16 psi) limits.
procedures to test the radiator and cooling sys-
tem. Repair any leaks or blockage.
• Test the engine thermostat. See “Cooling System
Tests” in this Section for procedures to test the
thermostat. Replace the thermostat if faulty.
Cooling System Tests

If the need is indicated for further maintenance and testing
of the cooling system, check for both external and internal
leaks in the cooling system with an accurate pressure
pump and gauge tester. 2. Observe the gauge reading for approximately two
minutes. The pressure should not drop during this
Testing the Radiator Cap time. If pressure drops, check for leaks in the radia-
tor, hoses, connections, and the engine components.
1. Pressure test the radiator cap to determine if it is
holding the correct pressure. Wash the cap in clean
water to remove any dirt or scale from the valve seal-
ing surfaces. Wet the rubber sealing surface and Testing the Thermostat
install the cap tightly on the tester. Pressurize the 1. Remove and test the engine thermostat to determine
tester and radiator cap. if it closes correctly and opens at the correct tempera-
ture:
Gas/LPG/Diesel
• Open (cracking) at 83°C ± 1.5° (181°F ± 2.7°)
• Fully open at 98°C (208°F).

2. Fully immerse the thermostat in a pan of water. Heat IMPORTANT

the pan slowly while stirring the water to produce an Dispose of the fluid in accordance with the
even temperature. Use a thermometer to measure the manufacturer’s and state and local regula-
temperature at which the thermostat valve cracks tions.
(starts to open) and when it is fully open. If the test
results are not to specification, replace the thermo- 4. Inspect coolant hoses and clamps to determine if they
stat. need to be replaced.
3. Replace the thermostat even if a slight opening of the

valve at normal temperature is found or if its appear-
ance shows any breakage. If the sensing part is dam-
aged, the thermostat valve will remain closed.
Engine Coolant Change

NOTE
Drain and replace the engine coolant after
2000 hours of operation or once a year. Sys-
tem coolant capacities are listed in Section 1.
Draining Radiator and Cooling System

To drain the radiator and cooling system:
1. Remove the radiator cap.
! CAUTION
Allow engine to cool first, then use extreme
care when removing the cap from the radia-
tor. Use a rag over the cap, turn cap to the
first stop, and allow all pressure and steam to
be released.
2. Place a large, 25-liter (6.6-gallon) drain pan under

the radiator.
3. Open the coolant drain plug of radiator.
SM 751, Nov ’06 Copyrighted Material Testing and Maintenance • 01-3-5

Cleaning and Flushing Cooling System 4. Fill the coolant recovery bottle (overflow reservoir)
to the cold range mark line with new coolant.
NOTE
If the condition of the used coolant indicates
severe contamination, rust deposits, scale, or
oil in the system, determine the cause of the
contamination and make sure to clean and
flush the cooling system with a commercial
cleaner. Choose a product from a reliable
manufacturer and follow all instructions for
its use.
1. Fill cooling system and perform the cleaning and Hot range mark
flushing operation according to the manufacturer’s
instructions. Cold range mark
2. Drain the system completely again using the steps
from “Draining Radiator and Cooling System.”
IMPORTANT 5. Start and run the engine until the radiator upper hose
Dispose of the fluid in accordance with the is warm, indicating the thermostat is open and cool-
manufacturer’s and state and local regula- ant is circulating through the system. Check for leaks
tions. at hose connections and engine drain valve.
6. Turn engine off and check coolant level in radiator
Filling Cooling System again. Add coolant as required to fill to bottom of
filler neck.
With the cooling system drained, the following procedure
should be used to insure complete fill:
! CAUTION
1. Close coolant drain valve in engine block.
2. Fill the radiator to the bottom of the filler neck with from the radiator. When checking coolant
new coolant (50% water and 50% glycol, permanent- level in the radiator, use a rag over the cap.
type antifreeze solution containing rust and corrosion Turn cap to the first stop and allow all pres-
inhibitors). sure and steam to be released.
3. Install radiator cap securely.
7. Check coolant level in reservoir again. Add coolant
as required to fill to the Cold Mark on the bottle.
NOTE
To cycle coolant from the recovery bottle into
the radiator, run the engine until it reaches
operating temperature, then stop the engine.
Check coolant level in the coolant recovery
bottle once the engine is again cold.
Again inspect cooling system hoses, connections and

components for any leaks that may have developed when
system was fully pressurized.

Section 4
Radiator Removal and Replacemant
Radiator
To Water Pump
Fan
To thermostat
SM 751, Nov ’06 Copyrighted MaterialRadiator Removal and Replacemant • 01-4-1

10. Remove the cushion assembled to upper and lower

! CAUTION sides.
SAFE PARKING. Before working on truck:
• Park truck on a hard, level, and solid sur- Installation of radiator
face, such as a concrete floor with no gaps
or breaks. 1. Install the radiator cushions on proper positions.
• Put upright in vertical position and fully 2. Put the radiator on to the cushions.
3. Install the bolts on original places.
• Put all controls in neutral. Turn key switch
OFF and remove key. 4. Fasten the bolts with tightening torque of
2~2.5kgf.m(14.5~18ft.lb).
• Apply the parking brake and block the
wheels. 5. Lay the shroud on engine before installing the fan.
6. Assemble the fan by four bolts.
Radiator Removal 7. Fasten the bolts with tightening torque of
NOTE 3.7~4.9kgf.m(27~35ft.lb).
Servicing radiators is not covered in this 8. Install 6 bolts for fastening the shroud.
manual and radiator repair shops should be The interval between shroud and fan shall be 13mm.
consulted for service and repair of defective
radiators. 9. Fasten the bolts with tightening torque of
1.26~1.54kgf.m (9~11 ft.lb).
1. Do not attempt to remove the radiator when the 10. Assemble the cooling auxiliary water tank to the
engine is hot. Wait until the system has entirely frame.
cooled down.
11. Remount the water pump and thermostat hoses
between the engine and radiator. Tighten the hose
! CAUTION clamps sufficiently to prevent leaks.
from the radiator. When removing the radia- IMPORTANT
tor cap, use a rag over the cap. Turn cap to Use new hoses if cracking or drying is evident
the first stop and allow all pressure and around the positions of the clamps or if the
steam to be released. hoses are deteriorated in any way.
2. Park the truck and block the wheels. Tilt the steering 12. Reset the hose from the overflow bottle across the
column forward and raise the operator’s seat deck. radiator cock.
3. Remove the rear hood. 13. Close engine drain cock and refill the radiator with a
4. Drain the radiator/engine coolant as described in mixture of 50% glycol (antifreeze) and 50% water as
Section 3. described in Section 3.
5. Disconnect the overflow bottle hose from the filler 14. Remount the rear hood.
neck of the radiator. Remove the auxliary sump hose. 15. Check the rear hood for correct operation once you
6. Loosen six shroud bolts, and push the shroud to the have completed reassembly.
fan side. 16. Once you have completed all the tests recommended
7. Loosen four bolts to remove the fan, and take off the for radiator refill (see Section 3), check to make sure
fan together with the shroud. no leaks are evident in the radiator hoses before
returning the truck to service.
8. Loosen two bolts at upper side of radiator and two
bolts at loser side of radiator.
9. Lift the radiator perpendicularly against to the
ground.
01-4-2 • Radiator Removal and ReplacemantCopyrighted Material SM 751, Nov ’06

GROUP 03
GROUP 03
AIR INDUCTION AND EXHAUST SYSTEM
Air Induction and Exhaust Systems

Specification and Description .................. Section 1

Troubleshooting ........................................ Section 2
Air Induction System Service .................. Section 3
Exhaust Systems ....................................... Section 4
SM 751, Nov ’06 Copyrighted Material Group 03, Air Induction And Exhaust System
NOTE :
Group 03, Air Induction And Exhaust System

Copyrighted Material SM 751, Nov ’06
Group 03, Air Induction and Exhaust System
Section 1

Specifications air pre-filter and dual elements. The dust injector port on
air cleaner body discharges the particles from the filter.
Air Cleaner Type: Canister style with replaceable paper All trucks are equipped with an “air restriction indicator”
element and air-restriction indicator. that warns the driver of dirty and restricted air intake. The
air cleaner should only be serviced when the air restriction
Fastener Torques indicator shows service is required or every 2000 hours.
However, the system components should be visually
Air Cleaner Hose Clamp Torques: 1.5-2.5 N⋅m (1.09-1.8 checked regularly for leaks, holes, or other damage that
ft-lb) could affect the readings of the air restriction indicator.
Air Cleaner Bracket Mounting Nut Torques: 20-25 N⋅m Air filter ass'y is composed of inlet/outlet hose, air cleaner
(14.5-18.5 ft-lb) body, filter element, air restriction indicator, dust injector
and clamps. The air intake opening is located in a leg of
the operator’s cell, high enough above the ground to pre-
Service Intervals
vent excessive dust and dirt from entering the system.
Air Cleaner (Filter) Replacement: Drain hose is connected to diesel suction manifold.
• Diesel trucks, replace every 1000 hours.
IMPORTANT
Filter replacement intervals also depend on
operating conditions. The air cleaner body
and element should be check visually at regu-
lar intervals to check for leaks, holes, or
other conditions that will affect the air
restriction indicator. Air cleaner should be
serviced when the air restriction indicator
shows service is required.
Air Hoses and Clamps Inspection: Every 50-250 hours or

each PM.
Exhaust Pipe and Muffler Inspection: Every 50-250 hours
or each PM.
Description
The reason for providing an air cleaner for the engine is to
protect the engine from abrasive dust and dirt entering the
cylinders and causing excessive wear. Industrial truck
operating environments can contain a high concentration
of dust, fibers, or other contaminants. Dirty filter elements
or loose, leaking, or broken hoses or clamps can dramati-
cally shorten engine life. Clogged air filters cause engine
power loss and poor fuel economy.
To lengthen the maintenance interval, the air cleaner used
in this fork lift truck is composed of one large centrifugal
SM 751, Nov ’06 Air InductionCopyrighted

and Exhaust Systems Specifications and Description • 03-1-1
Material
NOTE :

Section 2
Air Induction System Troubleshooting
Dirty or restricted air induction components can cause If any of these problems occur with the truck, the air filter
several problems with your truck’s operation. Regular may be clogged or the air intake system is restricted. Ser-
maintenance and service of the filter element and related vice the entire system to make sure that air flow is clean
components can prevent problems with your truck. The air and unrestricted. Change the filter element and check all
restriction indicator also automatically gauges the air hoses, tubing, and the air cleaner for tight fittings. Look at
induction system performance and can warn you when all connections for fan-shaped dust deposits that indicate
problems arise. The air restriction indicator switch is an possible air leaks. Check all hoses for proper seating and
mechanical control mounted on the air cleaner body. The look for cracks or damage. Make sure all hose clamps are
switch monitors the vacuum present in the system and properly torqued.
determines when the air flow is not adequate; either a
clogged air intake or dirty filter element prevents the full,
required amount of air from reaching the engine.
Clogged air filters may cause the following symptoms :
• Engine starts but does not remain running.
• Engine lacks power.
• Excessive black exhaust smoke.
• Fuel or oil leaking from exhaust manifold.
• Excessive fuel consumption.
• Low compression.
SM 751, Nov ’06 Copyrighted MaterialAir Induction System Troubleshooting • 03-2-1

NOTE :

Section 3
Air Induction System Service
Use the illustrations on the following pages to service the NOTE

air induction system, including changing the air filter ele- Do not try to air clean and blow out the filter.
ment. Filter is further clogged by air cleaning.
NOTE Always replace with a new filter element.
The air restriction indicator gauges vacuum
6. Reseat the air cleaner cover, making sure that it fits
present in the system. For diesel engines, the
tightly around the air cleaner.
filter should be replaced every 900-1000
hours. Regularly check the system compo- 7. Close and latch the air cleaner cover clamps.
nents, however, to check for leaks, holes, or
other damage that could affect the air restric-
tion indicator.
Air Cleaner Removal
1. Remove the two bolts that mount the air cleaner to
the frame.
! CAUTION
2. Loosen the clamp and remove the hose from the
engine.
1. Park truck on a hard, level, and solid
3. Remove the hose from the intake pipe.
surface, such as a concrete floor with no
gaps or breaks. 4. Remove the air cleaner and hosing from the truck.
2. Put upright in vertical position and fully
lower the forks or attachment. Air Cleaner Replacement
3. Put all controls in neutral. Turn key Installation is the reverse order of removal.
switch OFF and remove key.
• Torque the hose clamp bolts to 1.9-2.9 N•m (1.3-
4. Apply the parking brake and block the 2.1 ft-lb).
wheels.
• Torque air cleaner bracket mounting bolts to 20-25
N•m (14.8-18.5 ft-lb).
Air Filter Replacement
1. The air cleaner is located to the right of the driver’s
seat.
2. Inspect the components and look for fan-shaped dust
accumulation at all hose connections. Clean compo-
nents of dust, dirt, and other contaminants that might
enter the system on disassembly.
3. Loosen the air cleaner, and remove the hose from the
engine.
4. Clean the inside of the air cleaner.
5. Install the new filter element. Be sure that the filter
element is fully seated in the air cleaner.
SM 751, Nov ’06 Copyrighted Material Air Induction System Service • 03-3-1
Air Filter
Free cleaner
Intake Pipe
Air cleaner
Indicator
Torque 20~25 N.m

(14.8~18.5 lb.ft)
Outflow hose
Air filter element canister
Free cleaner cover

Torque 20~25 N.m
(14.8~18.5 lb.ft)
Hose connector
pipe
Intake Hose
Blow by hose
Radiator bracket
03-3-2 • Air Induction System Service Copyrighted Material SM 751, Nov ’06
Section 4
Exhaust Systems
! CAUTION
SAFE PARKING. Before working on
truck:
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
4. Apply the parking brake and block the
wheels.
SM 751, Nov ’06 Copyrighted Material Exhaust Systems • 03-4-1

Exhaust System - Cushion-Tire Truck
Vertical Exhaust Pipe

Hot Surface Wanning decal
Horizontal Exhaust Pipe Counterweight Cover
Torque to 60-65N.m
(44~48ft.lb)
Torque to 30-35N.m
(22~28ft.lb)
r
fle
uf Exhaust Pipe
M
Cushion Rubber
03-4-2 • Exhaust Systems Copyrighted Material SM 751, Nov ’06

GROUP 06
GROUP 06
TRANSMISSION
(3 WG-116 TRANSMISSION)
Layout 3WG-116 ........................................... Section 1
Disassembly .....................................................Section 2
Reassemly ........................................................Section 3
AEB Setting of T/M controller clutch

& INCHING calibration ............................... Section 4
Troubleshooting.............................................. Section 5
SM 751, Jan ’07 Copyrighted Material Group 06, TRANSMISSION

NOTE :
Group 06, TRANSMISSION Copyrighted Material SM 751, Jan ’07

Group 06, Transmission
Section 1
LAYOUT 3 WG-116
LAYOUT 3 WG-116
No Description Remarks 8
1 Engine connection B=Direct mounting
2 Converter
3 Input shaft
3
4 Transmission pump
5 Input gear
6 Clutch shaft "K2"
7 Mounting possibility Power 6
take-off; Coaxial engine-depen-
dent
8 Clutch shaft "KV" 9
9 Clutch shaft "KR"
10 Clutch shaft "K1"
11 Output flange 12
12 Clutch shaft "K3/Output"
10
1 2 Clutch arrangement
3 4
5 6
7
8
SM 709, Jun ’04 Copyrighted Material LAYOUT 3 WG-116 • 06-1-1

1 2 3 4 5 6
A
8
B
10
11
12
06-1-2 • LAYOUT 3 WG-116 Copyrighted Material SM 709, Jun ’04

MEASURING PLAN AND CONNECTIONS

Measurements have to be made with the transmission at operating temperature (approx. 80°C - 90°C)!
IDENTIFICATION
NO. DESIGNATION OF THE ITEM CONNECTION
ON VALVE BLOCK
MEASURING POINTS FOR PRESSURE OIL AND TEMPERATURE:
51 Before converter Opening pressure 11+2 bar M10x1 H
52 After converter Opening pressure 4.3+3 bar M10x1
53 Clutch Forward 16 +2 bar KV M10x1 B
55 Clutch Reverse 16 +2 bar KR M10x1 E
56 Clutch 16 +2 bar K1 M10x1 D
57 Clutch 16 +2 bar K2 M10x1 A
58 Clutch 16 +2 bar K3 M10x1 C
60 Not applicable K4 M10x1 F
63 After converter M14x1.5
Temperature 100°C, short-time 120°C
65 System pressure 16 +2.5 bar M10x1 K
MEASURING POINTS FOR FLOW RATES:
15 Connection from heat exchanger 1 5/16" - 12 UN-2B
16 Connection to heat exchanger 1 5/16" - 12 UN-2B
INDUCTIVE- PULSE- SPEED TRANSMITTERS AND SWITCHES:
21 Inductive transmitter n Turbine M18x1.5
34 Speed transmitter n Output -----------
47 Inductive transmitter n Internal speed input M18x1.5
48 Inductive transmitter n Engine M18x1.5
54 Differential pressure switch for pressure filter M14x1.5
CONNECTIONS:
10 Breather M10x1
49 Plug connection on electro-hydraulic control unit
10
10
34
34

65 51 54 10
49
57
60
53
48
58
52
55
56
63
15 16
21
47
06-1-4 • LAYOUT 3 WG-116 Copyrighted Material SM 709, Jun ’04

INSTRUCTIONS TO THE REQUIRED OIL QUALITY AND OIL CAPACITY:

Oil quality/grade: Only oils in accordance with the characteristics specified in the ZF List of Lubricants TE-ML 03
are allowed to be used !
Oil capacity:
approx. 20 liters (sump volume) for newly to be filled transmissions (i.e. upon dis- and reassembly).
External oil capacities (e.g. converter, cooler, lines etc.) depend on the vehicle.
Notes - as to oil level check, oil- and filter change - are first oil change after 100 operating hours in service.
Every further oil change after 1000 operating hours in service, however at least once a year !
At every oil change, the pressure filter has to be replaced.

NOTE :
Group 06, Transmission Copyrighted Material SM 709, Jun ’04

Section 2
DISASSEMBLY
(Electro-Hydraulic Control and Filter) Loosen the cap screws (2) and separate the filter head (1)
from the transmission housing.
Mount the transmission to the assembly truck. Remove the O-rings
Prior to start the disassembly, drain the oil!
Figure 3
1.2 Removal of the Electric Shift System

Remove the shift system (1).
Loosen the Torx screws (2) and separate the gearshift
housing from the intermediate sheet.
1
Figure1
1.1 Removal of the Filter

Figure 4
By means of the strap wrench separate the ZF-Micro Filter
(1) from the filter head. Remove the complete shift system (1) and the intermedi-
ate sheet (2).
S
2
Figure 2
Figure 5
SM 751, Nov ’06 Copyrighted Material DISASSEMBLY • 06-2-1

Mark the installation position of the cover (1) to the valve Loosen the cap screws (1) and remove the cover.
block (2). Remove the opposite cover.
2 1 1
Figure 6 Figure 10
Loosen the Torx screws (1). Remove the wiring harness (1).
Loosen the cap screws (3), remove the fixing plates and
1 the pressure regulators (1).
2
Figure7
1 3
Separate the duct plate (3), and intermediate sheet (2)
from the valve block (1). Figure 11
Loosen the cap screws, remove the fixing plates and the
pressure regulators (1).
2
3 1
1
Figure 8
Remove the retaining clamp (1).
Figure 12
1
Figure 9
06-2-2 • DISASSEMBLY Copyrighted Material SM 751, Nov ’06

Loosen two cap screws (1) and fasten the adjusting Remove the single parts on the opposite side analogously:
screws (S) preliminarily (housing is spring-loaded). Follow- 1 = Main pressure valve
ing to this loosen the remaining cap screws. 2 = Vibration damper
3 = Follow-on slide
1 S
Figure 13
Separate the housing from the valve housing by loosening 3

2
the adjusting screws equally.
Figure 16
Figure 14
Remove the single parts:
1 = Pressure reducing valve
2 = Vibration damper
3 = Follow-on slide
1 2
Figure 15

Inductive transmitters, Valves, Oil Remove the positioned parts.

1 =Breather
Filler and Oil Drain Plug, Screw Plugs 2 = Inductive transmitter - n engine
Mount the transmission to the assembly truck. 3 = Screw plug (measuring point after converter)
4 = Screw plug (option for temperature sensor)
5 = Fixing strap Oil filler tube
6= Oil filler tube with oil dipstick)
7 = Screw plug (oil drain bore))
2 5
3
6
4
7
Figure 3
Remove the positioned parts.

1 = Inductive transmitter n - Internal speed input
2 = Inductive transmitter n - Turbine
Figure 1
3 = Speed transmitter n - Output
Remove the converter pressure back-up valve (1) and dif- 4 = Cover (mounting possibility for oil filler tube)
ferential pressure switch (3) for the ZF-Micro Filter (2).
Do not remove the pressure relief valve.
3
3
1 1
2
2 4
Figure4
Figure 2

Engine Connection, Pressure Oil By means of the lifting equipment the converter bell (1)
with pressure oil pump (5) are commonly to be separated
Pump and Removal of the Clutches from the transmission housing rear section (4).
Mount the transmission to the assembly truck. Remove the intermediate sheet (3) and the stator hollow
shaft (2).
Loosen the hexagon screw (2) and separate the flexplate
(1) from the converter (3).
5
2 1
1 3
3 4
Figure 3
Separate the pressure oil pump (1) from the converter bell.
Figure 1
By means of the lifting equipment separate the converter Figure 4

(1) from the transmission. Loosen the bolted connection
(4) and (5). Loosen both cap screws and remove the cam disc.
1 =Converter If running-in marks should be found in the pump hous-
2 =Converter bell
ing or on the cam disc, the complete pump has to be
3 = Pressure oil pump
replaced!
4 =Bolted connection Converter bell/Transm. hsg rear sec-
tion
5 =Bolted connect. Pressure oil pump/Transm. hsg rear
section
6 =Transmission housing rear section
1
4
3 5
Figure 5
2
Figure 2

Squeeze out the snap ring (1) and remove the single parts. Unsnap the retaining ring (1) from the power take-off and
1 = Pump housing with rotor remove the O-ring (2).
2 =Snap ring
3 = Shaft seal 1 2
4 = Support shim
5 = Needle bearing
6 =Ring
5
3
Figure 9
1
Pull the pump shaft (1) out of the housing bore.
6 Unsnap the rectangular ring (2).
2 4 Press off the ball bearing (3) from the shaft.
Expel both cyl. pins (5) (see Figure 12).
Figure 6 Loosen the bolted connection (4) Transmission housing
Remove the tab washer (2) and loosen the hexagon rear section/ Transmission housing front section.
screws (1).
1 2
2 3
1
4 5
Figure 10
Figure 7
By means of the lifting equipment separate the transmis-
Pull off the input shaft (1). sion housing rear section (1) from the transmission hous-
Remove the shaft seal. ing front section (2).
1
1 S
Figure 8 Figure 11

Loosen the cap screws (2) and remove the suction tube Remove the pipes (system pressure from the electro-
(1). hydraulic control to the respective clutch).
Remove the O-ring from the suction tube. Remove the holding segment (6).
Loosen the cap screws (6) and remove the screen sheet The pipes are to disassembled in the following sequence:
(5). 1 =Pipe K3
Remove the pipes (4) with O-rings. 2 =Pipe K1
Cyl. pins (3) see Figure 10. 3 = Pipe K2
4 =Pipe KR
5 =Pipe KV
3
3 4 6
4
1
5
6 5
2
Figure 12 3 1
2
The clutch is to be removed from the transmission housing Figure 15
according to the sequence of numbers as described in the
legend. Remove all bearing outer rings (see arrows).
1 =Clutch K3 Should contrary to the ZF Recommendations the taper
2 =Clutch K1 roller bearings of the clutches as well as of the input
3 =Clutch K2 not be replaced, the assignment (bearing inner and
4 =Clutch KR outer ring) has to be kept at least!
5 =Clutch KV Mark the bearing inner and bearing outer rings to each
6 =Input shaft other accordingly!
S 6 S
2 3 1
Figure 13 Figure 16
Loosen the cap screws (1) and remove the screen sheet (2).
Figure 14

Clutches KV/KR/K1/K2/K3 and Input Unsnap the retaining ring (1).
See figure on the down. 1

AN K2
KV
K1
KR K3 Figure 5
Figure 1 Press the clutch shaft (1) out of the idler (2).
1
4.1 Clutch KV
Remove the stud (1) and unsnap the piston ring (2). S
2
1 2
Figure 6
Unsnap the retaining ring (2) from the idler (1) and remove
the ball bearing (3).
2
Figure 2
Pull the taper roller bearing (inner ring) from the shaft. 3
S 1
Figure 7
Remove the needle cage (1) from the shaft (2).
Figure 3 1
Pull the clutch (1) from the shaft.
Figure 8
1
Figure 4

Rotate the shaft (2) by 180° and unsnap the piston ring (1). Pull the clutch (1) from the shaft.
1
2
Figure 9 Figure 13
Pull the taper roller bearing (inner ring) from the shaft. Unsnap the retaining ring (1).
1
S
Figure 10 Figure 14
Press the clutch shaft (1) out of the idler (2).

4.2 Clutch KR
1
Remove the stud (1) and unsnap the piston ring (2).
1 S
2 2
Figure 15
Disassemble the idler (1).
Figure 11 1
Pull the taper roller bearing (inner ring) (2) from the shaft.
Figure 16
Figure 12

Unsnap the retaining ring (2) from the idler (1) and remove Pull the taper roller bearing (inner ring) from the shaft.
the ball bearing.
2 S
3
1
Figure 21
Figure 17
Remove the needle cage (1) from the shaft (2). 4.3 Clutch K1
1
1
2
Figure 18
Shaft (2) and gear (1) cannot be separated (shrink fit). Figure 22
Pull the taper roller bearing (inner ring) from the shaft.
2 S
Figure 19
Rotate the shaft (2) by 180° and unsnap the piston ring (1). Figure 23
1 Unsnap the retaining ring (1).
Figure 20
Figure 24

Remove the complete axial bearing (1). Pull the taper roller bearing (inner ring) from the shaft.
1
S
Figure 25 Figure 29
Take off the idler (1), remove the needle cage (2) and the
complete axial bearing (3). 4.4 Clutch K2
1 1
2
2
Figure 26
Pull the clutch (1) from the shaft. Figure 30
Figure 27
1 Unsnap the retaining ring (1).
Figure 28
Figure 32

Remove the complete axial bearing (1). Pull the taper roller bearing (inner ring) from the shaft.
1
S
Figure 33 Figure 37
Take off the idler (1), remove the needle cage (2) and the
complete axial bearing (3). 4.5 Clutch K3
Unsnap the piston ring (1).
1
1
2
3
Figure34
Pull the clutch (1) from the shaft. Figure 38
Figure 35
Remove the complete axial bearing (1).
1
1
Figure 36
Figure 40

Take off the idler (1), remove the needle cage (2) and the 4.6 Input
complete axial bearing (3).
Unsnap the piston ring (1).
The turbine wheel shaft (2) and the input gear (3) are
1 attached with a snap ring.
The components are destroyed at the separation !!
2 2
3
1
Figure 41
Pull the clutch (1) from the shaft.
3
Figure 45
Pull the taper roller bearing (inner ring) from the input gear.
1 S
Figure 42
Rotate the shaft (2) by 180° and unsnap the piston rings
(1).
Figure 46
1 Pull the taper roller bearing (inner ring) from the input gear.
Figure 43
Figure 47
Figure 44

NOTE :
Group 06, Transmission Copyrighted Material SM 751, Nov ’06

Section 3
REASSEMBLY
Clutches KV/KR/K1/K2/K3 and Input Mount the needle bearing (1) onto the shaft.
In the ECU-37A (electronic transmission control) the 1

gear changes ( filling times and pressure level) are
controlled via the drive program of the transmission
electronics. Additionally, the ECU-37A monitors the
disc clearance of the clutches and if exceeded, a fault
message is given in the ZF-Display.
To ensure the shifting quality continuously, no repairs
are allowed to be made on the clutches KV/KR/K1/K2/
K3 (see Figure), which means that only the complete
clutch is allowed to be replaced. Figure 3
Put the ball bearing (2) into the idler (1) until contact is
1.1 Clutch KV obtained and fasten it by means of retaining ring (3).
Press the taper roller bearing (inner ring) (1) onto the shaft
(2) until contact is obtained. 3
1 2
2 Figure 4
Press in the preassembled idler (1) until contact.
Figure 1
Install the piston ring (1).
Figure 5
Figure 2
SM 709, Jun ’04 Copyrighted Material REASSEMBLY • 06-3-1

Fasten the idler (1) by means of retaining ring (2). Press the taper roller bearing (inner ring) (1) until contact is
obtained.
2
1
Figure 6
Figure 9
Heat up the inner diameter of the clutch (1) (approx.
120°C) Install the piston ring (1)
1
S
1
Figure 7 Figure 10
Mount the clutch (1) until contact is obtained. Install the stud (1).
Tightening torque ........................................ MA = 17 Nm
! CAUTION
Check closing resp. opening of the clutch by means of
compressed air at the bore (2).
Wear safety gloves! Closing resp. opening of the clutch must be clearly audi-
ble.
1 2 1
Figure 8
Figure 11
06-3-2 • REASSEMBLY Copyrighted Material SM 709, Jun ’04

1.2 Clutch KR Undercool the shaft (2) ( approx. 80° C).

Mount the gear until contact is obtained.
Press the taper roller bearing (inner ring) (1) onto the shaft Install the chamfer of the gear (see arrow) showing
(2) until contact is obtained. upwards!
Observe the radial installation position!
1
! CAUTION
Wear safety gloves!
Chamfer
2
1
Figure 12
2
1 Figure 15
Fasten the gear (1) by means of retaining ring (2).
Figure 13
1
Heat up the inner diameter of the gear (1) (approx. 120° C)
.
! CAUTION Figure 16
Wear safety gloves!
Mount the needle bearing (1) onto the shaft (2).
1 2
Figure 14
Figure 17

Put the ball bearing (2) into the idler (1) until contact is Mount the clutch (1) and press it until contact is obtained.
obtained and fasten it by means of retaining ring (3).
3 ! CAUTION
Wear safety gloves!
2
1
1
Figure 18
Press in the preassembled idler (1) until contact.
Figure 22
Press the taper roller bearing (inner ring) (1) until contact is
obtained.
1
1
Figure 19
Fasten the idler (1) by means of retaining ring (2).
2 Figure 23

1
1
Figure 20
Heat up the inner diameter of the clutch (1) (approx. 120°
C).
Figure 24
S
Figure 21

Install the stud (1). Install the sealing cap (1)

Tightening torque ........................................ MA = 17 Nm Wet the contact surface with (Loctite Type No. 262) !
Check closing resp. opening of the clutch by means of
Closing resp. opening of the clutch must be clearly audi- 1
ble.
1 2
Figure 28
Heat up the inner diameter of the clutch (1) (approx. 120°
C).
Figure 25
S
1.3 Clutch K1
until contact. 1
1
Figure 29
Mount the clutch (1) until contact is obtained.
! CAUTION
Wear safety gloves!
Figure 26

1
1
Figure 30
Figure 27

Mount the running disc (1), axial cage (2) and axial washer (3). Fasten the idler (1) and the single parts by means of the
Install chamfer (see arrow) of the running disc (2) showing retaining ring (2).
towards the axial cage!
3 2
Chamfer
2 1
1
Figure 35
Figure 31
Mount the needle cage (1). obtained.
1 1
Figure 32 Figure 36
Install the idler (1). Install the piston ring (1).
Figure 33 Figure 37
Mount the axial washer (1), axial cage (2) and running disc (3).
Install chamfer (see arrow) of the running disc (3) showing
Chamfer
2
3
1
Figure 34

Install the stud (1). Heat up the inner diameter of the clutch (1) (approx. 120°
Tightening torque ........................................ MA = 17 Nm C).
Check closing resp. opening of the clutch by means of com-
pressed air at the bore (2).
Closing resp. opening of the clutch must be clearly audi-
S
ble.
2 1
Figure 41
Mount the clutch (1) until contact is obtained.
Figure 38 ! CAUTION
Wear safety gloves!
1.4 Clutch K2
until contact.
1
Figure 42
Mount the running disc (1), axial cage (2) and axial washer
Figure 39 (3).
Chamfer 3
1
2
1
Figure 43
Figure 40

Mount the needle cage (1). Press the taper roller bearing (inner ring) (1) until contact is
obtained.
1 1
Figure 44
Figure 48
Install the idler (1).
1
1
Figure 45
Figure 49
Mount the axial washer (1), axial cage (2) and running disc
(3). Install the stud (1).
Install chamfer (see arrow) of the running disc (3) showing Tightening torque ........................................ MA = 17 Nm
towards the axial cage! Check closing resp. opening of the clutch by means of
Chamfer
Closing resp. opening of the clutch must be clearly audi-
2
ble.
3
1 2 1
Figure 46
Fasten the idler (1) and the single parts by means of the
retaining ring (2). Figure 50
Figure 47

1.5 Clutch K3 Mount the clutch (1) until contact is obtained.
until contact.
! CAUTION
Wear safety gloves!
Figure 51
Figure 55
Mount the running disc (1), axial cage (2) and axial washer
(3).
1
3
Chamfer
2
1
Figure 52
Install the sealing cap (1)

Wet the contact surface with (Loctite Type No. 262) !
Figure 56
1
Mount the needle cage (1).
Figure 53
Heat up the inner diameter of the clutch (1) (approx. 120° C).
Figure 57
S
1
Figure 54

Install the idler (1). Install the screw plug (1).
Figure 58 Figure 62
Mount the axial washer (1), axial cage (2) and running disc Check closing resp. opening of the clutch by means of
(3). compressed air at the bore (1).
Install chamfer (see arrow) of the running disc (3) showing Closing resp. opening of the clutch must be clearly audi-
towards the axial cage! ble.
Chamfer 3 1
1 2
Figure 59 Figure 63
obtained. 1.6 Input
1 Press the taper roller bearing (inner ring) (1) until contact is
obtained.
Figure 60

Figure 64
1
Figure 61

Press the taper roller bearing (inner ring) (1) until contact is Engine Connection, Pressure Oil
obtained.
Pump and Installation of the Clutches
Install all bearing outer rings into the bearing bores of both
transmission housing sections.
1
Should contrary to the ZF Recommendations the taper
roller bearings of the clutches as well as of the input
not be replaced, the assignment (bearing inner and
outer ring) has to be kept at least!
Mark the bearing inner and bearing outer rings to each
other accordingly!
Figure 65
2.1 Transmission housing front section
Have the snap ring (1) engaged into the annular groove of
AN = Input
the turbine wheel shaft (2).
KV = Clutch - Forward
KR = Clutch - Reverse
K1 = Clutch - 1st gear
K2 = Clutch - 2nd gear
K3 = Clutch - 3rd gear
2
KV
AN
KR K2
1
Figure 66
K1 K3
Mount the turbine wheel shaft until the snap ring engages
into the recess of the input gear - turbine wheel shaft is axi-
ally fixed!
Figure 1
2.2 Transmission housing rear section

Put the bearing outer rings with assembly grease into the
bearing bores.
KV
AN
Figure 67 KR
K2
K1
K3
Figure 2

Install the pipes (system pressure from the electro-hydrau- The clutch is to be put into the transmission housing front
lic control to the respective clutch) section as described in the legend.
The pipes are to be installed in the following sequence: 1 = Input shaft
1 Pipe KV 2 = Clutch KV
3 = Clutch KR
2 Pipe KR 4 = Clutch K2
3 Pipe K2 5 = Clutch K1
4 Pipe K1 6 = Clutch K3
5 Pipe K3 S 1 S
Install the holding segment (6).
Tightening torque (M8/8.8) ........................ MA = 23 Nm 2
3 2 6
3
5
4 6
Figure 5
1 Put the pipes and O-rings into the bores and grease them.
5
1
Figure 3 4
Fasten the screen sheet (1) by means of cap screws (2).

Tightening torque (M8/8.8) ........................ MA = 23 Nm
1
Figure 6
Fasten the screen sheet (1) by means of cap screws (2).

Tightening torque (M6/8.8) ........................ MA = 9.5 Nm
2
2
Figure 4 1
Figure 7

Install the O-ring (3) and fasten the suction pipe (1) by Install both cyl. pins (1) centrally to the mounting face.
means of cap screws (2). By means of cap screws (2 and 3) fasten the transmission
Tightening torque (M8/8) ........................... MA = 23 Nm housing rear section to the transmission housing front sec-
tion.
2 2
Cap screws with different lengths.
1 Tightening torque (M8/8) ........................... MA = 46 Nm
3
1 1 3
Figure 8
Grease the rectangular rings (see arrows) and align them

centrically. Figure 11
Wet the mounting face with sealing compound Loctite
(Type No. 574) Install the shaft seal (1) with the sealing lip showing to the
oil sump.
The exact installation position is obtained by using the
specified mounting tool (S)!
Fill the shaft seal between dust lip and sealing lip with
grease.
Wet the outer diameter with spirit.
1 S
Figure 9
Cautiously place the transmission housing rear section (1)
by means of the lifting equipment to the transmission hous-
ing front section (2) until contact is obtained.
Figure 12
Insert the input flange (1) until contact and put in the O-
ring. Fix the input flange (1) by means of washer (2) and
hexagon screws (3).
1
Then fix the hexagon screws (3) with the tab washer (4) by
means of the mounting tool (S).
2
Tightening torque (M8/10.9) ...................... MA = 34 Nm
S
Figure 10 1
3 4
Figure 13

Press the ball bearing (1) onto the pump shaft (2) until con- Install the converter safety valve (1) until contact.
tact is obtained. S
1 1
2 Figure 18
Figure 14 Install two adjusting screws and mount the intermediate
sheet (1).
Install the pump shaft (1) until contact is obtained.
The intermediate sheet has always to be replaced!
1 1
Figure 15
Figure 19
Install the retaining ring (1) and the O-ring (2).
Cautiously place the converter bell (1) by means of the lift-
Grease the O-ring
ing equipment to the transmission until contact is obtained.
1 2
Figure 16
Figure 20
Install two adjusting screws and mount the stator hollow
shaft (1).
Observe the radial installation position!
Figure 17

Pressure oil pump: Cautiously put the shaft seal (3) with the sealing lip show-
ing downwards into the pump housing (1) until contact and
If running-in marks should be found in the pump hous- fasten it by means of the snap spring (2).
ing or on the cam disc, the complete pump has to be Wet the outer diameter of the shaft seal with spirit!
replaced!
Items 1 - 6 are allowed to be replaced! 2
1 = Pump housing with rotor
2 =Snap ring
3
3 = Shaft seal
4 = Support shim
5 = Needle bearing cpl. (bearing outer ring and needle
bearing)
6 =Ring
1
Figure 23
6
5 Installation of the external and internal rotor:
4 1
3 Install the external rotor.
2 Chamfer shows to the pump base (cannot be seen in the
picture) !
Install the internal rotor.
Gearing (arrow) shows downwards !!
Figure 21
Install the following parts into the pump housing (1).
6 = Ring
5A = Bearing outer ring
5B = Needle cage
4 = Support shim
4
5B
Figure 24
5A Put on the cam disc and by means of two cap screws (1)
6
fasten it radially.
Do not tighten the cap screws - just turn them in until con-
tact is obtained and then make approx. 1/2 rotation back!
1 Observe the installation position of the cam disc, see fig-
ure! Put the O-ring (2) into the annular groove and oil it.
Figure 22
Figure 25

Mount the preassembled pressure oil pump (1) and with Fasten the flexplate (1) by means of hexagon screws (2).
the cap screws (3 pcs.) first place it equally until contact is Install washers between converter (3) and flexplate (1)
obtained. under the hexagon screws.
Observe the radial installation position! Lock the hexagon screws with Loctite (Type No. 262)!
Then remove the cap screws again. Tightening torque (M12/10.9) .................... MA = 115 Nm
1
1
2
3
Figure 26 Figure 29
Fasten the converter bell, pressure oil pump and stator

hollow shaft together by means of cap screws.
Different bolted connections!
1 =Bolted connection converter bell/transmiss. hsg rear
section
Tightening torque (M10/8.8) ...................... MA = 46 Nm
2 = Bolted connect. pressure oil pump/ stator hollow shaft
transmission housing rear section
Cap screws with O-rings!
Grease the O-rings!
2
1
Figure 27
Mount the converter (1) by means of lifting equipment until

contact is obtained.
Figure 28

Inductive Transmitters, Valves, Oil Installation of:

1 = Inductive transmitter - n Engine
Filler and Oil Drain Plug, Screw Plugs 2 = Screw plug M10x1 (measuring point pressure after
converter)
Install the converter pressure back-up valve. 3 = Temperature transmitter M14x1.5 (measuring point
1 = Piston temperature after converter)
2 = Compression spring Tightening torque (1) ................................. MA = 30 Nm
3 = O-Ring (27x2) Tightening torque (2) ................................. MA = 9.5 Nm
4 = Screw plug (30x1.5) Tightening torque (3).................................. MA = 25 Nm
1
1
2
2
3
4 3
Figure 1 Figure 3
Installation of:
Install the differential pressure switch for the pressure filter. 1 = Inductive transmitter - n Internal speed input
1 = Compression spring 2 = Inductive transmitter - n Turbine
2 = Piston 3 = Breather
3 = Tappet switch Tightening torque (1 und 2) ....................... MA = 30 Nm
Tightening torque ........................................ MA = 30 Nm Tightening torque (3) ................................. MA = 12 Nm
Fasten the coverplate (4) by means of hexagon screws
(5).
1 3 Tightening torque (M16/8.8)...................... MA = 46 Nm
3 4
5
2
Figure 2
1
2
Figure 4

Installation of:
1 = Speed transmitter
2 = Cap screw
Tightening torque (2) (M8/8.8).................. MA = 23 Nm
3 = Install the coverplate (3) with gasket.
4 = Hexagon screw
Tightening torque (2) (M8/8.8).................. MA = 23 Nm
1
4
3
Figure 5
Fasten the oil filler tube (1) with O-ring (2) to the transmis-
sion housing by means of the hexagon screws (3).
Turn the oil dipstick (4) into the oil filler tube.
Tightening torque (M8/8.8)......................... MA = 23 Nm
Install the oil drain plug (5) with the O-ring.
Fasten the fixing plate (6) by means of cap screws (7).
Tightening torque (M10/8.8)........................... MA = 46 Nm
6 4
7
1
2
5 3
Figure 6

Electro-hydraulic control unit with proportional valves:

Di Different versions as to the positions of the wiring harness are possible!
Pa Pay attention to the data of the vehicle manufacturer!
The following sketches shows the sections of the electro-hydraulic control unit.
Main press. valve 16+2 bar Press. reducing valve 9 bar

Wiring harness
A A
Y6 Y1
Y5 Y2
B B
Y4 Y3
Cover Cover
Housing Valve block Housing
Figure 1
Section A - A
Section B - B Main press valve 16+2 bar Wiring harness
Proportional valve P5
Valve block
Vibration damper
Y5
Press regulator Duct plate Press reducing valve 9 bar

Follow-on slide
Figure 2 Figure 3

4.1 Mounting of the Electric Control Unit Install two adjusting screws.
Assemble flat gasket (1) and housing cover.
All single parts are to be checked for damage and Then place the housing cover by means of adjusting
replaced, if required! screws equally until contact.
Prior to installation check the mobile parts in the hous-
ing for functionality! Pistons can be replaced individu- 1
ally! S
Oil the single parts prior to installation acc. to the ZF
list of lubricants TE-ML 03! S
Place the orifices (1) with the concave side showing
upwards, until contact!
Installation position, see arrows!
1 1
Figure 7
Preload the pistons with cap screws and remove the cyl.
pins (assembly aid) again.
Figure 4
The figure on the left shows the following single parts:

1 = Pressure reducing valve (1x, Piston a. compr.spring)
2 = Vibration damper (3x, Piston a. compr.spring)
3 = Follow-on slide (3x, Piston a. compr.spring)
Figure 8
Fasten the housing cover by means of cap screws (1).

3 Tightening torque ....................................... MA = 5.5 Nm
1 2
Figure 5
Install the single parts acc. to Figure 5.
Preload the compression springs of the follow-on slides
and fasten the pistons preliminarily by means of cylindrical
pins Φ 5.0 mm (assembly aid), see arrows (S)! Figure 9
Figure6

Mount the pressure regulators (1) and fasten them by Preload the pistons with cap screws and remove the cyl.
means of fixing plates (2) and cap screws (3). pins (assembly aid) again.
Install the fixing plate with the neck showing downwards! Then fasten the housing cover by means of cap screws
Observe radial installation position of the pressure regula- (1).
tors, see Figure! Tightening torque ....................................... MA = 5.5 Nm
Tightening torque ....................................... MA = 5.5 Nm
1
1 3
Figure 13
Figure 10
Mount the pressure regulators (1) and fasten them by
Preassemble the opposite side means of fixing plates and cap screws.
The figure on the left shows the following single parts: Install the fixing plate with the neck showing down-
1 = Main pressure valve (1x, Piston a. compr.spring) wards!
2 = Vibration damper (3x, Piston a. compr.spring) Observe radial installation position of the pressure
3 = Follow-on slide (3x, Piston a. compr.spring) regulators, see Figure!
1
1
3
Figure 11 2
Install the single parts acc. to Figure 11. Figure 14
Preload the compression springs of the follow-on
slides and fasten the pistons preliminarily by means Assemble the wiring harness (1) and connect the pressure
regulators (6x).
of cylindrical pins (S) Φ 5.0 mm (assembly aid), see
See Figure 1 for installation position of pressure regulators!
arrows (S)!
Pay attention to the installation position of the wiring har-
Install two adjusting screws.
Assemble flat gasket (1) and housing cover. Then place ness, also see markings (Chapter/Figure 6)!
the housing cover by means of adjusting screws equally
until contact. 1
1
S Figure 15
Figure 12

Put on the flat gasket (1). Screens (1) are to be flush mounted into the bores of the
Assemble the plug socket with the slot showing to the lug intermediate sheet, see arrows !
of the cover until contact. Observe the installation position - the screens are showing
Fasten the cover by means of cap screws. upwards (to the duct plate)!
1
1
Figure 19
Figure 16
Put on the intermediate sheet (1).
Fix the wiring harness by means of retaining clamp (1). Screens (2) must show upwards!
Install the opposite cover.
1 2
1
Figure 20
Figure 17
Put on the duct plate (1) and tighten it equally with Torx
Install two adjusting screws. screws (2).
Tightening torque ........................................ MA = 9.5 Nm
S
1
2
Figure 18
Figure 21

Provide the screw plugs (1) with new O-rings and install them. 4.2 Mounting of ZF-Micro Filter (Pressure Fil-
Tightening torque ....................................... MA = 6 Nm
ter)
1 Fasten the filter head (1 ) with new O-rings by means of
cap screws (2) to the transmission housing.
Tightening torque (M8) .............................. MA = 23 Nm
Figure 22 1
Insert the pressure relief valve (1) and lock it with the
indented ring (2). 2
Figure 26
The filter is to be installed as follows:
- Oil the gasket slightly
1 - Turn in the filter until contact with the sealing surface
2 is obtained and then tighten it by hand with an
approx. 1/3 to 1/2 rotation.
Prior to initial operation of the transmission make the
oil filling in accordance with the Operating Instruc-
S tions
Figure 23
Mount the gasket (1) and the cpl. shift system (2).
1
2
1
Figure 27
Figure 24
Fasten the electro-hyraulic control unit (1) equally by
means of Torx screws (2).
Tightening torque (M6) .............................. MA = 11 Nm

NOTE :
Group 06, Transmission Copyrighted Material SM 709, Jun ’04

Section 4
AEB Setting of T/M controller clutch & INCHING calibration
• IntroductionThe AEB setting of T/M controller and fully, and release the parking brake.
Inching calibration should be performed for the follow-
ing cases, so that the normal operation (AUTO mode
and Inching operation) can be performed. 29MAR06[WED] H
AEB Setting of T/M controller

− When the truck is initially delivered C
− When T/M is repaired or replaced, when the

controller or the related parts (Solenoid valve,
C60
N
DR ML
W/Harness, connector) are replaced, or when
reassembling after disassembly
− When the condition of T/M is changed during
the operation 2) Turn the gear shift lever to Forward 3 (If F 1/F2 is
selected, the truck could run and the load be applied to
the gear). Press the accelerator pedal to maintain the
Conditions of AEB setting of T/M controller engine RPM as 1500 ~ 2000 RPM for 15~20 seconds
1. T/M temp : 80℃ ~ 85℃ (Process to raise the T/M oil temp). (Press button. '
2. Engine rpm : 900RPM ~ 1200RPM Move by use of or buttons, and then press
3. Gearshift lever: Neutral button in 4. ZF CONTROL DATA. ' Move by use
4. Parking brake : Operated of or buttons, and then check the functions in
4.1 Engine Speed.)
5. Placement : Well ventilated, flat and safe place
6. Oil volume in T/M : Nominal
29MAR06[WED] H
Preparations before AEB setting of T/M con-

troller
! CAUTION C
4.1 Engine speed

When the accelerator is pushed for more 1925 [rpm]
than 30sec in the process of 2), 3), 4) in above
para. 1.1 to increase the temp of T/M oil, T/M
may be overheated. Pay attention to the con-
dition of T/M. 3) Turn the gear shift lever to Neutral, and maintain the
engine RPM 1500 ~ 2000RPM for 15 ~ 20 seconds
1) Warming-up after starting the engine (Process to circulate the heated oil instantly).
Press the button to select the DR Mode(DR ↔ OP) 4) Turn the gear shift lever to Reverse, and maintain the
engine RPM 1500 ~ 2000RPM for 15 ~ 20 seconds.
and press the button to select ML Mode (ML → A1 5) Repeat the above 2), 3) and 4) procedures (5 ~
→ A2 → ML). (Under the OP mode in initial opera- 10times) to set the T/M oil temp to 80 ~ 85℃.
tion, the gear won't be operated). Press the brake pedal
(Press button ' Move by use of or buttons,
and then press button in 4. ZF CONTROL DATA '
Move by use of or buttons, and then check the
SM 751, Jan ’07 AEB Setting of T/M

Copyrighted controller clutch & INCHING calibration • 06-4-1
Material
functions in 4.3 T/M SUMP TEMP) 5) If "AEB STOP" is displayed, it means that the opera-
tion is stopped.
6) When the operation is stopped by "AEB STOP", stop
29MAR06[WED] H
the engine and then repeat the procedure from 1) after
5 seconds.
7) If the operation is normal, "[Y] K1 Adjusting" will be
displayed and the AEB setting of T/M checked on the
LCD. (Y means the frequency)
C
(If ① GO UP E/SPEED is displayed → Push Accelera-

tor pedal to increase the engine RPM.
② GO DOWN E/SPEED is displayed → Release
Accelerator pedal to decrease engine RPM.
③ Refer to AEB-MODE TABLE for display of nor-
mal operation)
AEB setting procedures of T/M controller
1) Set the gear shift lever to Neutral.
29MAR06[WED] H
2) Operate the parking brake.
3) Start the engine, and enter Command Menu Mode of
AEB setting of T/M controller.
(Press button → Move by use of or buttons, C
and then press button in 8. AEB MODE → Press [1] K1 Adjusting
button in Password Input window (10000 is dis-

played in the screen) → Enter by use of button)
8) The AEB setting of T/M controller will be automati-

cally performed in the order of "K1", "K2", "K3",
29MAR06[WED] H
"KR" and "KV".
9) If the AEB setting of T/M controller clutch is finished,
"AEB OK" will be displayed. It will be completed by
Key OFF.
C
PASSWORD INPUT
10000
29MAR06[WED] H
4) At this time, "8.1 AEB START YES[ENTER:M]"is C
displayed. Press button. AEB OK
29MAR06[WED] H
• The AEB setting of T/M controller and Inching calibra-

tion should be performed for the following cases, so
that the normal operation (AUTO mode and Inching
C
operation) can be performed.
8.1 AEB START
Yes[ENTER:M]
06-4-2 • AEB Setting of T/M controller clutchCopyrighted

& INCHING calibration
Material SM 751, Jan ’07
INCHING calibration YES[ENTER:M], and press button)

− When the truck is initially delivered
− When Inching system is repaired or replaced,
when the related parts (Solenoid valve, W/Har- 29MAR06[WED] H
ness, connector) are replaced, or when reas-

sembling after disassembly
− When the condition of Inching system is
changed during the operation C
8.2 INCHING START

YES[ENTER:M]
Conditions of inching calibration
1. T/M temp: Regardless
2. Engine rpm: Stop
3. Gearshift lever: Neutral 2) When "PUSH PEDAL" is displayed, start the engine
and push the inching pedal fully until "RELEASE
4. Parking brake : Operated PEDAL" is displayed, and then release the pedal.
5. Placement : Well ventilated, flat and safe place
6. Do not start the truck, but turn the key to "ON" posi- 29MAR06[WED] H
tion.
2.2 Inching calibration procedures

C
1) Check the safety condition of truck. (Press button ' PUSH PEDAL
Move by use of or buttons, and then press

button in 8. AEB MODE ' Press button in Pass-
word Input window (10000 is displayed in the screen) '
Enter by use of button ' Move by use of or
3) If the inching calibration can't be accomplished, the
buttons in 8.2 INCHING START condition will be displayed on LCD and the calibra-
tion procedure will be checked. (Refer to INCHING
CALIBRATION-MODE table.)
LCD Mode Actions
GO DOWN SENS-POS 1. Calibration is stopped. 1. Adjust the inching sensor

2. The inching sensor position is out of specifi- position.
cation when the inching pedal is released. 2. Recalibrate after KEY OFF.
GO UP SENS-POS 1. Calibration is stopped. 1. Adjust the inching sensor

2. The inching sensor position is out of specifi- position.
cation when the inching pedal is pushed. 2. Recalibrate after KEY OFF.
GO UP SENS-ANG 1. Calibration is stopped. 1. Adjust the inching pedal

2. The sensing angle of inching pedal is low angle.
when it is pushed and released. 2. Recalibrate after KEY OFF.
GO DOWN SENS-ANG 1. Calibration is stopped. 1. Adjust the inching pedal

2. The sensing angle of inching pedal is high angle.
when it is pushed and released. 2. Recalibrate after KEY OFF.

Material
4) If the inching calibration is normally completed,

"INCHING CAL OK" will be displayed on LCD. Stop
the engine.
29MAR06[WED] H
INCHING CAL OK
5) Start the engine and check the operating condition of

truck, and then stop the engine.(The INCHING opera-
tion can be performed under OP MODE only, set to
OP MODE before checking the operating condition.)
! CAUTION
In case of AEB setting of T/M controller, pay
attention to the safety accidents due to
abnormal operation of braking system and
safety devices.
The AEB setting of T/M controller and Inch-
ing calibration shall be performed separately.

AEB-Mode
Num LCD Mode Actions
1 AEB START 1. Press ENTER button.
YES[ENTER:M]
2 [Y] K1 Adjusting 1. K1 Clutch is under adjustment.
2. Y means the adjusting number.
6 [Y] KV Adjusting 1. KV Clutch is under adjustment.
7 [Y] KR Adjusting 1. KR Clutch is under adjustment.
8 AEB OK 1. AEB setting is completed. 1. KEY OFF
9 AEB STOP 1. AEB setting is stopped. 1. Reset after KEY OFF.
10 K1 Clutch Error 1. AEB setting is stopped. 1. Reset after KEY OFF.
2. Error is occurred to K1 clutch during AEB setting.
14 KV Clutch Error 1. AEB setting is stopped. 1. Reset after KEY OFF.
2. Error is occurred to KV clutch during AEB setting.
15 KR Clutch Error 1. AEB setting is stopped. 1. Reset after KEY OFF.
2. Error is occurred to KR clutch during AEB setting.
16 GO UP E/SPEED 1. Engine Speed is too low. 1. Increase the Engine Speed by
2. Go up the Engine Speed. pushing the accelerator pedal.
17 GO DOWN E/SPEED 1. Engine Speed is too high. 1. Decrease the Engine Speed by
2. Go down the Engine Speed. releasing the accelerator
pedal.
18 GO UP T/M TEMP 1. AEB setting is stopped. 1. Raise the T/M temp after KEY
2. T/M temp is too low. OFF.
3. Go up the T/M temp. 2. Reset after KEY ON.
19 GO DOWN T/M TEMP 1. AEB setting is stopped. 1. Lower the T/M temp after KEY
2. T/M temp is too high. OFF.
3. Go down the T/M temp. 2. Reset after KEY ON.
20 SPEED NOT ZERO 1. AEB setting is stopped. 1. Make the truck not to move.
2. The truck speed is not ZERO. 2. Reset after KEY OFF.
21 GO NEUTRAL SHIFT 1. AEB setting is stopped. 1. Put the F/R Lever to Neutral
2. F/R Lever isn't placed in Neutral position. position.
2. Reset after KEY OFF.
22 APPLY PARKING 1. AEB setting is stopped. 1. Lock the parking brake.
2. Parking brake isn't locked. 2. Reset after KEY OFF.

Material
Inching Calibration-Mode
Num LCD Mode Actions
1 INCHING CAL START 1. Press ENTER button.
YES[ENTER:M]
2 PUSH PEDAL 1. Push the Inching pedal fully.
2. Maintain the condition.
3 RELEASE PEDAL 1. Release the Inching pedal completely.
4 CAL ABORT 1. Error is occurred during Inching calibration. 1. Recalibrate after KEY OFF
2. Release the Inching pedal completely.
5 INCHING CAL OK 1. Inching Calibration is normally completed. 1. KEY OFF
6 GO NEUTRAL SHIFT 1. Calibration is stopped. 1. Place the F/R Lever to Neu-
2. F/R Lever isn't placed in Neutral position. tral position.
2. Recalibrate after KEY OFF.
7 SENS/INPUT V ERR 1. Calibration is stopped. 1. Recalibrate after KEY OFF.
2. The input voltage to inching sensor is out of speci- 2. Check the input voltage to
fication value. inching sensor.
8 SPEED NOT ZERO 1. Calibration is stopped. 1. Make the truck not to move.
2. Truck speed isn't ZERO. 2. Recalibrate after KEY OFF.
9 GO UP SENS-V 1. Calibration is stopped. 1. Adjust the input voltage to
2. The input voltage to inching sensor is under speci- inching sensor.
fication value. 2. Recalibrate after KEY OFF.
10 GO DOWN SENS-V 1. Calibration is stopped.
2. The input voltage to inching sensor is above spec-
ification value.
11 GO DOWN SENS-POS 1. Calibration is stopped. 1. Adjust the inching sensor
2. The inching sensor position is out of specification position.
when the inching pedal is released. 2. Recalibrate after KEY OFF.
12 GO UP SENS-POS 1. Calibration is stopped. 1. Adjust the inching sensor
2. The inching sensor position is out of specification position.
when the inching pedal is pushed. 2. Recalibrate after KEY OFF.
13 INTER ERROR 1. Calibration is stopped. 1. Recalibrate after KEY OFF.
2. Inner error is occurred in T/M controller.
14 TIME OUT 1. Time is over during Calibration. 1. Recalibrate after KEY OFF.
2. Inching pedal won't work after starting the Calibra-
tion.
15 GO UP SEN-ANG 1. Calibration is stopped. 1. Adjust the sensing angle of
2. The sensing angle of inching pedal is low when it inching pedal.
is pushed and released. 2. Recalibrate after KEY OFF.
16 GO DOWN SENS-ANG 1. Calibration is stopped. 1. Adjust the sensing angle of
2. The sensing angle of inching pedal is high when it inching pedal.
is pushed and released. 2. Recalibrate after KEY OFF.
17 MISMATCH SIG 1/2 1. Calibration is stopped. 1. Adjust the inching sensor
2. The inching sensor input signal 1 and 2 are mis- input signal.
matched. 2. Recalibrate after KEY OFF.

Section 5
TROUBLESHOOTING
Introduction TRANSMISSION-SHUTDOWN:
TCU has detected a severe failure that disables control of
Abbreviations the transmission.
o.c : open circuit TCU will shut off the solenoid valves for the clutches and
also the common power supply (VPS1).
s.c : short circuit
Transmission shifts to Neutral. The park brake will oper-
OP-Mode : operating mode ate normally, also the other functions which
TCU : transmission control unit use ADM 1 to ADM 8.
EEC : electronic engine controller The operator has to slow down the vehicle. The transmis-
PTO : power take off sion will stay in neutral.
Definition of operating modes TCU-SHUTDOWN:

TCU has detected a severe failure that disables control of
NORMAL: system.
There's no failure detected in the transmission-system or TCU will shut off all solenoid valves and also both com-
the failure has no or slight effects on transmission control. mon power supplies (VPS1, VPS2). The park brake will
TCU will work without or in special cases with little limi- engage, also all functions are disabled which use ADM 1
tations. (see following table) to ADM 8.
The transmission will stay in neutral.
SUBSTITUTE CLUTCH CONTROL:
TCU can't change the gears or the direction under the con-
trol of the normal clutch modulation. TCU uses the substi-
tute strategy for clutch control. All modulations are only
time controlled. (Comparable with EST 25)
LIMP-HOME:
The detected failure in the system has strong limitations to
transmission control. TCU can engage only one gear in
each direction. In some cases only one direction will be
possible.
TCU will shift the transmission into neutral at the first
occurrence of the failure. First, the operator must shift the
gear selector into neutral position.
If output speed is less than a threshold for neutral to gear
and the operator shifts the gear selector into forward or
reverse, the TCU will select the limp-home gear .
If output speed is less than a threshold for reversal speed
and TCU has changed into the limp-home gear and the
operator selects a shuttle shift, TCU will shift immedi-
ately into the limp-home gear of the selected direction.
If output speed is greater than the threshold, TCU will
shift the transmission into neutral. The operator has to
slow down the vehicle and must shift the gear selector into
neutral position.
SM 751, Jan ’07 Copyrighted Material TROUBLESHOOTING • 06-5-1

Table of fault codes
Fault MEANING OF THE FAULT CODE

reaction of the TCU possible steps to repair remarks
Code possible reason for fault detection
12 12 : Logical Error TCU shifts transmis- • check the cables from fault is taken back
TCU detected a wrong signal combina- sion to neutral TCU to shift lever if TCU detects a
valid signal for
tion for the direction OP-Mode: transmission • check signal combina-
shutdown tions of shift lever posi- the direction at
• cable from shift lever to TCU is bro- the shift lever
ken tions F-N-R
• cable is defective and is contacted to

battery voltage or vehicle ground
• shift lever is defective
21 21 : S.C Batt Clutch IN clutch cutoff function is • check the cable from
disabled TCU to the sensor
the measured voltage is too high:
OP-Mode: normal • check the connectors
battery voltage • check the clutch cutoff
• clutch cut off sensor has an internal sensor
defect
• connector pin is contacted to battery
voltage
22 22 : S.C Gnd Clutch IN clutch cutoff function is • check the cable from
disabled OP-Mode: nor- TCU to the sensor
the measured voltage is too low:
mal • check the connectors
vehicle ground • check the clutch cutoff
• cable has no connection to TCU sensor
• clutch cut off sensor has an internal
defect
• connector pin is contacted to vehicle
ground or is broken
25 25 : T/M Error no reaction, • check the cable from
the measured voltage is too high: TCU uses default tem- TCU to the sensor
• cable is defective and is contacted to perature • check the connectors
battery voltage OP-Mode: normal • check the temperature
sensor
• cable has no connection to TCU
• temperature sensor has an internal
defect
voltage or is broken
26 26 : T/M Error no reaction, • check the cable from
TCU to the sensor
the measured voltage is too low: TCU uses default tem-
perature • check the connectors
vehicle ground OP-Mode: normal • check the temperature
sensor
• temperature sensor has an internal
defect
ground
06-5-2 • TROUBLESHOOTING Copyrighted Material SM 751, Jan ’07


2B 2B : Inchsensor MIS During inching mode: • check the cable from
TCU shifts to neutral TCU to the sensor
the measured voltage from CCO and
CCO2 signal don’t match: While not inching: no • check the connectors
change
• cable is defective • check sensor
OP-Mode: normal
• sensor has an internal defect
31 31 : T/M Error OP-Mode: substitute • check the cable from
TCU measures a voltage higher than clutch control TCU to the sensor
7.00 V at speed input pin • check the connectors
• cable is defective and is contacted • check the speed sensor
tobattery voltage
• speed sensor has an internal defect
voltage or has no contact
clutch control TCU to the sensor
TCU measures a voltage less than 0.45V
at speed input pin • check the connectors
• cable / connector is defective and is • check the speed sensor
contacted to vehicle ground
33 33 : Logical Error OP-Mode: substitute • check the cable from This fault is reset
TCU measures a engine speed over a clutch control TCU to the sensor after power up of
TCU
threshold and the next moment the mea- • check the connectors
sured speed is zero
• check the speed sensor
• cable / connector is defective and has
bad contact • check the sensor gap
• sensor gap has the wrong size
TCU measures a voltage higher than
7.00 V at speed input pin if a failure is existing at • check the connectors
output speed,
• cable is defective and is contacted to • check the speed sensor
battery voltage TCU shifts to neutral
• cable has no connection to TCU OP-Mode: limp home
at speed input pin if a failure is existing at • check the connectors
output speed,
contacted to vehicle ground TCU shifts to neutral
• speed sensor has an internal defect OP-Mode: limp home


clutch control TCU to the sensor after power up of
TCU measures a turbine speed over a TCU
threshold and at the next moment the if a failure is existing at • check the connectors
measured speed is zero output speed,
• check the speed sensor
• cable / connector is defective and has TCU shifts to neutral
• check the sensor gap
bad contact OP-Mode: limp home
TCU measures a voltage higher than
• cable is defective and is contacted to • check the speed sensor
battery voltage
TCU measures a voltage less than 0.45V clutch control TCU to the sensor
at speed input pin • check the connectors
clutch control TCU to the sensor after power up of
TCU measures a internal speed over a
threshold and at the next moment the • check the connectors TCU
measured speed is zero • check the speed sensor
• cable / connector is defective and has • check the sensor gap
bad contact
3A 3A : T/M Error special mode for gear • check the cable from
TCU measures a voltage higher than selection OP-Mode: TCU to the sensor
substitute clutch control
if a failure is existing at
• cable is defective and is contacted to turbine speed, • check the speed sensor
battery voltage
TCU shifts to neutral
OP-Mode: limp home


3B 3B : T/M Error special mode for gear • check the cable from
selection TCU to the sensor
at speed input pin OP-Mode: substitute • check the connectors
clutch control
contacted to vehicle ground if a failure is existing at
• speed sensor has an internal defect turbine speed,
OP-Mode: limp home
3C 3C : Logical Error special mode for gear • check the cable from This fault is reset
selection TCU to the sensor after power up of
TCU measures a output speed over a
threshold and at the next moment the OP-Mode: substitute • check the connectors TCU
measured speed is zero clutch control • check the speed sensor
• cable / connector is defective and has if a failure is existing at • check the sensor gap
bad contact turbine speed,
• speed sensor has an internal defect TCU shifts to neutral
• sensor gap has the wrong size OP-Mode: limp home
3E 3E : T/M Error special mode for gear • check the sensor signal This fault is reset
if transmission is not neutral and the selection of output speed sensor after power up of
TCU
shifting has finished, OP-Mode: substitute • check the sensor gap of
clutch control output speed sensor
TCU measures outputspeed zero and tur-
bine speed or internal speed not equal to if a failure is existing at • check the cable from
zero. turbine speed, TCU to the sensor
• speed sensor has an internal defect TCU shifts to neutral
• sensor gap has the wrong size OP-Mode: limp home
71 71 : S.C Batt K1 TCU shifts to neutral • check the cable from
the measured resistance value of the OP-Mode: limp home TCU to the gearbox
valve is out of limit, the voltage at K1 if failure at another • check the connectors
valve is too high. from TCU to the gear-
clutch is pending box
• cable / connector is defective and has
contact to battery voltage TCU shifts to neutral • check the regulator
• regulator has an internal defect OP-Mode: TCU shut- resistance
down
• check internal wire har-
ness of the gearbox
72 72 : S.C Gnd K1 TCU shifts to neutral • check the cable from
valve is too low. from gearbox to TCU
clutch is pending
• cable / connector is defective and has • check the regulator
contact to vehicle ground TCU shifts to neutral resistance
• cable / connector is defective and has OP-Mode: TCU shut- • check internal wire har-
down
contact to another regulator output of ness of the gearbox
the TCU
• regulator has an internal defect


73 73 : S.C K1 TCU shifts to neutral • check the cable from
TCU to the gearbox
the measured resistance value of the OP-Mode: limp home
valve is out of limit. • check the connectors
if failure at another from gearbox to TCU
• cable / connector is defective and has clutch is pending
no contact to TCU • check the regulator
• regulator has an internal defect resistance
OP-Mode: TCU shut-
down • check internal wire har-
ness of the gearbox
valve is too high. from gearbox to TCU
clutch is pending
contact to battery voltage TCU shifts to neutral resistance
• regulator has an internal defect OP-Mode: TCU shut- • check internal wire har-
down
ness of the gearbox
TCU to the gearbox
valve is out of limit, the voltage at K2 • check the connectors
if failure at another
valve is too low. clutch is pending from gearbox to TCU
• cable / connector is defective and has TCU shifts to neutral • check the regulator
contact to vehicle ground resistance
OP-Mode: TCU shut-
• cable / connector is defective and has • check internal wire har-
contact to another regulator output of down ness of the gearbox
the TCU
TCU to the gearbox
OP-Mode: TCU shut-
ness of the gearbox
clutch is pending
• egulator has an internal defect OP-Mode: TCU shut- • check internal wire har-
down
ness of the gearbox


78 78 : S.C Gnd K3 TCU shifts to neutral • . check the cable from
TCU to the gearbox
valve is out of limit, the voltage at K3 • . check the connectors
valve is too low. if failure at another from gearbox to TCU
clutch is pending
• cable / connector is defective and has • . check the regulator
OP-Mode: TCU shut-
• cable / connector is defective and has down • . check internal wire
contact to another regulator output of harness of the gearbox
the TCU
TCU to the
• . cable / connector is defective and clutch is pending
has no contact to TCU • check the regulator
• . regulator has an internal defect resistance
OP-Mode: TCU shut-
down gearbox • check internal wire har-
ness of the gearbox
clutch is pending
• regulator has an internal defect OP-Mode: TCU shut- • check internal wire har-
down
ness of the gearbox
TCU to the gearbox
valve is out of limit, the voltage at K4 • check the connectors
valve is too low. if failure at another from gearbox to TCU
clutch is pending
OP-Mode: TCU shut-
• cable / connector is defective and has down • check internal wire har-
the TCU
TCU to the gearbox
OP-Mode: TCU shut-
ness of the gearbox


84 84 : S.C Batt KV TCU shifts to neutral • check the cable from
TCU to the gearbox
valve is out of limit, the voltage at KV • check the connectors
valve is too high. if failure at another from gearbox to
clutch is pending
contact to battery voltage resistance
OP-Mode: TCU shut-
• regulator has an internal defect down TCU • check internal wire har-
ness of the gearbox
85 85 : S.C Gnd KV TCU shifts to neutral • check the cable from
valve is out of limit, the voltage at KV if failure at another • check the connectors
valve is too low. from gearbox to TCU
clutch is pending
contact to vehicle ground TCU shifts to neutral resistance
• cable / connector is defective and has OP-Mode: TCU shut- • check internal wire har-
down
the TCU
86 86 : S.C KV TCU shifts to neutral • check the cable from
valve is out of limit. if failure at another • check the connectors
from gearbox to TCU
TCU shifts to neutral resistance
OP-Mode: TCU shut- • check internal wire har-
down
ness of the gearbox
87 87 : S.C Batt KR TCU shifts to neutral • check the cable from
TCU to the gearbox
valve is out of limit, the voltage at KR • check the connectors
valve is too high. if failure at another from gearbox to TCU
clutch is pending
contact to battery voltage resistance
OP-Mode: TCU shut-
• regulator has an internal defect down • check internal wire har-
ness of the gearbox
88 88 : S.C Gnd KR TCU shifts to neutral • check the cable from
valve is out of limit, the voltage at KR if failure at another • check the connectors
valve is too low. from gearbox to
clutch is pending
• . cable / connector is defective and • check the regulator
has contact to vehicle ground TCU shifts to neutral resistance
• . cable / connector is defective and OP-Mode: TCU shut- • check internal wire har-
down TCU
has contact to another regulator out- ness of the gearbox
put of the TCU
• . regulator has an internal defect


89 89 : S.C KR TCU shifts to neutral • check the cable from
TCU to the gearbox
OP-Mode: TCU shut-
ness of the gearbox
91 91 : S.C Gnd B/ALARM backup alarm will be on • check the cable from
TCU detected a wrong voltage at the out- until TCU to the backup
alarm device
put pin, that looks like a s.c. to vehicle TCU power down even
ground if fault vanishes (loose • check the connectors
connection) from backup alarm
vehicle ground OP-Mode: normal device to TCU
• backup alarm device has an internal • check the resistance of
backup alarm device
defect
ground
92 92 : S.C Batt B/ALARM no reaction • check the cable from
TCU detected a wrong voltage at the out- OP-Mode: normal TCU to the backup
alarm device
put pin, that looks like a s.c. to battery
voltage • check the connectors
from backup alarm
• . cable is defective and is contacted to
battery voltage device to TCU
• . backup alarm device has an internal • check the resistance of
backup alarm device
defect
• . connector pin is contacted to battery
voltage
93 93 : O.C B/ALARM no reaction • check the cable from
TCU to the backup
TCU detected a wrong voltage at the out- OP-Mode: normal
put pin, that looks like a o.c. for this out- alarm device
put pin • check the connectors
from backup alarm
• cable is defective and has no connec- device to TCU
tion to TCU
• check the resistance of
• backup alarm device has an internal
defect backup alarm device
• connector has no connection to TCU


B1 B1 : SLIP K1 TCU shifts to neutral • check pressure at clutch
K1
TCU calculates a differential speed at OP-Mode: limp home
closed clutch K1. If this calculated value • check main pressure in
is out of range, TCU interprets this as if failure at another the system
clutch is pending
slipping clutch. • check sensor gap at
• low pressure at clutch K1 internal speed sensor
OP-Mode: TCU shut-
• low main pressure down • check sensor gap at out-
put speed sensor
• wrong signal at internal speed sensor
• check signal at internal
• wrong signal at output speed sensor speed sensor
• wrong size of the sensor gap • check signal at output
• clutch is defective speed sensor . replace
clutch
TCU calculates a differential speed at OP-Mode: limp home K2
closed clutch K2. If this calculated value if failure at another • check main pressure in
is out of range, TCU interprets this as the system
slipping clutch. clutch is pending
• check sensor gap at
• low pressure at clutch K2 TCU shifts to neutral internal speed sensor
• low main pressure OP-Mode: TCU shut- • check sensor gap at out-
down
• wrong signal at internal speed sensor put speed sensor
• wrong signal at output speed sensor • check signal at internal
speed sensor
• wrong size of the sensor gap
• check signal at output
• clutch is defective speed sensor
• replace clutch
K3
• check main pressure in
closed clutch K3. If this calculated value if failure at another the system
clutch is pending
is out of range, TCU interprets this as • check sensor gap at
slipping clutch. internal speed
OP-Mode: TCU shut-
• low pressure at clutch K3 down sensor • check sensor gap at out-
put speed sensor
• low main pressure
• wrong signal at internal speed sensor speed sensor
• wrong signal at output speed sensor • check signal at output
• wrong size of the sensor gap speed sensor
• clutch is defective • replace clutch


K4
closed clutch K4. If this calculated value • check main pressure in
is out of range, TCU interprets this as if failure at another the system
clutch is pending
slipping clutch. • check sensor gap at
• low pressure at clutch K4 internal speed sensor
OP-Mode: TCU shut-
• low main pressure down • check sensor gap at tur-
bine speed sensor
• wrong signal at turbine speed sensor speed sensor
• wrong size of the sensor gap • check signal at turbine
• replace clutch
B5 B5 : SLIP KV TCU shifts to neutral • check pressure at clutch
KV
closed clutch KV. If this calculated value • check main pressure in
if failure at another
is out of range, TCU interprets this as clutch is the system
slipping clutch.
pending • check sensor gap at
• low pressure at clutch KV internal speed sensor
• low main pressure • check sensor gap at tur-
OP-Mode: TCU shut- bine speed sensor
down • check signal at internal
• wrong signal at turbine speed sensor
speed sensor
• wrong size of the sensor gap
• check signal at turbine
• replace clutch
B6 B6 : SLIP KR TCU shifts to neutral • check pressure at clutch
TCU calculates a differential speed at OP-Mode: limp home KR
closed clutch KR. If this calculated value if failure at another • check main pressure in
the system
is out of range, TCU interprets this as clutch is
• check sensor gap at
slipping clutch. pending internal speed sensor
• low pressure at clutch KR TCU shifts to neutral • check sensor gap at tur-
• low main pressure OP-Mode: TCU shut- bine speed sensor
down
• wrong signal at internal speed sensor • check signal at internal
speed sensor
• wrong signal at turbine speed sensor
• check signal at turbine
• wrong size of the sensor gap speed sensor
• clutch is defective • replace clutch
B7 B7 : Over Sump no reaction • cool down machine
TCU measured a temperature in the oil OP-Mode: normal • check oil level
sump that is over the allowed threshold. • check temperature sen-
sor


BA BA : Oil Filter Error no reaction • check oil filter
TCU measured a voltage at differential OP-Mode: normal • check wiring from TCU
pressure switch out of the allowed range to differential pressure
switch
• oil filter is polluted
• check differential pres-
• cable/connector is broken or cable/
connector is contacted to battery volt- sure switch (measure
resitance)
age or vehicle ground
• differential pressure switch is defec-
tive
D1 D1 : T/M Error see fault codes no. 21 to • check cables and con- fault codes no. 21
TCU measures more than 6V at the pin 2C nectors to sensors, to no. 2C
which are supplied from
AU1 (5V sensor supply) AU1 may be a reaction
of this fault
• check the power supply
at the pin AU1 (should
be appx. 5V)
D2 D2 : T/M Error see fault codes no. 21 to • check cables and con- fault codes no. 21
TCU measures less than 4V at the pin 2C nectors to sensors, to no. 2C
which are supplied from
AU1 (5V sensor supply) AU1 may be a reaction
of this fault
• check the power supply
at the pin AU1 (should
be appx. 5V)
D3 D3 : Battery Low shift to neutral • check power supply bat-
tery
measured voltage at power supply is OP-Mode: TCU shut-
lower than 10 V (12V device) down • check cables from bat-
lower than 18 V (24V device) teries to TCU
• check connectors from
batteries to TCU
D4 D4 : Battery High shift to neutral • check power supply bat-
measured voltage at power supply is OP-Mode: TCU shut- tery
higher than 18 V (12V device) down • check cables from bat-
teries to TCU
higher than 32.5 V (24V device)
batteries to TCU
D5 D5 : T/M Error shift to neutral • check fuse
TCU switched on VPS1 and measured OP-Mode: TCU shut- • check cables from gear-
VPS1 is off or TCU switched off VPS1 down box to TCU
and measured VPS1 is still on
• cable or connectors are defect and are gearbox to TCU
contacted to battery voltage
• replace TCU
• cable or connectors are defect and are
• permanent power supply KL30 miss-
ing
• TCU has an internal defect


D6 D6 : T/M Error shift to neutral • check fuse
TCU switched on VPS2 and measured OP-Mode: TCU shut- • check cables from gear-
down box to TCU
VPS2 is off or TCU switched off VPS2
and measured VPS2 is still on gearbox to TCU
• cable or connectors are defect and are • replace TCU
contacted to battery voltage
• cable or connectors are defect and are
• permanent power supply KL30 miss-
ing
• TCU has an internal defect
E3 E3: CAN Timeout no reaction • check the cable from

TCU to the display
TCU sends data to the display and mea- OP-Mode: normal
sures allways a high voltage level on the • check the connectors at
connector the display
• cable or connectors are defective and • change display
are contacted to battery voltage
• display has an internal defect
E4 E4: CAN Timeout no reaction • check the cable from
TCU sends data to the display and mea- OP-Mode: normal TCU to the display
sures allways a high voltage level on the • check the connectors at
connector the display
• cable or connectors are defective and • change display
are contacted to vehicle ground
• display has an internal defect
F1 F1 : EEPROM Error no reaction • replace TCU often shown
TCU can't read non volantile memoy OP-Mode: normal together with
fault code F2
• TCU is defective
F3 F3 : APP Error transmission stay neu- • replace TCU !! This fault occurs
tral only if an test
something of this application is wrong engineer did
OP-Mode: TCU shut-
down something wrong
in the application
of the vehicle
F5 F5 : Clutch Fail transmission stay neu- • check clutch TCU shows also
AEB was not able to adjust clutch filling tral the affected
clutch on the Dis-
parameters OP-Mode: TCU shut- play
down
• One of the AEB-Values is out of limit


F6 F6 : T/M Error default values = 0 for • execute AEB
AEB
TCU was not able to read correct clutch
adjustment parameters offsets used
• interference during saving data on OP-Mode: normal
non volatile memory
no Inchmode available
• TCU is brand new

GROUP 13
GROUP 13
ELECTRICAL SYSTEM
Cautions for working on the electrical system ..... Section 1
Specifications and features of

electrical system .......................................................Section 2
Electrical Circuit diagram & Electrical parts

Arrangement ...........................................................Section 3
Instrument Pod ........................................................Section 4
SM 751, Oct ’06 Copyrighted Material Group 13, Electrical system

NOTE :
Group 13, Electrical system Copyrighted Material SM 751, Oct ’06

Group 13, Electrical System
Section 1
Cautions for working on the electrical system
As checking the electrical components − Remove the jumper (-) cable from the engine body
of the discharged machine.
As working or checking on the electrical components − Remove the other end of jumper (-) cable from the
make sure to study the features and specifications of rele- battery (-) terminal of the running engine.
vant components in advance so that the possibility of acci- − Remove the jumper (+) cable from the battery (+)
dent will be avoided. terminal of the running engine.
− Remove the other end of jumper (+) cable from the
Cautions for welding battery (+) terminal of the discharged machine.
Any electrical components on the machine may be dam-

aged by the high-voltage current occurred as welding. If
the welding shall be worked on the machine, therefore,
disassemble the (-) cables from the battery in advance.
Start-up with jumper cable

When the machine cannot be started up as the battery has
been discharged, make use the jumper cable to start-up.
Proceed as followings:
As connecting the jumper cables

− Connect one end of jumper (+) cable to the battery
(+) terminal of the discharged machine.
− Connect the other end of jumper (+) cable to the
battery (+) terminal of the running engine.
− Connect one end of jumper (-) cable to the battery
(-) terminal of the running engine.
− Connect the other end of jumper (-) cable to the
engine body of the discharged machine.
! CAUTION
Confirm the clips of jumper cable are
secured on the terminals.
Try to start up only when there is no problem
on the connection of jumper cables.
Never make the jumper (+) cable and the
jumper (-) cable contact each other.
As removing the jumper cables

− For removing the jumper cables, take working as
reverse order of connecting.
SM 751, Oct ’06 Cautions

Copyrighted Materialfor working on the electrical system • 13-1-1
NOTE :
Group 13, Electrical System Copyrighted Material SM 751, Oct ’06

Section 2
Specifications and features of electrical system
Features of electrical system Battery

The electrical system of C60-80 model is consisted of • Diesel
start-up circuits, instrumental panel and auxiliary circuits. − Type: 12Volt 80AH(20hr) x 2
Input and output of most circuits will be controlled by − Cold start current: 630Amp (-18℃)
micro processor within the instrumental panel. − Capacity: 130minutes (27℃)
Start-up circuit Start motor

The start-up circuit is consisted of electric power circuits • Diesel
such as engine start-up, battery charging, etc. − Specification: 24Volt 4.0kW
Instrumental panel
The monitor circuit makes the operator to check the oper-
ational condition of machine always as concentrating the
required indicators. It indicates fuel level, engine temp.,
battery level, work hour and failure of sensors. Addition-
ally, monitoring for safe operation and controlling of
input/output will be functioned in accordance with the
condition of machine and or signal manipulated by the
operator. It is possible that starting at neutral position, pre-
vention of restart, restricted travel when parking and auto-
matic engine stop as critical failure.
Auxiliary circuit
The auxiliary circuit is consisted of lamps, horn and warn-
ing devices. It will be “ON” and “OFF” by the operator
according to the operational condition.
Specification
Voltage and Earthing

System voltage: 12/24Volt
SM 751, Nov ’06 Specifications

Copyrighted Material and features of electrical system • 13-2-1
NOTE :
Group 13, Electrical System Copyrighted Material SM 751, Nov ’06

Section 3
Electrical Circuit Diagram & Electrical Parts Arrangement
SM 751, Nov ’06 Electrical Circuit

Copyrighted Diagram & Electrical Parts Arrangement • 13-3-1
Material
Electrical Circuit Diagram

• Diesel
13-3-2 • Electrical Circuit Diagram & Electrical Parts Arrangement

Electrical Parts Arrangement

• Electrical

Material
• Main wire harness


Material


Material
• T/M wire harness

• Accessory

Material
• Battery Mounting

• Cassette
SM 751, Nov ’06 Electrical CircuitMaterial

• Air conditioner(1_3)

• (2_3)

• (3_3)

• Electrical component

NOTE :
Group 13, Electrical System Copyrighted Material SM 751, Nov ’06

Section 4
Instrument Pod
1 3 4 2 6 7 8
9
10
29MAR06[WED] H
11
12
13
C 14
SYSTEM CHECK
5
OP A2
1. Fuel level Indication 8. Error LED

2. Engine coolant temperature indicator 9. Down arrow button (Mode button)
3. Date & Time display 10. Up arrow button (Enter button)
4. Hourmeter & Speed 11. Left arrow button (Slow speed button)
5. Message display & Travel direction icon 12. Right arrow button (Power button)
6. Parking brake LED 13. Plus button
7. Seat belt LED 14. Minus button
SM 751, Oct ’06 Copyrighted Material Instrument Pod • 13-4-1

Pod Symbols and Functions Indication of display : Turn on the key

switch
Functions
1. General function When turning the key to ON
The instrument pod consists of indicator lights, an 1. The system will be initialized as displayed in the fol-
hour meter, a circuit board and attached gauges. Pro- lowing figure: To be displayed in 0.5sec
vides the operator with important information about
truck condition and shut down the truck in the event 2. After 1sec, the data will be displayed normally.
that certain critical conditions are present. (However, the clock displays the real time.)
2. Engine shutdown function 3. Seat belt LED and Buzzer: To be operated as 1hz in
The instrument pod circuit board receives signals 3sec.
from sensors in various locations and shut down the
truck when coolant temperature, transaxle fluid tem- Basic display screen (Normal display mode)
perature are excessive or engine oil pressure is low.
Before shutting down the truck, the instrument pod 1. Display screen after initialization of system
sounds alarm for 30 seconds and flashes indicator
2. Display the data delivered(CANBus) from other
lights. After shutdown, the truck may be restarted,
instruments
but if the fault condition persists, the truck is shut
down again in 30 seconds. 3. The date and time are controlled by internal system,
so the real-time information will be displayed.
Seat switch application (optional)
When the fuel level is low, the buzzer and warning lamp
The instrument pod shuts down the running truck
will be operated in the interval of 1sec. "LOW FUEL"
without warning when the operator leaves the seat
message will be displayed on LCD screen.
over 3 seconds with the FWD/REV switch is
engaged. Directional switch must open and key
switch must always be turned OFF, to restart engine. Gauges and indicators
When directional switch is open and parking brake is
Coolant temperature gauge
not engaged, if the operator leaves a seat, after 3 sec-
onds, the instrument pod will sound buzzer, and then •It is divided into 2 colour
honk horn. H zones according to tempera-
Setting the parking brake shall reset the alarm.(The ture.
engine is not shut down.)
3. Neutral start function and Anti-restart function
Neutral start function
The instrument pod will not allow the stater to be C
engaged if directional switches are closed or key has 10 Step specifications
been in start position once. Key switch must always
be turned OFF to restart engine. Step Status Temperature Remark
10 Hot Shutdown 116℃ Above Flashers(1Hz)
Anti-restart function
10 Hot Warning 113~115℃
When engine is already running, the start motor does
10 Hot 110~112℃
not rotate although the key switch is turned start
position. 9 Normal 106~109℃
8 Normal 100~105℃
4. Anti-drive and parking brake reminder function 7 Normal 94~99℃
When parking brake is engaged, the truck cannot be 6 Normal 88~93℃
driven although the directional switch closed. A
5 Normal 82~87℃
parking brake alarm shall be activated if key switch
4 Normal 76~81℃
is turned to the OFF position and the parking brake
is not applied. Applying the park brake will reset the 3 Normal 50~75℃
alram. 2 Normal 26~49℃
1 Cold 25℃ bolow
13-4-2 • Instrument Pod Copyrighted Material SM 751, Oct ’06

If the wire of cooling water temp gauge is broken or If the parking brake is set, buzzer and horn
the gauge scale doesn't move after 10min of engine will not sound.
starting, engine will be shut down because the gauge
is recognized as defective. Seat belt
At start-up, this light and a buzzer come
Message display
on for three seconds to remind the opera-
The following message will be displayed when it comes tor to fasten the seat belt. There is no
under the Red Zone (Beyond Hot Warning) start interlock.
IMPORTANT
You should always have your seat belt
W/TEMP WARN securely fastened when operating your
lift truck.
Fuel gauge
Service icon
It displays the remaining LED will illuminate when preset service
fuel level in fuel tank. time is reached. When LED is on, the pre-
If the level is low, the Flash- set service time has been reached indi-
ing and buzzer will sound 1 cating that a PM is required. Refer to
Secand and "LOW FUEL" Service Manual for proper PM proce-
message will be displayed dures.
on LCD window. Pre-set service time setting method -
initialized by "key on + FWD + F1 +
F2", service time display at hour
10 Step specifications meter. Here, F1 is for up set, F2 is for
down set with interval times of 50 hours. When
Step Percentage(%) Remark the key switch is turned OFF, the pre-set service
10(Full) 90 Above time setting time is saved. Pre-set service time
9 80 ~89 counts down opposite to operating time.
8 70~79 To disable the Service Icon, set the pre-set service
7 60~69 time to "-1000" (display 1 0 0 0 ); If you push the F2
switch when setting the pre-set service time, the time
6 50~59
will be adjusted to "-1000".
5 40~49
4 30~39 Date and time display
3 20~29 1. Function: To indicate the current date and time
2 10~19 2. Display
1 0~9 Flashers(1Hz) 29MAR06[WED]
Parking brake
Indicates that the parking brake is
engaged.
Anytime the parking brake is on, the Hour and Speed meter display
truck can't be driven because the tran- 1. Function: To display the accumulated operating hour
saxle solenoid valves switch is off. until now and the traveling speed of fork lift truck.
When the parking brake is not set
and the key switch is turned to the
OFF position, the instrument pod will sound.

2. Display. • When it is in neutral, the arrow and gear icon

Hour Meter will not be displayed.
Speed Meter
N
OP A1
2. Operation
3. Operation Display Direction/ Display Direction/
• When the speed is lower than 0.5km/h, the hour ICON Gear Select ICON Gear Select
will be displayed. FWD/ 1 Gear REV/ 1 Gear
• When the speed is higher than 0.5km/h, the Drive Mode/ Drive Mode/
speed will be displayed. AUTO 1step AUTO
• It can be dispayed in the of km/h or MPH. 1step‹
OP A1 OP A1
Message display
FWD/ 2 Gear REV/ 2 Gear
1. Function: To display model name, POWER selec- Drive Mode/ Drive Mode/
tion, travel direction, warning and error message AUTO 2step‹ AUTO
2step‹
2. Display OP A2 OP A2
FWD/ 3 Gear REV/ 3 Gear
Normal Operating Operating
OP A2
Mode/ Manual Mode/ Man-
01 : E.SHUT COIL S/C
Error
03 : ST.RELAY S/C
ual
OP ML OP ML
Warning NEUTRAL
OP A2
Drive Mode/
• Display when the truck is in normal condition:
Model name / POWER / Direction
N AUTO 1step
OP A1
3. Priority of displaying message
Error display ICON
• If there are several messages which shall be dis-
played on the screen, the priority of display will 1. Function: To display the ICON for easy reorganiza-
be in the order of Error > Warning > Normal tion when any error occurs.
conditions.
• If several errors occur simultaneously, the upper
2 items will be displayed on 2 lines. (The priority
is in the numerical order of Error.)
• When failure and warning are caused at the same Operation and Description
time, the content of failure will be displayed on Display Discription
top row and the warning icon at below row. ICON
Travel Direction display ICON Pilot light for preheater operating
When the preheater is operating
1. Function: To display the traveling direction or gear
under the 1.5 degree below zero,
selected condition of truck
this ICON operates and when it is
• Receive the traveling direction data from the T/
released, it will turn off.
M controller.
• Receive the gear selected data from the T/M con-
troller.

Warning light for engine oil Adjustment of function (Menu opera-

pressure tions)
When engine oil is short or
pressure switch fails, the warning Function
light will turn on and the engine 1. To display the data of the system on the screen.
shut down.
Warning light for T/M oil 2. The adjustable variables can be changed.
temperature Mode select button operation
When T/M oil is overheating while
in operation (operation: more than 1. Mode buttons are composed on right side of Display
120 ℃, release: less than 110 ℃), screen.
the warning light will turn on and 2. Each button has own function, and some of them can
engine shut down. perform various functions.
Warning light for battery
discharging
When the alternator isn't charged
because of failure of alternator or
the engine doesn't rotate, it will
turn on.
Warning light for engine
malfunction
When there are malfunctions to
engine system, it will turn on.
Pilot light for maintenance time

When reaches to 0HR as counting
reversely to the designated
maintenance time, it will turn on
to show the time of maintenance.
Button Function
Down arrow button (Mode button)
In normal working mode, move to Menu mode by pressing this button.
OP A2
In Menu mode, move to sub menu by pressing this button.
1 STATUS
1.1 BATTERY VOLTAGE

24.5V
In the lowest mode, the display won't be changed even through pressing this button.

Up arrow button (Enter button)

In Menu mode, move to upper menu by pressing this button.
1.1 BATTERY VOLTAGE
24.5V
1 STATUS
OP A2
Perform as "Enter" key function when confirming after the Password and important variables are
changed.
Left arrow button

In Menu mode, move to left menu by pressing this button.
1.2 ACCELERATOR
2.5V
1.1 BATTERY VOLTAGE

24.5V
1.10 SOFTWARE
V 1.0
Right arrow button (Power selection button)

In Menu mode, move to right menu by pressing this button.
1.2 ACCELERATOR
2.5V
1.1 BATTERY VOLTAGE

24.5V
1.10 SOFTWARE
V 1.0
Plus(+) button
It performs DR/OP selection function at normal mode.
It selects DR → OP in turns, whenever pressing the button.
The data for the selected mode will be transferred to T/M controller.
Under S/L mode, DR/OP does not change.

Minus(-) button
It performs ML/A1/A2 selection function at normal mode.
It selects ML → A1 → A2 in turns, whenever pressing the button.
The data for the selected mode will be transferred to T/M controller.
Under S/L mode, ML/A1/A2 does not change.
Configuration of menu mode
Menu No. Parameters Description Min Max Base Adjust

1 STATUS Display the Analog input/out-
put status of fork lift truck
1.1 Battery Voltage Display the Battery voltage 0.0V 30V Actual
1.2 Fuel Level Display the fuel level 0% 100%
1.3 Eng Coolant Temp. Display the engine coolant tem- 0µµ 150µµ Actual
perature
1.4 T/M Oil Temp. Display the T/M oil temperature 0µµ 150µµ Actual
1.5 Display Hour Display the truck working hour 0 9999 Actual
1.6 System Hour Display the system working 0 9999 Actual
hour
1.7 Maintenance Hour Display the maintenance hour 0 9999 Actual
1.8 Software Display Display the program (software) V1.00 Vx.xx Actual
version
1.9 Software Truck Display the program (software) V1.00 Vx.xx Actual
version (S60-Controller)
1.10 Stepping Motor Range Stepping motor output 0% 100% Actual
1.11 Slow Speed Value Speed limit value 2 km/hr 35km/hr Actual
1.12 Software Version Display the program (software) V1.00 Vx.xx Actual
version (S60-Controller)
1.13 Software Version Display the program (software) V1.00 Vx.xx Actual
version (Speed limiter)
2 SWITCH STATUS Display the switch input status

of fork lift truck
2.1 Parking Brake Parking brake OPEN CLOSE OPEN
2.2 Forward Forward OPEN CLOSE OPEN
2.3 Neutral Neutral OPEN CLOSE OPEN
2.4 Reverse Reverse OPEN CLOSE OPEN
2.5 T/M Oil Temp. Transmission oil temperature OPEN CLOSE OPEN
2.6 E/Oil Pressure Engine oil pressure OPEN CLOSE OPEN
2.7 LPG Pressure LPG pressure OPEN CLOSE OPEN
2.8 Seat Seat OPEN CLOSE OPEN
2.9 Tilt/Limit Tilt Limit Switch OPEN CLOSE OPEN
2.10 Option Switch Option Input OPEN CLOSE OPEN

2.11 Engine Shutdown output Engine Shutdown output ON OFF OFF

2.12 Alternator output Alternator charging ON OFF OFF
2.13 Horn relay Horn relay operation OPEN CLOSE OPEN
2.14 Option relay Option relay OPEN CLOSE OPEN
2.15 Key switch starter Key switch start output OPEN CLOSE OPEN
2.16 Preheater Preheater operation ON OFF OFF
3 MODEL SETUP Setup of model

3.1 C40 C40D, C45D, C50D, C40L, C40D C50L C40D
C45L, C50L
3.2 C60 C60D, C70D, C80D, C60L, C60D C80L C60D
C70L, C80L
4 ZF CONTROL DATA Display related to T/M condi-

tion
4.1 Engine speed Display of engine RPM 0 RPM 8031RPM Actual
(removes the decimal point)
4.2 Output shaft speed Display of shaft rotational speed 0 RPM 8031RPM Actual
(removes the decimal point)
4.3 T/M Sump Temp Display of T/M internal oil tem- -50℃ 200℃ Actual
perature (for AEB)
4.4 Clutch Cut-off Volts Display of inching sensor volt- 0V 6.25V Actual
age
5 PASSWORD Control the password

5.1 Ignition Mode Set up the right of using for the ON OFF OFF +/-
fork lift truck
5.2 Setup Mode Change of setting ON OFF OFF +/-
5.3 Password Change Change of password 00000 99999 10000 +/-
6 SETUP
6.1 Hour Adjust the working hour, 0 ~ 0 9950 0 +/-
9950(step 50)
6.2 Maintenance Adjust the maintenance period, Off 2000 Off +/-
off/ 50 ~ 3000(step 50)
6.3 Parking Reminder Set up the warning sound, Off Buzzer Horn +/-
buzzer / horn / off
6.4 Engine Shutdown Set up the warning sound, Off Buzzer Horn +/-
buzzer / horn / off
6.5 Seat Set up the function, seat S/R E/S S/R +/-
reminder / engine shutdown
6.6 Speed display Display of set unit, Km/h or Km/h MPH Km/h
MPH

7 TIME SETUP
7.1 Year 2000 2099 Actual +/-
7.2 Month 1 12 Actual +/-
7.3 Date 1 31 Actual +/-
7.4 Week MON SUN Actual +/-
7.5 Hour 0 23 Actual +/-
7.6 Minute 0 59 Actual +/-
7.7 PM/AM PM AM Actual +/-
8 AEB MODE Auto-adjustment function

related to T/M
8.1 AEB Start Operation of AEB function - - - -
8.2 Inching Start Operation of inching calibration - - - -
function
OPERATIONS OF MENU FUNCTION − The data of each menu is controlled through the
communication lines, and the set data will be
"1 STATUS" MODE stored at Travel controller.
• Display the analog output information of fork lift "7 TIME SETUP" MODE
truck on real time.
• Set up the date and time displayed.
"2 SWITCH STATUS" MODE − All the data has been controlled itself, regard-
• Display the digital (Switch On/Off) information less of the Travel controller.
of fork lift truck on real time. “8 AEB MODE" MODE
"3 MODEL SETUP" MODE − The AEB mode is possible to get into SUB
• Display the truck model menu when the PASSWORD is being entered.
• Model set up is composed of each family, and − Refer to the No 5 for AEB Request function.
the real model name is shown on Sub mode.
"4 ZF CONTROL DATA" MODE PASSWORD OPERATION
• Displays the condition of ZF transmission Set the permission/restriction for the operation of truck
and the setup change.
"5 PASSWORD SETUP" MODE
IGNITION MODE
− Set the permission/restriction for the operation
of truck and the setup change. Function able to operate the fork lift truck only when giv-
− Refer to the following Para. "4" for details. ing the password after turning the key on.
Ignition password can be set as "ON/OFF". If setting to
"6 SETUP" MODE OFF, the truck can be operated by key on, but if setting to
• Set up the adjustable function and variables of ON, it can be operated only by giving the password.
fork lift truck. How to input password
− In SETUP mode, you can enter sub menu only
when giving the password. If the ignition is set to "ON", the display is as follows
− If you set the value in the relevant menu, it will when turning the key on.
be set up immediately. Password is 5 figures. Input the numbers by use of "+/-"
buttons and move the position by use of left/right arrow
buttons.

When the input is completed, confirm by pressing − The new password will be displayed for 1 sec as
"ENTER" button.. shown in the following figure, and then the
mode will move to "5 PASSWORD"..
PASSWORD INPUT
YES : ENTER PASSWORD CHANGED
12345
When the password is agreed, the following will be dis-
played.
AEB REQUEST (Automatic adjust
PASSWORD OK ! clutch)
AEB execution
− When gets into SUB mode from "8 AEB
When the password isn't agreed, the following will be MODE" (Pressing down the DOWN arrow),
displayed. the PASSWORD input box will be shown and
the message is same in 4.1,
PASSWORD ERROR 8 AEB MODE
SETUP MODE 8.1 AEB START

In MENU mode, make sure to input the password to pro-
ceed to "6 SETUP" mode. In "6 SETUP" mode, press
YES : ENTER
"DOWN" arrow button to proceed to "SUB" mode. The − When it passes after entering the PASSWORD,
dialogue box to input the password will be displayed. "8.1 AEB START" will be shown in the figure
below.
The procedure to input the password is same with − When presses the ENTER (UP arrow) button to
above Para. "4.1". execute the AEB, the contents of execution will
When the PASSWORD is right, it gets into SUB mode. be shown and executed automatically. ,
PASSWORD CHANGE AEB OK

The function to change the password given to the fork lift
truck
− When there is error, perform the Key Off 'On
The passwords for Ignition and Setup shall be same. 'Cranking and re-execute in accordance with
the procedure.
How to change password
Inching Calibration execution
− If pressing Enter (Up arrow) button in the fol-
lowing conditions, − When gets into SUB mode from "8 AEB
MODE", enters the PASSWORD and presses
5.3 PASSWORD CHANGE? the "?" arrow button at 8.1 Menu, the below
message will be displayed. ,
YES : ENTER
8.2 INCHING
AEB OK START
YES : ENTER
− When presses the ENTER (UP arrow) button to
PASSWORD INPUT execute the Inching calibration, the contents of
YES : ENTER

execution will be shown and executed automat-

ically.,
INCHING CAL OK
− When there is error, perform Key Off ' On and

re-executes in accordance with the procedure.
Progress of AEB and Inching calibration
− When executes the AEB or Inching Calibra-
tion, refer to the attached file for the contents of
display and the message will be shown as
above figure.

Error Code
Abbre 1. o.c.: open circuit
viati 2. s.c.: Short circuit
ons 3. OP-Mode: operating mode
4. TCU: transmission control unit
5. EEC: electronic engine controller
6. PTO: power take off
ERROR LCD possible steps to
DESCRIPTION reaction of the TCU REMARK
CODE ERROR MESSAGE repair
This Error (01 to 04) Message is to S60 Controller - See reference file S60 CAN Protocol(DSCU ID
#3-Byte 8)
01 01: S.C E/Shut 0: No indication 1. Check the cables
Relay 1:It indicates in from S60 controller to
Error contents LCD E/shut Relay
02 02: S.C Option 0: No indication 1. Check the cables
Error contents LCD Option Relay
03 03: S.C Start 0: No indication 1. Check the cables
Error contents LCD Horn Relay
04 04: S.C Horn 0: No indication 1. See the sift lever
Relay 1:It indicates in
Error contents LCD
05 05: No Neutral 0: No indication
Shift 1:It indicates in
Error contents LCD
06 06: Warning E/ 0: No indication
Shut 1:It indicates in
Error contents LCD
12 12 : Logical LOGICAL ERROR AT TCU shifts 1. Check the cables from
Error DIRECTION SELECT transmission to TCU to shift lever
SIGNAL neutral 2. Check signal combina-
TCU detected a wrong tions of shift lever posi-
signal combination tions F-N-R"
for the direction
21 21 : S.C Batt S.C.TO BATTERY clutch cutoff 1. Check the cable from
Clutch IN VOLTAGE AT CLUTCH function is TCU to the sensor
CUTOFF INPUT disabled 2. Check the connectors
the measured voltage
is too high 3. Check the clutch cutoff
sensor"
22 22 : S.C Gnd S.C.TO GROUND O.C.AT clutch cutoff 1. Check the cable from
Clutch IN CLUTCH CUTOFF INPUT function is TCU to the sensor
the measured voltage disabled 2. Check the connectors
is too low
3. Check the clutch cutoff
sensor"


25 25 : T/M Error S.C.TO BATTERY no reaction 1. Check the cable from
VOLTAGE OR O.C.AT TCU to the sensor
TRANSMISSION 2. Check the connectors
SUMP TEMPERATURE
SENSOR INPUT the 3. Check the temperature
measured voltage is sensor"
too high
26 26 : T/M Error S.C.TO BATTERY no reaction 1. Check the cable from
TRANSMISSION 2. Check the connectors
SUMP TEMPERATURE
SENSOR INPUT the 3. Check the temperature
measured voltage is sensor"
too low
2B 2B : Inchsensor I N C H S E N S O R - S I G N A L 1. Check the cable from
MIS MISMATCH TCU to the sensor
the measured voltage 2. Check the connectors
from CCO and CCO2
signal don't match" 3. Check the speed sen-
no reaction sor"
31 31 : T/M Error S.C.TO BATTERY 1. Check the cable from
VOLTAGE OR TCU to the sensor
O.C.ATENGINE SPEED 2. Check the connectors
INPUT
TCU measures a 3. Check the speed sensor
volage higher than
7.00V at speed input
pin
32 32 : T/M Error S.C.TO GROUND AT 1. Check the cable from
ENGINE SPEED INPUT TCU to the sensor
TCU measures a 2. Check the connectors
voltage less than
0.45V at speed input 3. Check the speed sen-
pin sor"
33 33 : Logical "LOGICAL ERROR AT - 1. Check the cable from
Error ENGINE SPEED INPUT TCU to the sensor
TCU measures a engine 2. Check the connectors
speed over a threshold
and the next moment the 3. Check the speed sensor
measured speed is zero" 4. Check the sensor gap
34 34 : T/M Error "S.C.TO BATTERY if a failure is 1. Check the cable from
VOLTAGE OR O.C.AT existing at output TCU to the sensor
TURBINE SPEED INPUT speed, TCU shifts 2. Check the connectors
TCU measures a to neutral
voltage higher than 3. Check the speed sensor
pin"


35 35 : T/M Error S.C.TO GROUND AT if a failure is 1. Check the cable from
TURBINE SPEED INPUT existing at output TCU to the sensor
TCU measures a speed, TCU shifts 2. Check the connectors
voltage less than to neutral
0.45V at speed input 3. Check the speed sensor
pin
36 36 : Logical LOGICAL ERROR AT if a failure is 1. Check the cable from
Error TURBINE SPEED INPUT existing at output TCU to the sensor
turbine speed over a to neutral
threshold and at the 3. Check the speed sensor
next moment the 4. Check the sensor gap
measured speed is
zero
37 37 : T/M Error S.C.TO BATTERY - 1. Check the cable from
INTERNAL SPEED INPUT 2. Check the connectors
TCU measures a
pin
38 38 : T/M Error S.C.TO GROUND AT - 1. Check the cable from
INTERNAL SPEED INPUT TCU to the sensor
voltage less than
pin
39 39 : Logical LOGICAL ERROR AT - 1. Check the cable from
Error INTERNAL SPEED INPUT TCU to the sensor
internal speed over
a threshold and at 3. Check the speed sensor
the next moment the 4. Check the sensor gap
measured speed is
zero
3A 3A : T/M Error S.C.TO BATTERY if a failure is 1. Check the cable from
VOLTAGE OR O.C.AT existing at turbine TCU to the sensor
OUTPUT SPEED INPUT speed, TCU shifts 2. Check the connectors
TCU measures a to neutral
pin
3B 3B : T/M Error S.C.TO GROUND AT if a failure is 1. Check the cable from
OUTPUT SPEED INPUT existing at turbine TCU to the sensor
voltage less than to neutral
pin


3C 3C : Logical LOGICAL ERROR AT if a failure is 1. Check the cable from
Error OUTPUT SPEED INPUT existing at turbine TCU to the sensor
output speed over a to neutral
threshold and at the 3. Check the speed sensor
next 4. Check the sensor gap
moment the measured
speed is zero
3E 3E : T/M Error OUTPUT SPEED ZERO if a failure is 1. Check the sensor signal
DOESN'T FIT TO OTHER existing at turbine of output speed sensor
SPEED SIGNALS speed, TCU shifts 2. Check the sensor gap of
if transmission is to neutral output speed sensor
not neutral and the
shifting has 3. Check the cable from
finished TCU to the sensor
TCU measures output
speed zero and
turbine speed or
internal
speed not equal to
zero
71 71 : S.C Batt S.C.TO BATTERY if failure at 1. Check the cable form
K1 VOLTAGE AT CLUTCH K1 another clutch is TCU to the gearbox
the measured pending, TCU shifts 2. Check the connectors
resistance value of to neutral from gearbox to TCU
the valve is out of
limit, 3. Check the regulator
the voltage at K1 resistance
valve is too high 4. Check internal wire
harness of the gearbox
72 72 : S.C Gnd K1 if failure at if failure at 1. Check the cable form
another clutch is another clutch is TCU to the gearbox
pending, TCU shifts pending, TCU shifts 2. 2. Check the connectors
to neutral to neutral from gearbox to TCU
3. 3. Check the regulator
resistance
4. 4. Check internal wire


73 73 : S.C K1 O.C.AT CLUTCH K1 if failure at 1. Check the cable form
the measured another clutch is TCU to the gearbox
resistance value of pending, TCU shifts 2. Check the connectors
the valve is out of to neutral from gearbox to TCU
limit
3. Check the regulator
resistance
4. Check internal wire
the value is out of
valve is too high 4. 4. Check internal wire
75 75 : S.C Gnd K2 S.C.TO GROUND AT if failure at 1. Check the cable form
CLUTCH K2 another clutch is TCU to the gearbox
the value is out of
valve is too low 4. Check internal wire
limit
resistance
the value is out of


limit
resistance
81 81: S.C Batt K4 S.C.TO BATTERY if failure at 1. Check the cable form
VOLTAGE AT CLUTCH K4 another clutch is TCU to the gearbox
the value is out of
82 82 : S.C Gnd K4 S.C.TO GROUND AT if failure at 1. Check the cable form
CLUTCH K4 another clutch is TCU to the gearbox
the value is out of
valve is too low 4. Check internal wire
limit
resistance
KV VOLTAGE AT CLUTCH KV another clutch is TCU to the gearbox
the value is out of
the voltage at KV resistance


85 85 : S.C Gnd KV S.C.TO GROUND AT if failure at 1. Check the cable form
CLUTCH KV another clutch is TCU to the gearbox
the value is out of
limit, the voltage at 3. Check the regulator
KV valve is too low resistance
86 86 : S.C KV O.C.AT CLUTCH KV if failure at 1. Check the cable form
limit
resistance
harness of the gearbox"
KR VOLTAGE AT CLUTCH KR another clutch is TCU to the gearbox
the value is out of
KR valve is too high resistance
88 88 : S.C Gnd KR S.C.TO GROUND AT if failure at 1. Check the cable form
CLUTCH KR another clutch is TCU to the gearbox
the value is out of
KR valve is too low resistance
89 89 : S.C KR O.C.AT CLUTCH KR if failure at 1. Check the cable form
limit
resistance


91 91 : S.C Gnd B/ S.C.TO GROUND AT backup alram will 1. Check the cable from
ALARM RELAY REVERSE be on until TCU TCU to the backup
WARNING ALARM power down alarm device
TCU detected a wrong even if fault 2. Check the connector
voltage at the vanishs(loose from backup alarm
output pin, that connection) device to TCU
looks like a s.c. to
vehicle ground 3. Check the resistance of
backup alarm device
92 92 : S.C Batt S.C. TO BATTERY no reaction 1. Check the cable from
B/ALARM VOLTAGE AT RELAY TCU to the backup
REVERSE WARNING alarm device
ALARM 2. Check the connector
TCU detected a wrong from backup alarm
voltage at the device to TCU
output pin, that
looks like a s.c. to 3. Check the resistance of
battery voltage backup alarm device
93 93 : O.C B/ O.C.AT RELAY REVERSE no reaction 1. Check the cable from
ALARM WARNING ALARM TCU to the backup
TCU detected a wrong alarm device
voltage at the 2. Check the connector
output pin, that from backup alarm
looks like a s.c. for device to TCU
this output pin
3. Check the resistance of
backup alarm device"
B1 B1 : SLIP K1 SLIPPAGE AT CLUTCH if failure at 1. Check pressure at

K1 another clutch is clutch K1
TCU calculates a pending, TCU shifts 2. Check main pressure in
differential speed to neutral the system
at closed clutch K1.
If this calculated 3. Check sensor gap at
this as slipping internal speed sensor
clutch 4. Check sensor gap at tur-
bine speed sensor
5. Check signal at internal
speed sensor
6. Check signal at turbine
speed sensor
7. Replace clutch


bine speed sensor
speed sensor
speed sensor
7. Replace clutch"
bine speed sensor
speed sensor
speed sensor
7. Replace clutch
bine speed sensor
speed sensor
speed sensor
7. Replace clutch


B5 B5 : SLIP KV SLIPPAGE AT CLUTCH if failure at 1. Check pressure at
KV another clutch is clutch KV
at closed clutch KV.
bine speed sensor
speed sensor
speed sensor
7. Replace clutch
B6 B6 : SLIP KR SLIPPAGE AT CLUTCH if failure at 1. Check pressure at
KR another clutch is clutch KR
at closed clutch KR.
bine speed sensor
speed sensor
speed sensor
7. Replace clutch
B7 B7 : Over Sump OVERTEMP SUMP no reaction 1. Cool down machine
TCU measured a 2. Check wiring from
temperature in the TCU to differential
oil sump that is pressure switch
over the
allowed threshold 3. Check temperature sen-
sor
BA BA : Oil Filter D I F F E R E N T I A L no reaction 1. Check oil filter
Error PRESSURE OIL FILTER 2. Check wiring from
TCU measured a TCU to differential
voltage at pressure switch
differential
pressure switch out 3. Check differential pres-
of the sure switch
allowed range (measure resitance)


D1 D1 : T/M Error S.C.TO BATTERY see fault codes no. 1. Check cables and con-
VOLTAGE AT POWER 21 to 2C nectors to sensors,
SUPPLY FOR SENSORS which are supplied
TCU measures more from AU1
than 6V at the pin 2. Check the power supply
AU1 (5V sensor at the pin AU1
supply) (should be appx. 5V)
D2 D2 : T/M Error S.C.TO GROUND AT see fault codes no. 1. Check cables and
POWER SUPPLY FOR 21 to 2C connectors to sensors,
SENSORS which are supplied from
TCU measures less AU1
than 4V at the pin 2. Check the power
AU1(5V sensor supply at the pin AU1
supply) (should be appx. 5V)
D3 D3 : Battery LOW VOLTAGE AT shift to neutral 1. Check power supply
Low BATTERY battery
measured voltage at 2. Check cables from bat-
power supply is teries to TCU
lower than 10V(12V
device) 3. Check connector form
lower than 18V(24V batteries to TCU
device)
D4 D4 : Battery HIGH VOLTAGE AT shift to neutral 1. Check power supply
High BATTERY battery
measured voltage at 2. Check cables from bat-
power supply is teries to TCU
higher than 18V(12V
device) 3. Check connector form
higher than batteries to TCU
32.5V(24V device)
D5 D5 : T/M Error ERROR AT VALVE POWER shift to neutral 1. Check fuse
SUPPLY VPS1 2. Check cables from
TCU switched on VPS1 gearbox to TCU
and measured VPS1 is
off or TCU switched 3. Check connectors from
off VPS1 and gearbox to TCU
measured VPS1 is 4. Replace TCU
still on
D6 D6 : T/M Error ERROR VALVE POWER shift to neutral 1. Check fuse
SUPPLY VPS2 2. Check cables from
TCU switched on VPS2 gearbox to TCU
and measured VPS2 is
off or TCU switched 3. Check connectors from
off VPS2 and gearbox to TCU
measured VPS2 is 4. Replace TCU
still on


E3 E3: CAN Timeout S.C.TO BATTERY no reaction 1. Check the cable from
VOLTAGE AT DISPLAY TCU to the display
OUTPUT 2. Check the connectors at
TCU sends data to the display
the display and
measures always a 3. Change display
high voltage
level on the
connector
E4 E4: CAN Timeout S.C.TO GROUND AT no reaction """1. Check the cable
DISPLAY OUTPUT from TCU to the display
TCU sends data to 2. Check the connectors
the display and at the display
measures always a 3. Change display"
high voltage
level on the
connector
F1 F1 : EEPROM GENERAL EEPROM FAULT no reaction replace TCU !!
Error TCU can't read non
volantile memory
F3 F3 : APP Error APPLICATION ERROR transmission stay replace TCU !!
something of this neutral
application is wrong
F5 F5 : Clutch CLUTCH FAILURE transmission stay check clutch
Fail AEB was not able to neutral
adjust clutch
filling parameters
F6 F6 : T/M Error CLUTCH ADJUSTMENT default values = 0 execute AEB
DATA LOST OR for AEB offsets
I N C H P E D A L used
CALIBRATION
DATA LOST
TCU was not able to
read correct clutch
a d j u s t m e n t
parameters

NOTE :
Group 13, Electrical System Copyrighted Material SM 751, Oct ’06

GROUP 20
GROUP 20
DRIVE AXLE
Specification and description for drive axle .... Section 1
Differential ...........................................................Section 2
Assembly and disassembly of drive axle ...........Section 3
Troubleshooting of drive axle ............................Section 4
SM 751, Oct ’06 Copyrighted Material Group 20, DRIVE AXLE

NOTE :
Group 20, DRIVE AXLE Copyrighted Material SM 751, Oct ’06

Group 20, Drive Axle
Section 1
Specification and description for drive axle
Specifications
General specification
• The power transmission system is composed with differential (1), drive axle (2), and drive wheel (3). The power is
transferred from the torque convert in the engine fly wheel to the transmission input shaft. It is transferred to the
spiral bevel gear set in the differential gear through the output gear of transmission and then the power is trans-
ferred to the wheel through the drive axle.
1 Differential 5 Oil lever port in

drive axle
2 Drive axle 6 Disc brake
3 Drive wheel 7 -
4 Parking lever 8 -
SM 751, Oct ’06 Copyrighted Specification

Material and description for drive axle • 20-1-1
Specification table of drive axle
Differential 2.636
Reduction ratio Planetary gear 4
Drive axle Total 10.545
Working oil Torque Fluid 56
Flow 12.5 L
Service brake Oil disc brake
Brake Working oil RANDO-HD32
Parking brake Lever rotation type (service brake unit type)
Gear type spiral bevel gear

Differential
Differential type 4 pinion type
U-Joint - 6C
20-1-2 • Specification and description for drive axle

Section 2
Differential
Differential
1. Specification
1 Inner diameter of differential pinion 20.000 - 20.021
2 Outer diameter of spider 19.959 - 19.980
3 Pinion gear washer 1.92 - 2.08
4 Side gear washer 1.95 - 2.05
5 Side gear -
The differential is used to transfer the power from the
transmission to the wheel. When a wheel rotates, the other
wheel in the opposite side rotates slowly. The differential
is composed with four pinions (1), two side gears (5) and
a spider (2). The gearing is the right angle as it connected
to four pinions (1) and two side gears (5).
SM 751, Oct ’06 Copyrighted Material Differential • 20-2-1

Drive Axle
1. Specification
1 Sun gear 6 Hub ass'y 11 Pinion shaft
2 Planetary gear 7 Disc brake 12 Spider
3 Internal gear 8 Drive shaft 13 Differential pinion gear
4 Internal gear carrier 9 Deep carrier ass'y 14 Differential side gear
5 Taper bearing 10 Ring gear
As the drive axle drives the fork lift truck by receiving the to four pinions (13) and two side gears (14). The side gear
power that the speed has changed by transmission, it is (14) and drive shaft (8) are connected to the spline, and
composed with deep carrier assembly (9), drive shaft (8) drive shaft (8) is connected to planetary gear (2), internal
and the hub ass'y, and the pinion shaft (11) is connected to gear (3), wheel hub(6) and drive wheel.
the output shaft and spline of transmission. The transmis-
sion power is transferred assembled differential based on
pinion shaft (11) and ring gear (10), and the differential
rotates the drive shaft (8).
The differential is used to transfer the power from the
transmission to wheel. When a wheel rotates, the other
wheel in the opposite side rotates slowly. The differential
is composed with four pinions (13), two side gears (14)
and a spider. The gearing is the right angle as it connected
20-2-2 • Differential Copyrighted Material SM 751, Oct ’06

2. Tightening torque of drive axle
1. Internal carrier ............................................................220 ± 30 kg

2. Spindle .......................................................................1,200 ± 50 kg
3. Parking piston .............................................................150 ± 10 kg
4. Adjustor nut ...............................................................100 ± 20 kg
5. Differential cap ..........................................................1,600 ± 50 kg
6. Differential case .........................................................600 ± 50 kg
7. Deep carrier drive axle contact ...................................Gasket
8. Ring gear ....................................................................1,350 ± 50 kg
9. Deep carrier assembly ................................................1,800 ± 50 kg
10. Wheel hub...................................................................300 ± 30 kg
SM 751, Oct ’06 Copyrighted Material Differential • 20-2-3

3. Disc brake
1 Spindle 5 Parking piston 9 Parking lever
2 Steel plate 6 Fixing bolt for parking piston 10 Parking lever shaft
3 Disc plate 7 Spline collar 11 Brake housing
4 Service piston 8 Drive shaft - -
As it is hydraulic disc brake system and hermetic type, it

guarantees braking performance under the poor environ-
ment where is humid, easy to corrode, and has much dust.
As the life of brake is semi-permanent, it does not need
frequent-change of lining like a drum-type brake.
As the parking brake is the serration-type lever system
that is possible to adjusting the play, the braking is stable
because it is easy to maintain the brake gap between right
and left wheels and minimizes the side brake deviation.
The main components are four disk plates (3), five steel
plates (2), service piston (4), parking piston (5), parking
lever (9), and brake housing (11). The braking is per-
formed by compressing the disc plate (3) and steel plate
(2) with driving power that is applied to driving shaft (8)
and spline collar (7).
20-2-4 • Differential Copyrighted Material SM 751, Oct ’06

Section 3
Assembly and disassembly of drive axle
Drive axle 3. Tighten the two taps (4) by using socket head bolt (2)
and take off the planetary housing.
Disassembly of drive axle

Removal and disassembly of wheel hub
1. Release the axle housing and drain plug of hub by
using torque wrench (1) and then drain the oil.
4. Disassemble the snap ring (5) from the planetary

housing.
2. Release four socket head bolts (2) and a plug (3)

from the planetary housing.
5. Disassemble three planetary pins (6) by using ham-

mer.
SM 751, Oct ’06 Assembly and disassembly of drive axle • 20-3-1

6. Disassemble the needle bearing (8), planetary gear 9. Unscrew a bolt (13) and remove the ring gear (14)
(7) and thrust washer (9). and torque plate ass'y from the axle tube.
7. Remove the sun gear (10) and drive shaft (11).
10. Remove the snap ring from the ring gear (14) and
disassemble the internal gear carrier.
8. Remove the retainer ring (12), and disassemble the

11. Disassemble the bearing cup from the wheel hub by
sun gear (10) from the shaft (11).
using jig and hammer. The shaft seal will be dam-
aged in this procedure.
20-3-2 • Assembly and disassembly of driveCopyrighted

axle Material SM 751, Oct ’06
Removal and disassembly of axle housing 3. Check the location of cap (4) on the carrier before
removing the differential ass'y from the carrier (3). If
1. Unscrew twelve bolts (1) and remove the carrier there is nothing, mark it in addition.
from the housing by using hoist.
4. Unscrew four hexagon bolts (5) and remove the cap
(4).
(1) (5)
(4)
2. Measure and record the differential assembly and

rotating resistance for reassembly. Remove the fixing
plate (2).
(3)
5. Disassemble the bearing (6) in the differential hous-

ing and remove twelve bolts (7).

6. Remove the differential assembly from the carrier. 10. Unscrew the lock nut 99) and remove the yoke (10).
7. Unscrew twelve housing bolts (8) from the differen- 11. Carefully take off the drive bevel pinion shaft (11) by
tial and disassemble the ring gear. using plastic hammer.
! CAUTION
Take care not to damage the bevel pinion
shaft while taking it off.
(10)
(11)
(9)
8. Check if there is any mark on the differential housing

and disassemble it.
12. Remove the shim (12) and spacer (13) from the pin-
If there is no mark, mark it in addition.
ion shaft. Disassemble the inner ring of taper roller
It has to be reassembled to the same direction.
bearing from the pinion shaft by using bearing puller.
(12)
(13)
9. Remove the thrust washer, side gear, pinion gear and

spider and place them to the clean place.

13. Remove the outer ring and shim of taper roller bear- • When the tooth of gear is damaged, replace
ing from the housing by using jig and hammer. it with the new set.
NOTE • Replace the damaged taper roller bearing.
Never reuse the damaged shim. • Never reuse the deformed shim or worn
thrust washer.
• Make the surface that the seal contacts
smooth by using a file.
<Adjustment for reassembly>

How to adjust bevel pinion shaft shim
1. The thickness of shim and bevel pinion shaft shall be
adjusted according to the following methods.
- Measure the dimension of "E" from housing.
- Decide the thickness of shims(1) by use of for-
mula, "X = E-B-T ± C".
B : Installation dimension of bevel pinion shaft. It is
14. Remove the outer ring of taper roller bearing located
131.10.
at the opposite side.
T : Width of bearing
C : Craved dimension to the end of pinion. If there is
no crave, it is "0",
Example:
When "E" of housing is 162.85mm,
B determined by maker is 131.10mm,
"T" measured from bearing is 31.5mm, and
"C" craved to pinion is 0.05mm, the thickness X
required for shims will be:
X=162.85-131.10-31.5-0.05 = 0.20mm
! WARNING
<Reassembly> When the gear tooth is damaged, replace the
bevel gear shaft and bevel gear together.
Clean all parts with cleanser and remove all remained Never reuse the deformed shim or damaged
Loctite. bearing.
! WARNING
Pay attention to prevent the cleanser from
contacting to the skin, and never drink or
inhale the vapor.
Wear the safety glove and protective glass. If
it gets on the skin, immediately wash it out
with much water.
If swallow the cleanser on accident, immedi-
ately see a doctor. Fully understand all the
regulations to prevent the accident.
• Check the abrasion, damage and crack of

all the parts and replace them if required.

2. Match the shim thickness to the calculated value thickness (Z) of required shims (2) with following for-
above by mixing various types of shim. Insert the mula.
shims to the bearing location.
Assemble that the outer ring of drive bearing contacts
to the bearing surface of housing by using jig.
"Z = S + Q"
3. Heat the inner ring of bearing to maximum 100 and
assemble it to bevel pinion shaft. It also contacts to Example:
the bearing surface and inner ring. If S from bearing is 2.25 and Q from housing is 3.15,
the thickness Z of required shims is Z = 2.25+3.15 =
5.40mm.
< End gap measurement of bevel pinion

shaft>
(Unit: mm)
Decide the thickness of required spaces (2) with following
method. S Q Z
Dimension Q: Distance from bearing surface of outer ring 2.25 3.15 5.40
to spacer surface: 2.30 3.15 5.45
Dimension S: Distance between outer ring surface of 2.35 3.15 5.50
bearing and inner ring surface of bearing. Decide the 2.40 3.15 5.55
2.45 3.15 5.60

Adjustment for reassembly Assembly of differential

1. Assemble the bearing cup. 1. Assemble the thrust washer, side gear and spider
with gear, and assemble it to the differential housing.
Apply the grease to the bevel gear and thrust washer.
Assemble the spacer to the pinion shaft, and then shims on

the spacer.
2. Assemble the differential housing.
2. Insert the pinion shaft into the carrier.

Assemble the bearing cone, yoke and lock nut.
NOTE
Apply the Loctite #271 or #277 to thread part of pin-
ion, and assemble the lock nut with tightening torque Check the direction of mark on the housing.
of 45~51 kg.m. Both housings have to be assembled to the
Measure the rolling friction of pinion shaft. same direction.
Adjust the thickness of shims to make the rolling
friction with 20~41.
Cock the lock nut to the slot of pinion shaft.

3. Tighten the differential housing by using twelve bolts Measure the rolling friction of taper roller
(7). Apply the Loctite #271 or #277 to thread part of bearing.
bolt and tighten with tightening torque of The following table is the relations between
500~750kg.m. adequate rolling frictions against to the roll-
ing friction of bevel pinion shaft that is mea-
sured from "No. 2, preloading adjustment of
bevel pinion shaft."
4. Assemble the ring gear by using twelve bolts (6).

Apply the Loctite #271 or #277 to thread part of bolt
and tighten with tightening torque of
1250~1450kg.m.
(Unit: kg,cm)
Pinion adjustment Ring-pinion overall adjust-
value ment value
20 35 ~ 41
25 40 ~ 46
30 45 ~ 51
35 50 ~ 56
5. Place the differential assembly to the carrier. Place 40.8 56 ~ 62
the bearing cup and screw to the housing. At this (50) 62 ~ 70
moment, adjust the rotating backlash by using the
screw.
7. Check if the screw and bearing are contacting.
Install the dial gauge to the tooth of gear, rotate the
bevel gear and measure the backlash. 8. Re-measure the rotating backlash after completely
- Rotating backlash: 0.18 ~ 0.23mm assemble the bearing cap, and readjust it with screw
if required.
6. Assemble the bearing cap.
9. Apply the Loctite #271 to thread part of bearing cap
NOTE
bolt, and assemble it with tightening torque of
Fix the bearing cap with hexagon-head bolt. 15~17kg.m.
The tightening torque is 15 ~ 17kg.m.

10. Assemble the fixing plate with hexagon-head bolt. 2. Assemble the pre-assembled wheel hub to tube
Apply the Loctite #271 or #277 to thread part of bolt flange of axle until they contact. Insert the bearing
and tighten it with tightening torque of 0.8~1.2kg.m. cone.
NOTE
Assemble the other side in the same way.
11. Apply the marking liquid to the sides of three or four

crown gear teeth, and contact with bevel pinion gear
several times. Check the shape of contact.
Assembly of carrier to axle housing

1. Insert the carrier ass'y into the axle housing.
2. Fix the carrier assembly to axle housing with hexa-
gon-head bolt (1). Apply the Loctite #271 or #277 to
3. Insert the shim, assemble the torque plate to ring gear
thread part of bolt and tighten it with tightening
with snap ring, and assemble it to axle tube. Apply
torque of 110~1300 kg.m.
the Loctite #271 or #277 to thread part of bolt (12)
and tighten it with tightening torque of
Assembly of wheel hub to axle housing 1500~1700kg.m.
Apply the grease to bush.
1. Insert the bearing into the wheel hub.
NOTE
Apply the grease or oil to shaft seal and
assemble it so that it faces to the outer side of
wheel hub.
4. Apply the oil (MOBIL #424) to Squaring rings (4, 5)

of brake housing (1) and assemble it.
Apply the oil (MOBIL 424) to outer diameter of pis-
ton(3), and apply the Loctite #271 to spring (6) and
four bolts (4), and then tighten them with tightening
torque of 1.4~1.6 kg.m.

NOTE f. Apply the Loctite #5127 to spindle assembling

Check the torn and dent of squaring ring and surface of brake housing (1).
replace it if it is damaged.
5. Assemble the sun gear to axle shaft and fix it with

snap ring.
Assemble the axle shaft ass'y to axle.
Apply the grease to the shaft on which contacts with
the bush.
Apply the grease to the teeth of planetary gear.
Assembly and check item of plate

a. Assemble four plates (8) and three discs (9) to the
brake housing (1) as shown in the figure.
b. Clean all the parts and remove oil before assem-
ble and remove the harmful burr.
c. Place the disc into the oil within 12 hours before
assembly. (MOBIL #424)
d. After assemble the plate and disc, check if the
stage gap against brake housing surface is
2.1~2.6 mm.
<The stage height of spindle (13) is 1.4mm and
the operational stroke of plate (8) and disc (9)
ass'y is 1.0~1.5mm.>
e. When pull in the parking lever (11) with force of
25kgf.m after tightening the bolt (10), check it
becomes 17~32mm.
• If the distance of parking level (11) is not
matched, disassemble it from the lever shaft (12)
and reassemble it by rotating the spline by one
turn.
When rotating the spline by one turn, the moving
distance of parking lever (11) is 17mm.
20-3-10 • Assembly and disassembly of drive axle

6. Reassemble the parts to planetary carrier with the 8. Assemble the wheel hub and tighten the plug (1) with
reversed order of disassembly. tightening torque of 3.5~6kg.m.
7. Assemble the planetary carrier ass'y to the wheel

hub.
Tighten the bolt (2) with tightening torque of
2.5~4kg.m.

NOTE :
Group 20, Drive Axle Copyrighted Material SM 751, Oct ’06

Section 4
Troubleshooting of drive axle
No. Problem Cause
(1) Lack of lubricant

(2) Different type of lubricant
(3) Defective or poor adjustment of wheel bearing
Constant abnormal sounds of (4) Poor adjustment of drive gear and pinion
1
differential (5) Damaged or worn drive gear and pinion gear
(6) Gear backlash is too much or little
(7) Abrasion or release of pinion bearing
(8) Abrasion or release of side bearing
(1) The rotation of ring gear is unstable

a. Poor tightening of fixing bolt of drive gear
2 Unstable abnormal sounds
b. Defective drive gear
(2) The bearing in the differential is broken
(1) The pinion shaft or spider of differential driving gear is too tight.
(2) The side gear in the differential case is too tight
Abnormal sounds when
3 (3) Defective pinion and side gear of differential
rotating
(4) Damaged or worn thrust washer
(5) Too much backlash (between side gear and pinion)
(1) Leakage of axle hub carrier

a. Too much oil
b. Use of wrong lubricant
c. Blockage of axle housing bleeder
4 Leakage of lubricant (2) Leakage of pinion shaft
a. Too much oil
b. Use of wrong lubricant
c. Blockage of bleeder
d. Abrasion of oil seal or wrong assembly
(1) Brakeage of axle shaft

a. Loosen wheel bearing
b. Short shaft
5 The drive wheel does not rotate c. Loosen stud and nut
(2) Damage of drive gear teeth
(3) Brakeage of side gear pinion of differential
(4) Brakeage of pinion shaft or spider of differential
SM 751, Oct ’06 Copyrighted Material Troubleshooting of drive axle • 20-4-1

NOTE :
Group 20, Drive Axle Copyrighted Material SM 751, Oct ’06

GROUP 22
GROUP 22
WHEELS AND TIRES
Wheels and Tires Specifications and

Description ............................................ Section 1
Pneumatic Wheels and Tires ....................Section 2
SM 751, Oct ’06 Copyrighted Material Group 22, Wheels and Tires
NOTE :
Group 22, Wheels and Tires Copyrighted Material SM 751, Oct ’06
Group 22, Wheels and Tires
Section 1
Wheels and Tires

Steer Tire Types : Pneumatic rubber/Cushion rubber, non- The wheels and tires used on the truck come in pneumatic
marking, and urethane. or cushion types in a variety of sizes depending on truck
model and application. Pneumatic tires are mounted on
Drive Tire Types : Pneumatic rubber/Cushion rubber, non-
multi-piece rims with locking rings.
marking, and urethane.
Pneumatic Drive and Steer Tire Inflation Pressure : ! WARNING
Drive C60-C70: 820 kPa (119psi) For your safety and the safety of others,
C80 : 1000 kPa (145psi) before you do tire or rim maintenance or ser-
Steer C60-C70 : 820 kPa (119psi) vice, read the OSHA rules regarding owner
C80 : 1000 kPa (145psi) responsibility. Do not work on tires or rims
unless you have been trained in the correct
procedures. Read and understand all mainte-
Fastener Torques nance and repair procedures on tires and
rims. Serious injury or death can result if
Steer Tire Mounting Nut Torque : Check mounting proce-
safety messages are ignored.
dure in Sections 2 and 3 for pneumatic tires and wheels.
Wheel Mounting Nut Torques : The Occupational Safety and Health Act (OSHA) speci-
fies required procedures for servicing multi-piece rim
Classification Model Torque wheels in 29 CFR Section 1910.177. It is the owner’s
Drive Wheel C60/C70 540-588 N.m(398-434 ft.lb) responsibility to comply with OSHA.
(Dual Tire) C80 540-588 N.m(398-434 ft.lb) In accordance with OSHA, the owner must provide a
C60/C70 440-490 N.m(325-362 ft.lb) training program to train and instruct all employees who
Steer Wheel
C80 440-490 N.m(325-362 ft.lb) service multi-piece rim wheels in the hazards involved
and the safety procedures to be followed. Do not let any-
one mount, demount, or service multi-piece rim wheels
Service Intervals without correct training.
Wheel Mounting Bolts Check and Tightening : Every 50- The owner should obtain and maintain in the service area
250 hours of operation and each PM. current copies of the United States Department of Trans-
portation, National Highway Traffic Safety Administra-
Tire Condition : Daily inspection.
tion publications entitled “Safety Precautions for Mount-
Tire Pressure Check : Daily inspection. ing and Demounting Tube-Type Truck/Bus Tires,” and
Multi-Piece Rim/Wheel Matching Chart” or other similar
publications applicable to the types of multi-piece rim
wheels being serviced.
SM 751, Nov ’06 Wheels

Copyrighted and Tires Specifications and Description • 22-1-1
Material
NOTE :
Group 22, Wheels and Tires Copyrighted Material SM 751, Nov ’06
Section 2
Pneumatic Wheels and Tires
SM 751, Oct ’06 Copyrighted Material Pneumatic Wheels and Tires • 22-2-1
5. Always remove all air from a single tire and from

! CAUTION both tires of a dual assembly prior to removing any
SAFE PARKING. Before working on truck : rim components, or any wheel components, such as
nuts and rim clamps. Always remove the valve core
1. Park truck on a hard, level, and solid to remove air from tire. Be sure all air is removed.
gaps or breaks. 6. Check rim components periodically for fatigue
cracks. Replace all cracked, badly worn, damaged,
2. Put upright in vertical position and fully and severely rusted components.
7. Do not, under any circumstances, attempt to rework,
3. Put all controls in neutral. Turn key switch weld, heat, or braze any rim components that are
OFF and remove key.
cracked, broken, or damaged. Replace with new parts
4. Apply the parking brake and block the or parts that are not damaged, which are of the same
wheels. size, type, and make.
8. Never attempt to weld on an inflated tire/rim assem-
Pneumatic Tire Maintenance bly.
Precaution 9. Clean rims and repaint to stop detrimental effects of
corrosion. Be very careful to clean all dirt and rust
The following instructions supplement the OSHA require-
from the lock ring gutter. This is important to secure
ments. In the event of any conflict or inconsistency
the lock ring in its proper position.
between these instructions and the OSHA requirements,
A Filter on the air filling equipment to remove the
the OSHA requirements shall be controlling.
moisture from the air line prevents a lot of corrosion.
The filter should be checked periodically to make
! WARNING sure it is working properly.
Before you do tire or rim maintenance, read 10. Make sure correct parts are being assembled. Ask
the OSHA rules regarding owner responsib- your distributor or the manufacturer if you have any
lilty. Read and understand all maintenance doubts.
and repair procedures on tires and rims. Do
not work on tires or rims unless you have 11. Do not be careless or take chances. If you are not
been trained in the correct procedures. Seri- sure about the proper mating of rim and wheel parts,
ous injury or death can result if the safety consult a wheel and rim expert. This may be the tire
messages are ignored. man who is servicing your fleet, the rim and wheel
distributor in your area, or the CLARK dealer.
1. Do not let anyone mount or demount tires without 12. Mixing parts of one manufacturer’s rims with those
proper training. of another is potentially dangerous. Always ask man-
2. Never sit on or stand in front of a tire and rim assem- ufacturer for approval.
bly that is being filled with air. Use a clip-on chuck 13. Do not use undersized rims. Use the right rims for
and make sure the hose is long enough to permit the the job.
person filling the tire with air to stand to the side of
the tire, not in front or in back of the tire assembly. 14. Do not overload rims. Ask your rim manufacturer if
special operating conditions are required.
3. Never operate a vehicle on only one tire of a dual
assembly. The carrying capacity of the single tire and 15. Do not seat rings by hitting with a hammer while the
rim is dangerously exceeded, and operating a vehicle tire is filled with air pressure. Do not hit a filled or
in this manner can result in damage to the rim and partially-filled tire/rim assembly with a hammer.
truck tip-over and driver injury. 16. Double check to make sure all the components are
4. Do not fill a tire with air that has been run flat with- properly seated prior to filling tire with air.
out first inspecting the tire, rim, and wheel assembly. 17. Have the tire in a safety cage when filling with air.
Double check the lock ring for damage. Make sure
that it is secure in the gutter before filling the tire
with air.
22-2-2 • Pneumatic Wheels and Tires Copyrighted Material SM 751, Oct ’06
18. When removing wheels, regardless or how hard or • Incorrect (low) tire pressure can reduce the sta-
firm the ground appears, put hardwood blocks under bility of a lift truck and cause it to tip over.
the jack.
IMPORTANT
19. Block the tire and wheel on the other side of the vehi- Check wheels and tires for damage every
cle, before you place the jack in position. Place time you check tire pressure. Make repairs
blocks under the truck frame as near as possible to when needed. Dirt can get into cuts and cause
the jack to prevent the truck from falling if the jack
damage to the tire cord and tread. Remove
should fail.
debris from all cuts.
20. Remove the bead seat band slowly to prevent it from
dropping off and crushing your toes. Support the 2. Check the condition of the drive and steer wheels and
band on your thigh and roll it slowly to the ground. tires. Remove objects that are imbedded in the tread.
This will protect your back and feet. Inspect the tires for excessive wear, cuts and breaks.
21. Bead breakers and rams apply pressure to bead
flanges. Keep your fingers away from the bead
flanges. Slant bead breaker about 10° to keep it
firmly in place. If it slips off, it can fly with enough
force to kill. Always stand to one side when you
apply hydraulic pressure.
General Tire Maintenance, Inspection,

and Repair
3. Check all wheel lug nuts or bolts to be sure none are
1. Park the truck as described in “Safe Parking” and loose or missing. Have missing bolts replaced and
check for correct tire inflation air pressure. loose bolts tightened to the correct torque before
Drive C60-C70: 820 kPa (119psi) operating the truck.
C80 : 1000 kPa (145psi)
Classification Model Torque
Steer C60-C70 : 820 kPa (119psi)
Drive Wheel C60/C70 540-588 N.m(398-434 ft.lb)
C80 : 1000 kPa (145psi)
(Dual Tire) C80 540-588 N.m(398-434 ft.lb)
! CAUTION Steer Wheel
C60/C70 440-490 N.m(325-362 ft.lb)
Check tire pressure from a position facing C80 440-490 N.m(325-362 ft.lb)
the tread of the tire, not the side. Use a long-
handled gauge to keep your body away from Inspection and Minor Repair
the side.
Inspect pneumatic tires and wheels carefully for.
1. Low inflation pressure.
2. Damaged tires. Check tires for cuts and breaks.
3. Damaged wheels or loosening of the lock ring on
multi-piece rims.
• If tires are low, do not add air. Have the tire and
wheel inspected by a person trained and autho-
rized to do tire and wheel maintenance. The tire
may require removal and repair.
4. Check for loose nuts or bolts not in position.

5. Check the nuts or bolts for damage.
6. Check the surface of the wheels for bent flanges. Tire and wheel
assembly
7. Check all parts for rust or corrosion.
Wheel Nut
8. Mark the damaged areas with chalk so that the parts
can be removed from operation.
9. Remove all parts that are damaged and install new
parts in the same position.
10. Replace parts with the correct sizes and types. See
your parts manual. Drive axle Hub
11. Include your truck serial number when ordering

replacement parts.
3. Use a portable jack of adequate capacity placed

Wheel Dismounting and Remounting under the frame of truck to raise drive or steer wheels
Refer to “Lifting, Jacking, and Blocking” in Group SA for off floor.
information on jacking up or raising the truck for wheel 4. Once tire is off the ground enough to rotate freely,
removal. Always start with the truck parked safely. remove the lug nuts and lift the wheel from the hub.
Use caution when lifting tire and wheel.
Drive and Steer Wheel Dismounting
Drive and Steer Wheel Remounting
1. Remove the valve core from the valve stem to be sure
all air is removed from the tire. IMPORTANT
2. Loosen the lug nuts on the wheel. See “Tire Installation” in this Section to
make sure the wheel and tire mounting orien-
tation is correct. Check the information for
correct tire-to-wheel mounting and wheel-to-
hub mounting.
1. Make sure the truck is parked on a flat, hard surface

and the jacking and blocking devices are secure to
hold the truck in a safe position.
2. Inspect the removed lug nuts for damage to the
threads. Also inspect all hub studs for thread damage.
Steer axle Hub Replace any lug nuts or studs that have damaged
threads. Make sure studs are secure in the axle hub.
Steer axle
hub lug Nut
3. Set the wheel on the hub and start the lug nuts on the Dual-Drive Wheel Dismounting
hub studs. Tighten the nuts only enough to seat the
nuts into the beveled openings on the wheel and to 1. Remove the valve core from the valve stem of the
secure the wheel on the axle hub. outer wheel to be sure all air is removed from the tire.
4. Use a crisscrossing nut tightening sequence to torque Drive axle hub
the nuts to a pre-final torque of 54-81 N⋅m (40-60
ft⋅lb). Make sure all nuts seat into beveled spacer Wheel nut
holes correctly.
1 8
5 4
3 6
7 2
Stud bolt
Drive and Steer Wheel inner wheel
5. Begin the crisscrossing sequence again and tighten Outer wheel
the lug nuts to final torque.
2. Use a portable jack of correct capacity placed under
Classification Model Torque
the frame of truck to raise drive wheels off floor.
Drive Wheel C60/C70 540-588 N.m(398-434 ft.lb)
(Dual Tire) 3. Remove the eight outer-wheel nuts and remove the
C80 540-588 N.m(398-434 ft.lb)
outer wheel and tire from the drive axle studs.
C60/C70 440-490 N.m(325-362 ft.lb)
Steer Wheel 4. Remove the valve core from the valve stem of the
C80 440-490 N.m(325-362 ft.lb)
inner wheel to be sure all air is removed from the tire.
6. Carefully lower the truck and remove the jack. 5. Remove the tire and wheel from the drive-axle hub.
Use caution when lifting wheel and tire assembly.
7. Check tire pressure for correct inflation pressure.
Drive C60-C70: 820 kPa (119psi)
C80 : 1000 kPa (145psi) Dual-Drive Wheel Remounting
Steer C60-C70 : 820 kPa (119psi) IMPORTANT
C80 : 1000 kPa (145psi) See “Tire Installation” in this Section to
make sure the wheel and tire mounting orien-
! WARNING tation is correct. Check the information for
If tires are not fully inflated, see “Adding Air correct tire-to-wheel mounting and wheel-to-
Pressure To Mounted Wheel/Tire Assem- hub mounting.
blies” and follow the procedures for adding 1. Make sure the truck is parked on a flat, hard surface
air to the mounted tires. and the jacking and blocking devices are secure to
Before you add air pressure to the tire, make hold the truck in a safe position.
sure the lock ring is correctly positioned in
the rim and side ring. The lock ring can sepa- 2. Inspect the lug nuts for damage to the threads. Also
rate from the rim with enough force to cause inspect all studs for thread damage. Replace any lug
injury or death. nuts or studs that have damaged threads. Make sure
studs are secure in the drive-axle hub.
3. Install inner wheel and tire assembly on drive-axle

hub shoulder studs. ! WARNING
Before starting disassembly, remove the air
from the tire. Failure to remove the air from
the tire can result in serious injury.
1 8 2. Remove lock ring.

5 4
3 6
7 2
4. Install the outer wheel to the drive axle hub, and

tighten the wheel nut to fix the drive axle wheel hub.
5. Use a crisscrossing nut tightening sequence to torque
the nuts to a pre-final torque of 540-588 N.m(398-434
ft.lb). Make sure all nuts are seating into beveled
3. Remove wheel wedge.
spacer holes correctly. See illustration above. 4. Remove tire from wheel.
6. Begin the crisscrossing sequence again and torque
the lug nuts as described in step 4 and 5.
NOTICE
The outside diameter of the left or right
wheel or set of wheels must not differ more
than 6mm (0.25 in) per side.
7. Check tire presssure for correct inflation pressure :

• Drive wheel pressure is C60-70 : 820kPa
(119psi), C80 : 1000kPa (145psi).
5. Remove the rubber inner tube protector (flap).
! WARNING
If tire are not fully inflated, see “Adding Air
Pressure To Mounted Wheel/Tire Assem-
blies” and follow the procedures for adding
air to the mounted tires.
Before you add air pressure to the tire, make
the rim and side ring. The lock ring can sepa-
rate from the rim with enough force to cause
injury or death.
6. Repair tire and/or tube, as needed.
Wheel Disassembly and Tire Removal
1. Remove valve core from the valve stem to be sure all
air is removed.
7. Check for cracks in the wheel. 12. Clean the tire bead seat area. Remove all rust and
rubber with a wire brush or wheel.
Cracks in the wheel are caused by :

• Deep rim tool marks.
13. Clean wedge and lock rings. Make sure the seating
• Overload on wheels. surface and bead seat areas are clean.
• Too much air pressure in the tires.
• Using the wrong size tires.
8. Check for cracks in the lock ring.
9. Check for cracks between the stud holes in the wheel.
Cracks are caused by :
• Loose wheel nuts.
• Wheel not installed correctly.
• Wrong size or type of parts used.
• Too much torque on the wheel fasteners. If the
wheel mounting parts are too tight, the studs or
bolts can break, causing cracks in the wheel 14. Apply paint to the tire rim with a brush. Or, use an
between the stud holes. aerosol can of metal primer.
• Too little torque on the wheel fasteners. If the The parts must be clean and dry before you apply the
wheel mounting parts are too loose, damage to paint. Make sure to apply paint to the outside or tire
parts and tire wear will result. side of the rim. This is important because air is on the
metal surface of the tire side of the rim
10. Check wedge ring for wear or damage. Corrosion
buildup will cause wear and damage to the wheel 15. Apply lubricant on the tire side of the rim base. Do
wedge ring. not use a lubricant that has water or solvent which
will cause damage to the rubber.
11. Clean the wheels. Remove rust and dirt.
NOTE
Clark dealers can supply the correct lubri-
cant, which contains a rust inhibitor.
Tire Replacement and Wheel 5. Install the wheel wedge.

Reassembly
1. Put the tube into the tire.
6. Put the side ring over the rim and install the lock ring
as shown.
IMPORTANT
Install washer 22.123 on tube over valve stem
before flap is installed, when specified. See
sketch. Refer to Service Parts List.
Wheel Washer
Tube
7. Connect air chuck and turn the tire over with the
2. Put the rubber tube protector(flap) over the tube. valve stem down. Put 21 kPa (3 psi) of air into the
tire.
3. Install the tire onto the wheel rim, against the bead
seat area.
8. Turn wheel to the other side. Check to make sure

lock ring is in correct location.
4. Put the wheel wedge over the rim.
9. Disconnect the air chuck. Use a mallet and hit the above the wheel center. Arrow must point to ward
ring to make sure the ring is fully installed. front of truck.
INSIDE
TRUCK
10. Put the tire in an OSHA-approved safety cage. 2. Outside dual tire arrow to point in the direction of
rearward rotation. Rotate wheel to bring arrow on tire
above the wheel center. Arrow should point toward
rear of truck.
Tire-to-Wheel Mounting
Directional-Tread Tires
All directional-tread tires are to be mounted in the correct
position with respect to the arrow cast on the side of the
tire as explained below.
Directional-Tread Dual Tires
1. Inside dual tire arrow to point in the direction of for-

ward rotation. Rotate wheel to bring arrow on tire
Filling Tires with Air 2. Turn the regulator valve counterclockwise (CCW)
until you can feel no resistance from the regulator.
Follow these procedures when putting air into tires. All This will adjust the regulator presssure to a low pres-
wheel and tire assemblies must be filled in a safety cage. sure near zero.
The hose must have an adapter that can be connected to
the valve stem.
1. Attach an air hose to valve stem.
2. Open the control valve which will let compressed air
into the tire.
3. At intervals, close the control valve and check the
pressure in the tire by reading the gauge. Do not put
too much presssure into the tire.
4. Continue to fill the tire to the correct air pressure
reading of 3. Slowly turn the cylinder valve counterclockwise
Drive C60-C70: 820 kPa (119psi) (CCW) to open position.
C80 : 1000 kPa (145psi)
Steer C60-C70 : 820 kPa (119psi)
C80 : 1000 kPa (145psi)
IMPORTANT
Put equal pressure in both tires of a dual
assembly. Do not put air into a tire that is flat
without first inspecting it and the wheel for
damage.
Filling Tires with Nitrogen

4. The tank gauge will now show tank pressure.
If your air supply does not have enough pressure to fill the
tire, you can use a pressurized cylinder of commercial
nitrogen gas to get the correct tire pressure. With the tire
in a safety cage, connect the nitrogen cylinder to the valve
stem with the use of an air chuck.
! WARNING
Use introgen only. Do not use oxygen or any
other gas to fill tires. Make sure all items of
equipment used (nitrogen cylinder, regulator, 5. Turn the regulator valve clockwise (CW) until the
gauges, hoses) are UL approved and in good regulator gauge reads the correct tire pressure. Fill
condition. Use the correct regulator and hose the tire with nitrogen.
for the pressures that are necessary.
1. Be sure tank valve is closed to connect hose to valve

stem. Tank vlave is closed by turning handle on top
of tank clockwise to a stop.
6. Turn the tank valve clockwise (CW) and close the Checking and Adjusting Tire Pressure
valve.
! WARNING
Before you add air pressure to the tire, make
the rim and wheel wedge. The lock ring can
separate from the rim with enough force to
cause injury or death.
7. Disconnect the air chuck from the valve stem.
1. Attach a clip-on air chuck to valve stem. Stand by the

side of the wheel and put the correct air pressure in
the tire.
8. Turn the regulator valve counterclockwise (CCW) to

the off position.
2. If your air supply does not have enough pressure to

fill the tire, you can use a nitrogen cylinder to get the
correct pressure.
NITROGEN
9. Use a tire pressure gauge to check the tire pressure. If

necessary, put more air into the tire. Do this as many
times as necessary to reach the correct tire pressure.
3. Put a clip-on type air chuck on the nitrogen cylinder
! CAUTION hose and attach it to the valve stem. Follow the pro-
Use a long-handled gauge so that your hand cedures described previously for adjustment of the
does not go inside the cage, or in front of any nitrogen cylinder valves.
component of a multi-piece wheel.
! WARNING
Use nitrogne only. Do not use oxygen or any
other gas to fill tires.
NOTE :
Group 22, Wheels and Tires Copyrighted Material SM 751, Oct ’06
GROUP 23
GROUP 23
BRAKE SYSTEM
Braking/Inching System
Specifications and Description ............ Section 1
Service Brake Troubleshooting ................Section 2
Brake/Inching Pedals and Linkages

Adjustments ...........................................Section 3
Brake Bleeding ...........................................Section 4
Brake Master Cylinder Service ................Section 5
Parking Brake Service ..............................Section 6
SM 751, Nov ’06 Copyrighted Material Group 23, Brake System

NOTE :
Group 23, Brake System Copyrighted Material SM 751, Nov ’06

Group 23, Brake System
Section 1
Braking/Inching System
NOTE
INCHING. This Section only covers inching in re-
gard to the linkage between the brake and inching
pepals. The inching system is more fully covered in
Group 06, “Transaxle.”
Specifications
Service Brake : Parking Brake :
Type : Wet disc brake. Master cylinder provide by reserve Type : Cam-structure type that each wheel is connected to
tank. the service brake piston
Fluid : Fluid provided by reserve tank. Holding Test: Rated load on 15% grade.
Pedal Freeplay : 4-6mm (0.16-0.24in)
Inching : also see standard transaxle specs in Group 06
Type: Inching pedal which is mechanically connected to
the inching spool and brake pedal of transaxle.
Pedal Freeplay: None
Overlap Adjustment : 0-5 mm.(0-0.20in)
SM 751, Nov ’06 Braking/Inching System Specifications and Description • 23-1-1

General Description Inching Operation

The service brake and inching system (diagrammed The inching pedal allows the operator to vary transmission
below) consists of : slippage through the clutch pack so that travel speed and
lifting speed can be independent.
Service brake assembly — Wet disc brake.
The inching pedal also applies the service brakes. When
Brake Master Cylinder — This is step-bore type master
the inching pedal is depressed to a certain point, a
cylinder and the oil reservoir shall be separately equipped.
mechanical linkage between the inching pedal and the
The brake oil will be supplied from the reservoir to the
brake pedal begins to apply the service brake. When the
master cylinder.
inching pedal is fully depressed, the clutch pack fully dis-
Inching sensor — It senses the displacement of inching engages and the service brake fully applies.
pedal, and transfers the signal to the controller.
Service brake and inching pedals and linkages — A Braking Operation
mechanical system through which the brake pedal or inch-
ing pedal operates the brake master cylinder. The inching When the operator depresses the brake pedal, or depresses
pedal is mechanically linked to the brake pedal so that the the inching pedal far enough to operate the brake pedal,
inching pedal, near the end of its stroke, also operates the the brake link operates a piston in the brake master cylin-
service brakes. der.
Inching control valve — A hydraulic valve in the tran- The brake master cylinder receives flow from the reser-
saxle control valve assembly that hydraulicly varies clutch voir. In general, the brake master cylinder allows pressure
pack pressure so the operator can “inch” the truck. to build in the wheel cylinder in proportion to the extent
the brake pedal is depressed.
Parking brake pedal — Operates the service brake via
cables. See “Parking Brake Adjustment,” in this Group, When the operator applies the brakes, the brake master
for details. cylinder piston shifts to provide pressure to the wheel cyl-
inders for braking. The amount of pressure is modulated
by the position of the piston. When the pedal is released,
pressure in the brake piston vents to the sump and the
return springs on the piston retract the brake piston.
Service Requirements
Operational checks and inspection of linkages, brake lines
are specified in the Periodic Service Chart in Group PS.
Service brake linkage adjustment and lube are not nor-
mally required.
Parking brake should be adjusted if indicated by opera-
tional check.
23-1-2 • Braking/Inching System Specifications and Description

Section 2
Service Brake
Troubleshooting
SM 751, Nov ’06 Copyrighted Material Service Brake Troubleshooting • 23-2-1

Service Brake Troubleshooting
Causes/Corrective
Condition Actions
Brake pedal drops to floor ...................................................................... B D F
Brake pedal spongy................................................................................. B C
Brake pedal kicks back when applied ..................................................... C E
Brakes stick, drag excessively, make noise, or overheat ........................ E G
Insufficient stopping power; excessive effort required........................... F B E
Excessive effort required to apply brake................................................. F B
Inching pedal does not apply brake at right time .................................... A D
Causes/Corrective Actions
A. Overlap adjustment incorrect... Adjust.

B. External leak in wheel cylinder or other component of braking system... Inspect/replace/repair.
C. Air in braking system... Bleed and recheck.
D. Linkage misadjusted or broken. Return spring damaged... Inspect/repair.
E. Brake master cylinder defective... Inspect/overhaul or replace.
F. Disc worn or brakes misadjusted... Inspect/repair/adjust.
G. Parking brake misadjusted... Adjust.
23-2-2 • Service Brake Troubleshooting Copyrighted Material SM 751, Nov ’06

Section 3
Brake/Inching Pedals and

Linkages Adjustments
Introduction Overlap Adjustment
Figures 1 show : See Figure 1. When the inching pedal is depressed, the
strike bolt threaded into the inching pedal pushes against
• The service brake linkage, which links the brake
the strike lever on the brake pedal, applying the brake.
pedal to the brake master cylinder.
• The inching pedal linkage, which links the inching The clearance between the top of the strike bolt and the
pedal to the inching sensor. strike lever should be 0 to 5 mm (0~0.2 in), depending on
operator preference.
• The inching pedal overlap, which allows the inch-
ing pedal to operate the brake pedal. 1. Measure clearance.
The illustrations and accompanying text serve as guide to If necessary, adjust as follows:
disassembly/assembly and adjustment.
2. Loosen jam nut.
Pedal Height Adjustment 3. Turn strike bolt to obtain desired clearance.

4. Tighten jam nut.
See Figure 1. The brake pedal must be at the same height
as the inching pedal. To adjust brake pedal height :
1. Loose the pedal stop bolt of brake and adjust pedal
height to be 168 ± 3mm(6.6 ± 0.1in) from cross
plate.
2. Loose the pedal stop bolt of inching and adjust pedal
height to be 168 ± 3mm(6.6 ± 0.1in).
Freeplay Adjustment
When the brake pedal linkage is properly adjusted, brak-
ing should begin only after the pedal is depressed a certain
distance, This is “Freeplay” is Adjusted as follows :
1. Loosen the jam nut on the rod brake master cylinder
(Figure 1).
2. Depress the brake pedal 4~6mm (0.16~0.24 in).
3. Adjust the rod until you feel the push rod make clear-
ance with the cylinder piston.
SM 751, Nov ’06 Brake/Inching

Copyrighted Material Pedals and Linkages Adjustments • 23-3-1
Inching pedal
Inching sub ass'y
Inching rod ass'y
Figure 1. Brake/Inching Pedals and Linkage
23-3-2 • Brake/Inching Pedals and Linkages Copyrighted

Adjustments Material SM 751, Nov ’06
Section 4
Brake System
Bleeding
Bleed brakes when : 5. Operate the brake pedal at various rates. If you feel
the pedal kick back, bleed the system again.
• The brake pedal kicks back during braking or the
pedal feels spongy.
• The brake valve or wheel cylinders — or lines
between — have been leaking and/or have been
repaired or replaced.
• Troubleshooting otherwise indicates that air has
been introduced into the system.
Because the brake system is supplied with brake

fluid(Hydraulic fluid ; RANDO HD 32, or in accor-
dance with CLARK specification MS-68 ) from the res-
ervoir, brake bleeding is simplified. Proceed as follows :
1. Park truck on level floor. Put direction control in neu-
tral. Lower forks to floor, tilt forward, and apply
parking brake.
2. Attach a clear hose to a bleed screw on one of the
brake cylinders. Place the other end of the hose in a
jar containing Hydraulic fluid, Clark part #2776239.
3. Open the bleed screw.

4. Depress the brake pedal and watch fluid flow into the
jar. When the fluid appears to be free of bubbles,
tighten the bleed screw, then release the pedal.
SM 751, Nov ’06 Copyrighted Material Brake System Bleeding • 23-4-1

NOTE :

Section 5
Brake Master Cylinder Service
SM 751, Nov ’06 Copyrighted Material Brake Master Cylinder Service • 23-5-1
Brake Master Cylinder Removal

and Replacement
1. Remove the spring clip and pin from the yoke on the
brake master cylinder rod. (See box below).
2. Remove and plug the feed line.
3. Loosen the two mounting bolts.
4. Replacement is reverse of removal. Bleed system and
test brakes as described in Section 4.
23-5-2 • Brake Master Cylinder Service Copyrighted Material SM 751, Nov ’06
Brake Master Cylinder Overhaul

• Use the Clark overhaul kit to overhaul the brake
master cylinder.
• Clean all parts with a safety-approved commercial
solvent before inspection.
• Inspect all parts. Inspection includes :
- Checking bores and pistons for scratches,
nicks, burrs, and wear.
- Making sure springs are not bent or cracked.
- Making sure all orifices are free of blockage.
- Making sure boot is not torn or loose.
- Making sure push rod is not bent.
• Replace all seals. Do not reassemble with old seal.
• Coat all components with hydraulic fluid, Clark
part #2776239, before reassembly. Lubricate and
wrap parts if reassembly will not be done immedi-
ately.
IMPORTANT
CLEANLINESS. Perform overhaul proce-
dure in a clean environment. Make sure all
parts are cleaned before, and kept clean dur-
ing, reassembly.
SM 751, Nov ’06 Copyrighted Material Brake Master Cylinder Service • 23-5-3
NOTE :

Section 6
Parking Brake Service
Operation Adjustment
If the user pulls the parking brake lever, the parking brake 1. While the parking brake lever is completely released,
will begin to work and the latchet maintain this condition. adjust the loose brake cable and tighten the adjust/
The cable connected to the parking brake lever draws the lock nut.
drive axle brake lever, so the brake will work. When
2. Actuate and release pedal foru to five times.
releasing the parking brake, the user shall press the lock
button and push down the parking brake. The parking 3. Readjust and tighten nuts.
brake lever pin will operate the parking brake interlocking
switch and parking brake indicator light switch.
SM 751, Nov ’06 Copyrighted Material Parking Brake Service • 23-6-1

NOTE :

GROUP 25
GROUP 25
STEERING COLUMN AND GEAR
Steering System Specifications

and Description .................................... Section 1
Steering System Troubleshooting ........... Section 2
Steering Column and Component

Removal and Replacement .................. Section 3
Steering System Relief Pressure Check

and Adjustment .................................... Section 4
Steering Gear Overhaul ........................... Section 5
SM 751, Dec ’06 Copyrighted Material Group 25, Steering Column and Gear
NOTE :
Group 25, Steering Column and Gear Copyrighted Material SM 751, Dec ’06
Group 25, Steering Column and Gear
Section 1
Steering System Specifications and

Description
Steering System Type : Hydrostatic power steering with All truck models have a hydrostatic power steering sys-
load sensing, dynamic signal neutral circuit. tem, which is supplied with oil pressure from the main
hydraulic system pump. The steering hand wheel operates
Steering System Relief Pressure Setting : 13000 kPa
the steering gear (steering control unit), which directs oil
(1885 psi)
flow to the steering cylinder on the steer axle. A steering
system pressure relief valve is built in the hydraulic pump
Service Intervals to prevent over-pressurization of the steering system. The
pressure relief setting can be tested using the gauge port of
Check the steering system relief pressure annually or after the hydraulic pump. A steering priority valve, also in the
every 2000 hours of operation. Make a visual inspection pump, diverts flow from the main hydraulic system to the
of steering control unit hydraulic fittings periodically to steering system when it senses the pressure increase
ensure that the fittings are tight with no leakage. caused by turning the steering hand wheel.
The power steering gear is a remote positioning control
Fastener Torques valve that senses the input signal from the steering hand
Steering Handwheel Nut : 35-45 N⋅m (25.5-33.5 ft⋅lb) wheel, multiplies this signal to assist in reducing the steer-
ing effort, and causes the steering axle to turn the wheels
to the desired position by supplying hydraulic flow to the
steering cylinder.
The steering gear is connected to the bottom of the steer-
ing column. When the steering hand wheel is turned, it is
linked mechanically to the steering gear spool and causes
this spool valve to shift from its closed neutral position to
a “turn” position that allows oil under pressure to flow to
the steering cylinder.
When the steering hand wheel stops turning, centering
springs in the valve automatically center the spool, stop-
ping the flow of oil to the cylinder.
The low pressure oil from the opposite side of the steering
cylinder is returned through the opposite port in the gear.
It is controlled by the same spool as the high pressure
port.
In the event of a pump failure, the steering gear can gener-
ate sufficient hydraulic power by movement of the steer-
ing handwheel to serve as a limited steering method. An
internal check valve automatically closes to divert this
generated oil flow to the proper port of the steering cylin-
der.
SM 751, Dec ’06 Steering

Copyrighted System Specifications and Description • 25-1-1
Material
The handwheel turning effort is considerably higher, how- the up position by the use of gas spring. The tilt lock
ever, than with power steering. mechanism, the directional control lever are protected by
the steering column cover. The cover can be removed for
The column tilt lock mechanism allows the operator to
service to steering column components. The entire col-
adjust the steering column. The column tilt lever knob
umn can be removed for service or replacement.
releases the adjustment setting and the column returns to
Locker Switch Steer Handle
Direction Control Light Switch Lever

Assembly
Steer Handle
Screw
Column Upper Cover
Tilt Lock Lever
Gas Spring
Tilt Lock Assembly

Column Lower Cover
Wire Harness
Column Outside Column Inside
25-1-2 • Steering System Specifications andCopyrighted

Description Material SM 751, Dec ’06
Section 2
Steering System Troubleshooting
No steering Truck turns in wrong direction

• Hydraulic fluid level very low. • Hydraulic lines not installed correctly.
• Air in hydraulic oil.
Handwheel kickback
• Steering column sections not connected properly.
• Hose broken. • Check valve faulty (or not in system).
• Hydraulic pump contaminated or defective.
Slow steering response
Hard steering • Oil viscosity too high.
• Hydraulic fluid level low. • Contaminated or defective steering gear.
Chatter conditions
• Steering gear contaminated or defective.
• Loose mountings or linkage. Make certain all
• Relief valve setting too low ; adjust or replace.
mounting fasteners and other linkage is tight.
• System leaking.
• Pressure relief valve set too low and is out of
• Incorrect tire pressure. adjustment ; adjust or replace the relief valve.
• Axle load too heavy. • Insufficient pump flow. Check pump for leaks and
• Lack of lubrication. see Group 29, Section 2.
Unsatisfactory steering in either direction
• Defective steering gear.
• Malfunctioning, damaged, or worn priority • Air in system due to excessive wear in steering cyl-
demand valve (flow control valve). inder. Check for air in system. Excessive noise or
foamy condition of hydraulic fluid indicates aera-
High number of handwheel turns tion. Check that air is not entering the system
through poor threads, cracked, split, or worn hoses,
• Steering cylinder seal leakage. bad pump seals, bad O-rings, bad gaskets, or loose
• Worn steering gear. connections.
Worn cylinders result in leakage past the piston.
Steering handwheel spins freely Overhaul (see Group 26, Section 7) or replace the
steer cylinder.
• Air in system (cavitation).
• Incorrect system pressure due to worn pump.
• Low oil supply.
Replace the relief valve or repair or replace the
• Steering column detached from steering gear. pump (see Group 29).
• Defective steering gear.
Noise during turns
Jerky steering
• Worn bearing (s) in steering arm; replace bearings.
• Steering gear malfunction because of worn parts or • Worn pin in steering knuckle ; replace pin.
contamination. Steering gear may require over-
• Worn bearings in steering knuckle ; replace bear-
haul.
ings.
• Steering knuckle is loose ; tighten castle nut.
SM 751, Dec ’06 Copyrighted Material Steering System Troubleshooting • 25-2-1

Constant noise from steering axle Low pressure at the pump

• Loose or worn hub bearing cones. Adjust or • Refer to the pump troubleshooting and overhaul
replace hub bearing cones. Replace bearing cones procedures in Group 29.
and bearing cups as a set.
Low pressure at the steering gear
Noise when axle pivots
• Refer to Section 5, “Steering Gear Overhaul.”
• Lack of lubricant in steering axle mounting.
• Steering axle mountings worn; replace mountings. Low pressure at the steer cylinder
• Steering axle mounting cap(s) loose ; tighten • Seals worn out at piston rod end of steer cylinder;
mounting cap(s). replace seals.
Fluctuating pressure Steer cylinder rod binding or sticking

• Faulty operation of relief valve. Fluctuating pres- • Binding of linkage. With hydraulic flow shut off
sure or loss of pressure in the system is usually from the cylinder and the rod end uncoupled, the
caused by scales, chips, sludge, or filings that have rod should slide freely in or out by hand. If the pis-
lodged between the relief valve and seat. A dam- ton is binding, overhaul or replace the cylinder.
aged spring or worn valve may also be the cause of
the trouble. Flush and refill the system and replace
the hydraulic return line filter element. If condition
still exists, replace the relief valve.
25-2-2 • Steering System Troubleshooting Copyrighted Material SM 751, Dec ’06

Section 3
Steering Column and Component Removal and Replacement
IMP ORTANT
Before removing any component for overhaul, make sure the
correct repair parts, seals, and gasket sets are available.
Locker Switch Steer Handle
Direction Control Light Switch Lever

Assembly
Steer Handle
Screw
Column Upper Cover
Tilt Lock Lever
Gas Spring
Tilt Lock Assembly

Column Lower Cover
Wire Harness
Column Outside Column Inside
SM 751, Dec ’06 Steering Column and

Copyrighted Component Removal and Replacement • 25-3-1
Material
3.
! CAUTION
SAFE PARKING. Before working on truck :

gaps or breaks.
Tilt Lock Lever
4. Apply the parking brake and block the Cover Screw
wheels.
Steering Column and Component

Removal NOTE
Use care when removing the back side cover
Determine which component requires service and check as the rocker switch wiring is attached.
the procedure for removing that component. Read the pro-
cedure completely before beginning disassembly. 4.
Hand Wheel, Light Switch Lever and Column Tilt Lock Assembly Removal
Directional Control Assembly Removal
NOTE
1. Disconnect the negative lead at the battery. The tilt lock assembly is not serviceable; only
2. the gas springs are serviceable. The tilt lock
assembly should be removed only for replace-
Steer Handle Cover
ment as a complete assembly.
1. Disconnect the negative lead at the battery.

2.
3.
Steer Handle Screw
Steer Handle Washer

Column Upper
Cover
Steer Handle
Gas Spring
Column Lower
Cover
25-3-2 • Steering Column and Component Removal andMaterial

Copyrighted Replacement SM 751, Dec ’06
4. 2. Remove the four bolts and the lower column shaft

and steering gear to the bracket on the frame.
Tilt Lock Assembly

Mounting Screw
Steering Gear
3. Remove the lower shaft and steering gear assembly

from the truck.
Steering Gear Removal

1. Put a pan under the truck to catch hydraulic fluid
which will drip when fittings are loosened. Label the
four hose fittings of the steering gear to make sure
they are reassembled correctly. Loosen and remove
the hydraulic fittings at the steering gear. Cap the
ends to prevent fluid leaks. Cap the steering gear
ports to prevent dust and debris from getting into the
steering gear. Keep hydraulic ports and hoses clean.
Steering Gear
SM 751, Dec ’06 Steering Column and

Copyrighted Component Removal and Replacement • 25-3-3
Material
Steer Column and Component

Replacement
IMPORTANT
Make sure all parts are clean and dry before
reassembling.
It may be necessary to assemble the steering
column in place and hand tighten fittings so
that the correct alignment of the entire col-
umn and parts can be checked. Once you
have the correct alignment, torque all fittings
to their correct specifications.
25-3-4 • Steering Column and Component Removal andMaterial

Copyrighted Replacement SM 751, Dec ’06
Section 4
Stering System Relief Pressure Check and Adjustment
The steering system relief pressure is adjusted by the ADJUSTMENT

relief valve in the steering unit specification 140 kgf/㎠
(1990 psi). If the relief pressure setting is higher than 1. Remove plug.
specification it can cause defects of the hydraulic hoses,
tear the steering cylinder seal, and cause damage to the
steering shaft link. If the relief pressure setting is lower
than specification, excessive force is required to turn the
steering wheel.
CHECK
NOTE
Loosen the oil filler cap on the hydraulic tank
and operate the steering wheel several times
to release the pressure in the hydraulic cir-
cuit. 2. Adjust the pressure.
- Specification : 140 kgf/㎠ (1990 psi)
1. Engage the parking brake and put the transmission - To increase : turn clockwise
into neutral. - To decrease : turn counter.clockwise
2. Block the driving wheels.

3. Remove the plug (PT 1/8”) from the fitting on the To increase
steering cylinder.
4. Install the hydraulic pressure gauge 0~350 kg/㎠ To decrease
(0~5000psi)
5. Start the engine and run at high idle.
6. Turn the steering wheel and measure the pressure
when the relief valve is actuated.
SM 751, Dec ’06 Stering System

Copyrighted Relief Pressure Check and Adjustment • 25-4-1
Material
TROUBLESHOOTING
Steering systems with load sensing

Fault Possible cause Remedy
Steering wheel is heavy to turn. • Insufficient oil pressure. • Check the oil pressure.
1. Pump drive defective. 1. Replace pump drive.
2. Pump is worn out. 2. Replace pump.
• Pressure relief valve is stuck in • Repair or clean pressure relief valve.
open position or setting pres- Adjust the valve to the correct pres-
sure is too low. sure.
• Priority valve spool stuck. • Clean or replace valve.
• Too much friction in the • Grease/repair axle knuckle pins, steer-
mechanical parts of the steering ing cylinder pins, steering column
system. bearings.
Check the hydraulic cylinder for mal-
function.
Constant steering is necessary for • Leaf springs without spring • Replace leaf springs.
straight travel. force or broken.
(“Snake-like driving”) • Spring in relief valve broken. • Replace relief valve.
• Gerotor assy worn. • Replace gerotor assy.
• Cylinder scored or piston seals • Replace defective parts.
worn.
Neutral position of steering wheel • Steering column and steering • Align the steering column with steer-
can not be obtained, i.e. there is a unit out of alignment. ing unit.
tendency towards “motoring”. • Too little or no end play • Adjust the end play and if necessary,
between steering column and shorten the splined shaft.
steering unit input shaft.
• Pinching between inner and • Dismantle the steering unit and repair
outer spools. as required.
“Motoring” effect. The steering • Leaf springs are stuck or bro- • Replace leaf springs.
wheel can turn on its own. ken and therefore have reduced
spring force.
• Inner and outer spools sticking • Dismantle the steering unit and clean/
possibly due to dirt. repair as required.
Backlash • Cardan shaft fork worn or bro- • Replace cardan springs.

ken.
• Leaf springs without spring • Replace leaf springs.
force or broken.
• Worn splines on the steering • Replace steering column/shaft.
column.
25-4-2 • Stering System Relief Pressure Check and Adjustment


Shimmy.abnormal vibration of • Air in the steering cylinder. • Bleed steering system, remedy cause
steering wheel. of air ingression.
• Worn axle knuckles or steering • Replace worn parts.
cylinder pins. • Repair/replace relief valve, anticavita-
• Leaking relief valve and anti- tion valves.
cavitation valves or broken Replace the springs.
valve springs.
Steering wheel can be turned con- • Oil is needed in the tank. • Fill with clean oil and bleed the sys-
tinuously without articulating the tem.
steering axle wheels. • Steering cylinder worn. • Replace or repair cylinder.
• Gerotor set worn. • Replace gerotor set.
• Spacer across cardan shaft • Install spacer.
missing.
Steering wheel can be turned • One or both anticavitation • Clean or replace defective valves.
slowly in one or both direction valves leaking.
without articulating the axle • Relief valve is leaking. • Clean or replace defective valve.
wheels.
Steering is too slow and heavy • Insufficient oil supply to steer- • Replace pump.
when trying heavy to turn quickly. ing unit, pump defective.
• Relief valve setting too low. • Adjust valve to correct setting.
• Relief valve sticking owing to • Clean the valve.
dirt.
• Check valve in emergency • Clean or replace the check valve.
steering unit stuck open allow-
ing pressure to return to tank.
(if equipped)
Heavy kick.back in steering wheel • Incorrect setting of cardan shaft • Correct setting as shown in service
in both directions. and gerotor set. manual.
Turning the steering wheel articu- • Hydraulic hoses for the steer- • Reverse the hoses.
lates the axle wheels in the oppo- ing cylinder have been inter-
site direction. changed.
• Incorrect assembly of cardan • Reassemble correctly
shaft and gerotor.
Hard point when starting to turn • Pump output low. • Check pump flow.
the steering wheel. • Relief valve set pressure to low. • Inspect relief valve and adjust.
• Cross.over relief valve set pres- • Replace the valves if defective.
sure to low. (if equipped)
• Priority valve spool orifice • Clean spool orifice.
blocked.
• Oil is too thick (cold). • Let motor run until oil is warm.
SM 751, Dec ’06 Stering System

Copyrighted Relief Pressure Check and Adjustment • 25-4-3
Material

Leakage at either input shaft, end • Shaft defective. • Replace shaft seal, see service manual.
cover, gerotor set, housing or ports. • Screws loose. • Tighten screws (3±0.3 kgf·m).
• Washers or O–rings defective. • Replace washers or O–rings.
25-4-4 • Stering System Relief Pressure Check and Adjustment

Section 5
Steering Gear Overhaul
IMP ORTANT
NOTE
The following material does not show the load sensing port
on the steering gear (steering control unit). The port is
located in the center of the other four ports. The load sensing
port requires no special overhaul procedures.
SM 751, Dec ’06 Copyrighted Material Steering Gear Overhaul • 25-5-1

Disassembly 5. Remove meter (gerotor). Be careful not to drop star

(rotor).
Cleanliness is extremely important when repairing a steer-
ing gear. Work in a clean area. Before disconnecting lines,
clean port area of unit thoroughly. Use a wire brush to
remove foreign material and debris from around exterior
joints of the unit.
NOTE
Although not all illustrations show the unit in
a vise, it is recommended to keep the unit in
the vise during disassembly. Follow the
clamping procedures explained throughout
the text.
6. Remove seal from meter.

Meter (Gerotor) End
7. Remove drive spacer(s).
1. Clamp unit in vise, meter end up. Clamp lightly on
edges of mounting area, as shown. Use protective 8. Remove drive.
material on vise jaws. Do not overtighten jaws.
9. Remove spacer plate.

2. Remove capscrews. 10. 10.Remove seal from housing.
Control End
11. Remove housing from vise and place on a clean soft
cloth to protect surface finish. Use a thin-bladed
screwdriver to pry retaining ring from housing.
3. Remove end cap.

4. Remove seal from end cap.
25-5-2 • Steering Gear Overhaul Copyrighted Material SM 751, Dec ’06

12. Place assembly so shaft is horizontal. Rotate spool IMPORTANT

and sleeve until pin is horizontal. Push spool and Do not bind spool and sleeve in housing.
sleeve assembly forward with your thumbs just far Rotate spool and sleeve assembly slowly
enough to free seal gland bushing from housing. when removing from housing.
Remove bushing.
17. Push pin from spool and sleeve assembly.
18. Push spool partially from control end of sleeve, then
remove six centering springs from spool carefully by
hand. Note their position in the unit before they are
removed.
13. Remove quad ring seal from seal gland bushing.
14. Use a thin-bladed screwdriver to pry dust seal from

seal gland bushing. Do not damage bushing.
15. Remove two bearing races and the needle thrust bear-
ing from spool and sleeve assembly. 19. Push spool back through and out of sleeve. Rotate
spool slowly when removing from sleeve.
20. Remove seal from housing.
16. Remove spool and sleeve assembly from cap (14-

hole) end of housing.
21. Remove set screw from housing.

22. Screw a 1/8-inch-24 NC machine screw into end of
check ball seat. Then pull on screw with pliers to lift
seat out of housing.
23. Remove two seals from check valve seat.
24. Tip housing to remove check ball and check ball
retainer.

Parts Inspection 4. Lubricate check ball seat and seals thoroughly before
installing seat in housing. When installing seat do not
Inspect all parts for damage, cracks, broken parts, dam- twist or damage seals. Install check ball seat in hous-
aged threads, corrosion or erosion of surfaces, worn spots, ing; insert open end of seat first. Push check ball seat
nicks or scratches. to bottom of hole.
Check all mating surfaces. Replace any parts that have 5. Install set screw. Use a 5/16-inch Allen wrench to
scratches or burrs that could cause leakage. Discard all old torque set screw to 11 N⋅m (100 in-lb; 8.3 ft⋅lb). To
seals and replace with new ones. prevent interference of parts, make sure top of set
Clean all metal parts in clean solvent. Blow dry with air. screw is slightly below housing mounting surface.
Do not wipe dry with cloth or paper towel because lint or 6. Assemble spool and sleeve carefully so that the
other matter can get into the hydraulic system and cause spring slots line up at the same end. Rotate spool
damage. Do not use a coarse grit or try to file or grind while sliding parts together. Some spool and sleeve
these parts. sets have identification marks ; align these marks.
If parts are left exposed, cover them with a clean cover to Test for free rotation. Spool should rotate smoothly
prevent airborne dust from collecting on them. in sleeve with finger tip force applied at splined end.
Reassembly
Refer to Service Parts Book when ordering replacement
parts. A good service policy is to replace all old seals with
new seals at overhaul.
NOTE
Lubricate all seals (with exception of new
quad ring seal) with clean petroleum jelly
such as Vaseline. 7. Bring spring slots of both parts in line and stand parts
Do not use excessive lubricant on seals for on end of bench. Insert spring installation tool (avail-
meter (gerotor) section. able as Part No. 6000057) through spring slots of
Make sure all parts are clean and free of both parts. Position three pairs of centering springs
dust. Before assembly, lightly coat all internal (or two sets of 3 each) on bench so that extended
metal parts with oil. edge is down and arched center section is together. In
this position, insert one end of entire spring set into
spring installation tool, as shown.
Control End
1. Use a needle-nosed pliers to lower check ball retainer
into check valve hole of housing. Make sure retainer
is straight (not tilted on edge) in housing.
On those units which use the low torque centering

springs, there are two pairs of centering springs (or
two sets of each) and one pair (two) spring spacers.
The spring spacers are installed together between the
two sets of centering springs. The installation proce-
dure is the same as that used on the standard (three
2. Install check ball in housing.
pairs of centering springs) units.
3. Lubricate 5/8-inch diameter seal and 7/16-inch diam-
eter seal. Install seals on check ball seat, as above.

8. Compress extended end of centering spring set and 13. Install two bearing races and the needle thrust bear-
push into spool sleeve assembly withdrawing instal- ing in the order shown.
lation tool at the same time.
9. Center the spring set in the parts so that they push
down evenly and flush with the upper surface of the
spool and sleeve.
10. Install pin through spool and sleeve assembly until
pin becomes flush at both sides of sleeve.
14. Install 1-1/4-inch diameter dust seal in seal gland

bushing; flat or smooth side of dust seal must face
11. Position the spool and sleeve assembly so that the down towards bushing.
splined end of the spool enters the 14-hole end of 15. Install dry quad ring seal in seal gland bushing.
housing first. Smooth seal in place with your finger. Do not use any
seal that falls freely into pocket of bushing. Seal
should not “fall” into place but should require light
force to seat.
IMPORTANT
Be extremely careful that the parts do not tilt
out of position while being installed. Push
parts gently into place with slight rotating
action; keep pin nearly horizontal. Push the
spool assembly entirely within the housing
bore until the parts are flush at the meter end
or 14-hole end of housing. Do not push the
spool assembly beyond this point to prevent
the cross pin from dropping into the dis-
charge groove of the housing. With the spool
assembly in this flush position, check for free
rotation within the housing by turning with
light finger tip force at the splined end.
12. Place housing on clean, lint free cloth. Install 2-1/8-

inch diameter seal in housing.

16. Install seal gland bushing over the spool end with a Meter (Gerotor) End
twisting motion. Tap the bushing in place with a rub-
ber hammer. Make sure the bushing is flush against 18. Clamp housing in vise, as shown. Clamp lightly on
the bearing race. edges of mounting area. Do not overtighten jaws.
On those units which use the Teflon seal, install the
Teflon back-up ring into the recess cut into the seal
gland bushing. Install the Teflon seal over the spool
end, then carefully install the seal gland bushing over
the spool end using a rotary motion.
NOTE
The seal gland bushing which is used with the
Teflon seal is not the same as the seal gland
bushing used with the standard quad-ring
seal. The seal gland bushing with the Teflon
seal has an identification groove cut into the
outer diameter of the bushing. The grooved
bushings can only be used with the Teflon NOTICE
seals and the non-grooved bushings used only Check to ensure that the spool and sleeve are
with the quad-ring seals. flush or slightly below the surface of the
housing.
IMPORTANT
Clean the upper surface of the housing by
wiping with the palm of clean hand. Clean
each of the flat surfaces of the meter section
parts in a similar way when ready for reas-
sembly. Do not use cloth or paper to clean
surfaces.
19. Install 3-inch diameter seal in housing.
17. Install retaining ring in housing. After installing ring,

tap on ring or pry with screwdriver around entire cir-
cumference of ring to properly seat ring in groove.
20. Install spacer plate. Align bolt holes in spacer plate

with tapped holes in housing.

21. Rotate spool and sleeve assembly until pin is parallel 24. Install drive spacer(s) when used, in meter.
with port face. Install drive, making sure you engage
drive with pin.
IMPORTANT
Failure to properly install drive and pin may
cause unit to self steer.
25. Install 3-inch diameter seal in end cap.
NOTE
To assure proper alignment, mark spline end 26. Install end cap on gerotor, and align holes.
of drive shaft with a line parallel to slot on 27. Install 7 dry cap screws in end cap. Pretighten screws
other end, before installing. to initial torque of 17 N⋅m (150 in⋅lb), then torque
screws to final torque of 31 N⋅m (275 in⋅lb) in the
22. Install 3-inch diameter seal in meter (gerotor). sequence shown.
23. With seal side of meter toward spacer plate, align star 28. Inspect the assembly to be sure all parts have been
valleys on drive. Note the parallel relationship of ref- installed and fasteners correctly installed and tight-
erence lines A, B, C, and D in figure. Align bolt ened.
holes without disengaging meter from drive. Be sure
star has engaged drive spline in position shown.

NOTE :
Group 25, Steering Column and Gear Copyrighted Material SM 751, Dec ’06
GROUP 26
GROUP 26
STEER AXLE
Steering Axle Specifications

and Description .................................... Section 1
Steer Axle Wheel Bearing Maintenance

and Adjustment .................................... Section 2
Steer Axle Removal and Replacement .... Section 3
Steer Axle Overhaul ................................. Section 4
Steer Cylinder Removal and

Replacement ......................................... Section 5
Steer Cylinder Overhaul .......................... Section 6
SM 751, Nov ’06 Copyrighted Material Group 26, Steer Axle

NOTE :
Group 26, Steer Axle Copyrighted Material SM 751, Nov ’06

Group 26, Steer Axle
Section 1
Steer Axle Specifications and Description
Steering System Relief Pressure Setting : 11 MPa(1600 The steer axle has the steer cylinder, steer knuckles, and
psi). steering links mounted on it. All these components can be
removed, serviced, and replaced.
Steer Cylinder Type : Double-acting, piston-type.
The steering gear (steering control unit) at the base of the
Turning Arc : Maximum inside turning angle 72°,
steering column directs hydraulic fluid to one end or the
maximum outside turning angle 51°.
other of the steer cylinder to pivot the steer wheels.
Bearing Grease : Grade No. 2 EP multi-purpose grease,
The steer axle is bolted to the truck frame. The steer cylin-
Clark Part MS-107C.
der is connected to the steering knuckles by steer links.
Mounting trunnions allow the axle to tilt independently of
Fastener Torques the truck and “silent” mounts cushion the axle on the trun-
nions.
Steer Axle Mounting Bolts : 235-288 N⋅m (173-213 ft⋅lb),
All bearings used in the steer axle linkage have lubrication
Cylinder to Axle Mounting Bolts : 460-562N⋅m (339-415 fittings and are serviceable. Axle removal, replacement,
ft⋅lb). and service for all components, including overhaul of the
Steering Link to Steering Knuckle Nuts : 66-68 N⋅m (49- steer cylinder, is explained in the Sections for this Group.
50 ft⋅lb).
Steer Knuckle King Pin Castle Nuts : See installation pro-
cedures in Section 4, “Steer Axle Overhaul.”
Service Intervals
Steering Linkage Inspection and Lubrication : Every 50-
250 hours and each PM.
Steer Wheel Bearing Inspection and Lubrication : Every
500 hours of operation.
Steer Cylinder Seals Leakage Check : Every 50-250 hours
and each PM.
Steer Axle Mounting Inspection : Every 50-250 hours and
each PM.
Power Steering Relief Pressure Check : Every year or
2000 hours of operation.
SM 751, Oct ’06 Steer Axle Specifications and Description • 26-1-1

Silent Block
Steer Axle
Steer Link
Steer Knuckle
Steer Cylinder
Steer Axle and Mounting-Pneumatic Tire Axle
26-1-2 • Steer Axle Specifications and Description

Section 2
Steer Axle Wheel

Bearing Maintenance and Adjustment
IMP ORTANT
2. Try to pull it in and out along the wheel spindle.

! CAUTION
Watch for excessive free movement in wheel bearings or
SAFE PARKING. Before working on truck: steering knuckle bearings. There should be a small
amount of free movement. If the wheel has excessive free
1. Park truck on a hard, level, and solid movement, the bearings require additional service and or
surface, such as a concrete floor with no adjustment.
gaps or breaks.
Wheel Bearing Lubrication
These procedures cover bearing lubrication. Use the pro-
cedures to clean, repack and adjust bearings for hub.
wheels.
Wheel mounting hub
Wheel Bearing Check
A wheel bearing check should be performed about every
500 hours of operation or three or four times a year.
Wheel bearings need adjustment only after 2000 hours or
as needed. It is recommended that you clean and repack
the bearings before adjustment. Check hourmeter total
hours and refer to the truck’s PM schedule. See steer
wheel bearing lubrication procedure below.
To check the steer wheel bearings for excessive free play Steering axle knu
or looseness :
1. Grasp the wheel with both hands and try to move it
by a rocking motion top-to-bottom.
SM 751, Nov ’06 Steer Axle Wheel

Copyrighted Bearing Maintenance and Adjustment • 26-2-1
Material
Bearing Disassembly 9. Clean and inspect the bearing cups and cones for
wear or other damage. Replace, as necessary.
1. Be sure truck is parked and blocked up correctly and
safely to raise steer wheels off the floor. Refer to IMPORTANT
“Lifting, Jacking, and Blocking,” in the Group “SA.” Keep serviceable bearing cups and cones
matched together. Always replace bearing
2. Loosen lug nuts of pneumatic-tire wheels before cups and cones as a set.
completely raising rear wheels off the floor.
3. Lower truck onto blocking. Remove lug nuts and 10. Inspect grease seal for wear and damage. Replace as
then wheel assembly. necessary. It is recommended to install a new grease
seal whenever old ones are removed.
NOTE
Because of the heavy weight of the pneumatic 11. Use a standard puller to remove bearing cups from
wheel and tire, it is suggested to first remove hub or wheel if bearings require replacement.
the wheel and tire assembly from hub when
servicing the bearings to avoid damage to the Bearing Reassembly
grease seal when the wheel hub is moved off
or on the spindle. It also makes the work The procedures for packing and reassembling the bearing
simpler and easier. are the same for the cushion wheel or pneumatic wheel
hub.
4. Clean the excess grease from around the wheel nut. NOTE
5. Remove cotter pin, loosen and remove wheel nut and Use Grade No. 2 EP multi-purpose grease,
bearing washer. Clark MS-107C.
NOTE
1. Install new inner and outer bearing cups by pressing
Remove outer bearing by pulling out on the into hub or wheel. Be sure cups are fully seated in
cushion wheel or pneumatic hub slightly to bore.
loosen bearings.
6. Pull the wheel or hub off the spindle. Support the

wheel or hub to avoid dragging the grease seal at the
back side across the thread on spindle end. Spindle
guard remains on spindle.
7. Clean the old grease out of center of the wheel or
hub.
8. To remove inner bearing and seal, lay wheel or hub
down with outer edge up (support hub on blocking).
Remove the inner bearing cone and grease seal, using
a brass drift pin, rod, or piece of pipe to drive the 2. Pack the bearings with grease and install the inner
bearing and seal out of the hub. bearing in the hub or wheel.
Bearing
and cone
Grease seal
3. Pack cavity between bearing and grease seal half full

with grease.
26-2-2 • Steer Axle Wheel Bearing Maintenance and Adjustment

4. Install new grease seal in hub or wheel inner bore. 13. Back up wheel nut to nearest slot and install new cot-
Apply coating of grease to inside diameter of seal ter pin. Bend cotter pin tabs.
lips prior to assembly, then install seal in hub or
14. Recheck for correct bearing adjustment by rotating
wheel bore.
the wheel by hand. Wheel should rotate freely or
with only slight “drag”. Readjust bearings by adjust-
ing wheel nut as necessary to avoid binding in bear-
ings.
15. Pack the area around wheel nut with grease.
16. Refit O-ring on hubcap and install hubcap by tapping
into place with a rubber or plastic-faced hammer.
5. Carefully press or tap grease seal into place with a

soft-faced mallet until seal is seated in bottom of
bore.
6. Install hub or wheel on spindle. Be careful not to
damage grease seal lip when moving the hub over the
end of spindle and threads.
7. Pack cavity in hub between bearings one-half full
with grease.
8. Install the outer wheel bearing after it has been 17. Remount wheel and tire as applicable for pneumatic-
packed with grease. tire assemblies. See Group 22 for mounting proce-
dures and nut torques.
Wheel Bearing Adjustment

The steer wheel bearings are retained and adjusted by the
wheel nut.
NOTE
You should clean and repack the wheel bear-
ings before performing a wheel bearing
9. Install bearing washer and hand tighten wheel nut. adjustment. See “Wheel Bearing Lubrica-
tion” in this Section for the complete proce-
dure.
1. Make sure the truck is parked on a level, hard sur-

face, the upright is fully lowered, the drive wheels
are chocked, and the steer wheels are jacked and
blocked securely. Refer to “Lifting, Jacking, and
Blocking” for safe procedures.
2. Remove hubcap.
10. Rotate hub or wheel counter clockwise and torque 3. Remove and discard cotter pin.
wheel nut to 27-31 N⋅m (20-23 ft⋅lb).
4. Loosen wheel nut.
11. Back wheel nut up until it is loose.
5. After wheel nut is loosened, hit the top of wheel to
12. While turning the hub or wheel counter clockwise, loosen the bearings. This moves the bearings free of
torque the wheel nut to 2.3-2.8 N⋅m (1.7-2 ft⋅lb). their seated, running position.
SM 751, Nov ’06 Steer Axle Wheel

Copyrighted Bearing Maintenance and Adjustment • 26-2-3
Material
6. Rotate hub or wheel counter clockwise and torque

wheel nut to 27-31 N⋅m (20-23 ft⋅lb).
7. Back wheel nut up until it is loose.
8. While turning the hub or wheel counter clockwise,
torque the wheel nut to 2.3-2.8 N⋅m (1.7-2 ft⋅lb).
9. Back up wheel nut to nearest castellation slot and
install new cotter pin.
10. Recheck for correct bearing adjustment by rotating
the wheel by hand. Wheel should rotate freely or
with only slight “drag”. Readjust bearings by adjust-
ing wheel nut as necessary to avoid binding in bear-
ings.
11. Bend cotter pin tabs over.
12. Pack the area around wheel nut with grease.
13. Refit O-ring on hubcap if removed or replaced and
install hubcap by tapping into place with a rubber or
plastic-faced hammer.
26-2-4 • Steer Axle Wheel Bearing Maintenance and Adjustment

Section 3
Steer Axle Removal and Replacement
SM 751, Oct ’06 Copyrighted MaterialSteer Axle Removal and Replacement • 26-3-1
installation of the axle without disturbing the

! CAUTION blocking.
4. Loosen and remove hydraulic steering lines from
1. Park truck on a hard, level, and solid steering cylinder. Plug fittings and cap open ends of
surface, such as a concrete floor with no lines. Keep all hydraulic fittings and openings clean.
gaps or breaks.
wheels.
Steer Axle Removal Disconnect cylinder lines here.

These procedures describe steer axle removal for both
cushion-tire and pneumatic-tire steer axles. The removal
procedures are basically the same for both axles even
though the axles are different. Minor differences will be
explained in the text. ! CAUTION
1. Remove the counterweight before removing the steer Axle must be supported before any attaching
axle. Refer to Group 38, Section 2, “Counterweight fasteners are removed.
Removal and Replacement.”
5. If another lift truck is used to temporarily support
! axle while removing, put forks in center of carriage
WARNING
about 305 mm (12 in) apart. Move forks under axle
Do not remove the counterweight unless you and raise it just to remove its weight from mounting
have training and are familiar with the cor- bolts. Or use a portable floor jack to carefully sup-
rect procedures. Counterweights can fall if port the axle at its center section.
not handled correctly and cause severe injury
or death. 6. Loosen and remove nuts from axle mounting bolts,
front and rear.
2. Loosen lug nuts of steer wheels. • For cushion-tire axles, remove the mount plates
from the bottom of the trunnion mounts of the
! WARNING steer axle (Figure A.).
• For pneumatic-tire axles, remove the washers
Do not raise truck by hoisting on overhead
behind the nuts also (Figure B.).
guard or by jacking or lifting on counter-
weight. 7. Remove the mounting bolts.
8. Lower the axle allowing its weight to pull the silent
3. Block the drive wheels of the truck and raise and
blocks out of frame recesses. Watch the silent blocks
block the rear end. Remove steer wheels. See “Lift-
to be sure they release freely from frame. You may
ing, Jacking, and Blocking” in Group “SA” for safe
have to loosen blocks with a pry bar if they bind.
procedures to jack the truck.
9. Carefully withdraw the axle from beneath the truck
! CAUTION and move to safe storage.
Make sure truck is correctly raised and
safely blocked using hardwood blocks under
the frame. Be sure the blocking will permit
26-3-2 • Steer Axle Removal and ReplacementCopyrighted Material SM 751, Oct ’06
NOTE Steer Axle Replacement

On pneumatic-tire trucks, removal of the
silent blocks after a long period of usage may Replacement is the reverse of removal. Refer to Figures
be difficult. Routine removal of the silent for replacement.
blocks from the steer axle trunnions (pivot
pins) is not recommended unless they have ! CAUTION
obvious wear, damage, or failure. If removal Make sure truck is correctly raised and
by conventional pulling methods is not suc- safely blocked using hardwood blocks under
cessful, they then must be removed by the frame. Be sure the blocking will permit
destruction of the silent block assembly using installation of the axle without disturbing the
a cutting torch and/or hammer and chisel to blocking.
separate them from the axle trunnions. Be
sure that the axle trunnions are not damaged. 1. If silent blocks have been removed from axle, install
new silent block assemblies. Use a rubber or plastic
mallet to seat the silent mounts onto the axle trun-
nions.
2. Make sure that the silent blocks are positioned cor-
rectly front and rear on the steer axle trunnions at the
start of installation. Align the silent blocks square
with the axle.
3. Use a fork lift truck or mobile floor jack to tempo-
rarily support and raise the axle into place under the
truck. If another lift truck is used to handle axle, cen-
ter the forks with about 305 mm (12 in) spread
between them. Place steer axle assembly in secure
position on fork tips.
If hydraulic jack is used, be sure axle is securely sup-
ported on jack pad.
Silent Block
Steer Axle
Steer Link
Steer Knuckle
Steer Cylinder
Steer Axle Mounting
SM 751, Oct ’06 Copyrighted MaterialSteer Axle Removal and Replacement • 26-3-3
the truck slowly. Fully steer the vehicle in each direc-

! WARNING tion and check response.
Heavy components can fall and cause severe 13. Check steering cylinder hose line connections and
injury. Keep your body clear at all times. cylinder rod seals for any evidence of oil leakage
before returning the truck to service.
4. Install axle assembly into frame by slowly raising it
up while guiding silent block bushings into frame
sockets.
5. Install silent block mounting bolts through frame
socket holes and silent block, front and rear.
For cushion-tire steer axles, reset the two mounting
plates under the silent blocks of the axle.
6. Install nuts on silent block fasteners and tighten to
235-288 N⋅m (173-212 ft⋅lb).
7. Remove temporary axle support from under truck.
8. Connect the hydraulic lines to steering cylinder.
IMPORTANT
Make sure all fittings and openings on the
hydraulic lines are clean.
Connect cylinder lines here.
9. As applicable, install pneumatic wheel and tire

assemblies. See Group 22, “Wheels and Tires” for
mounting procedures.
10. Carefully raise the truck off the blocking as described
in “Lifting, Jacking, and Blocking.” Remove the
blocking and lower the truck to the floor.
11. Install counterweight; refer to Group 38, Section 2,
“Counterweight Removal and Replacement.”
12. Check the axle and steering system for proper opera-
tion. Start the engine and operate the steering gear to
move the steer wheels to maximum travel in both
directions. Note any unusual motion or noise.
If the system appears to be operating correctly, drive
26-3-4 • Steer Axle Removal and ReplacementCopyrighted Material SM 751, Oct ’06
Section 4
Steer Axle Overhaul
IMP ORTANT
! CAUTION
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.
remove key.
SM 751, Oct ’06 Copyrighted Material Steer Axle Overhaul • 26-4-1

Preparation For Steer Axle 2. Remove and discard cotter pin from kingpin castel-
lated nut. Remove the nut.
Disassembly and Overhaul
Kingpin castellated nut
NOTE
Cleanliness is of extreme importance in the
repair and overhaul of this assembly.
• Before starting disassembly, thoroughly clean the

axle assembly of all accumulations of dirt, oil, cor-
rosion, and other substances to prevent contamina-
tion of the parts during disassembly and overhaul.
• Work in a clean area. Kingpin retainer pin
• Keep all parts in order as disassembly progresses.

Take care to properly identify each part and its 3. Drive the kingpin down and out of the assembly.
order of removal. If necessary, keep notes and put Remove the steering knuckle. Note right and left
markings on parts using a non-destructive marker knuckle parts.
such as a grease pencil or felt-tipped pen.
• See Section 2, “Steer Axle Wheel Bearing Mainte- IMPORTANT
nance,” for procedures to remove the pneumatic- Do not let the knuckle or pin fall when the
tire assembly hub from the spindle/knuckle of the pin is removed.
steer axle. Removal of the hub assembly will make
disassembly of the steer axle knuckle easier. 4. Remove the kingpin retainer pin from the base of the
• If necessary, see Section 3, “Steer Axle Removal kingpin.
and Replacement,” for the procedures to remove
the steer axle from the truck. 5. Remove the knuckle bearing washers, dust covers,
upper and lower grease seals, bearings, and bearing
• See Section 5, “Steer Cylinder Removal and
Replacement,” for the procedures to remove the cups from the assembly.
steering cylinder and steering links from the steer
axle. Grease
Seals
• See Section 6, “Steering Cylinder Overhaul,” to Washer
disassemble the steer cylinder.
Steer Axle Disassembly

To disassemble the steering knuckle, kingpin, and bearing
from the steer axle, it is not necessary to remove the axle
from the truck.
1. Remove the snap ring from the bottom of the steering
link pin and remove the pin. Steering link is free to
be removed from the cylinder rod and knuckle.
Steering link pin Bearing Cup
Bearing
Bearing cups may be removed by hand, by using a bearing

puller, or by tapping out using a brass drift pin.
Snap ring
Steering link Cylinder rod
26-4-2 • Steer Axle Overhaul Copyrighted Material SM 751, Oct ’06

Parts Inspection 3. Set the retainer pin into the king pin and slide the
king pin into the steer axle/knuckle bore.
1. Clean all bearings, cups, seals, pins, and other parts
in an approved cleaning fluid. IMPORTANT
Make sure that retainer pin enters the hole in
2. Inspect all parts for scratches, chips and wear. Check the underside of the axle.
the steering arms of the knuckles to be sure they are
Kingpin castellated nut
not bent or twisted. Check all threaded parts for dam-
age.
3. Replace all parts which show damage.
4. If parts are to be left exposed, coat all mating sur-
faces of parts with a light coating of engine oil.
Steer Axle Reassembly Kingpin retainer pin

Recommended greasing procedure :
a. Use Grade No. 2 EP multi-purpose grease, Clark 4. Reset the kingpin castellated nut to the top of the
MS-107 or equivalent. kingpin. Torque nut to 66-68 N⋅m (49-50 ft⋅lb).
b. Pack all tapered roller bearings with grease 5. Rotate the steer knuckle three times through its full
before assembly. range of movement. Check to be sure that it is free to
c. Pack knuckle pin (bearing) seals with grease rotate in the bearings without binding.
before assembly.
d. Fill steer link sockets with grease through grease 6. Loosen the kingpin nut and retorque the nut to 11-14
fittings after axle is assembled. N⋅m (8-10 ft⋅lb).
1. Install the upper and lower knuckle bearing cups into 7. Advance the nut to the next castellated slot and lock
the knuckle housing bore. Tap into place with a brass the nut into position with a new cotter pin. Bend cot-
drift pin or equivalent. ter pin tabs over.
Grease 8. Replace steering link pin and snap ring to join the
Seals cylinder rod to the steering link and knuckle.
Washer
Steering link pin
Snap ring
Steering link Cylinder rod
Bearing Cup 9. Reinstall grease fitting in knuckle housing and lubri-

Bearing
cate with recommended grease.
IMPORTANT Knuckle Housing
Make sure that bearing cup is fully seated Grease Fitting
against the shoulder in bore. There must be
no gap left between cup and the shoulder in
the bore at assembly.
2. Apply grease to upper and lower knuckle bearings

and install bearings, grease seals, and washers to
bores of knuckle.
SM 751, Oct ’06 Copyrighted Material Steer Axle Overhaul • 26-4-3

NOTE :
Group 26, Steer Axle Copyrighted Material SM 751, Oct ’06

Section 5
Steer Cylinder Removal and Replacement
2. Remove the snap ring from the bottom of the steering

! CAUTION link pin. Steering link pin attaches steer cylinder rod
SAFE PARKING. Before working on truck: end to steering link.
Steering link pin
gaps or breaks.
Snap ring
wheels. Cylinder rod
Steering link
Steer Cylinder Removal NOTE

Mark left-side and right-side parts for cor-
The steer cylinder can be removed from the steer axle for rect reassembly.
overhaul or replacement without removing the steer axle
from the truck. The cylinder should be overhauled or 3. Tap steer link pin upward until it clears the steering
replaced if steering problems or troubleshooting informa- link bearing and remove the pin.
tion indicate the cylinder is malfunctioning. See Group
4. Remove steer link bearing from steering link-to-cyl-
25, Section 2, “Steering System Troubleshooting,” for
inder rod end bore.
steering problem diagnoses. See Section 6 in this Group
for steer cylinder overhaul procedures. 5. Rotate the steering link away from the cylinder rod
end.
1. Place a drain pan under the steer cylinder and remove
the hydraulic lines from the cylinder fittings. Cap fit- 6. Repeat steps 1 through 5 for the opposite side of the
tings and lines to prevent fluid from leaking and to steer cylinder.
protect the components and hydraulic system from 7. Remove the four steer cylinder mounting bolts and
dust and dirt. Label hoses and fittings for correct washers from the steer axle. Removal torque on these
reassembly. bolts can be as high as 460-562 N⋅m (339-415 ft⋅lb).
Cylinder is now ready to be removed from the steer axle
body. Cylinder must be lifted off dowel pins positioning
cylinder to axle body.
Disconnect cylinder lines here.

Mounting Screw
SM 751, Oct ’06 Steer Cylinder Removal and Replacement • 26-5-1

full weight of the cylinder as you set it into

! CAUTION position.
Cylinder is somewhat heavy and bulky.
When removing cylinder from mounting be 2. Position the steering link with the cylinder rod end.
prepared to lift and move the full weight of Reuse steer link bearing if still serviceable. Install
the cylinder. new bearings if scoring or wear marks are evident or
if the bearings do not operate smoothly.
Steering link pin
Parts Inspection
Completely inspect all parts :
1. Clean all bearings, cups, seals, pins, and other parts
in an approved cleaning fluid.
2. Inspect all parts for scratches, chips, scoring, and
uneven or heavy wear. Check steering links to be sure
they are not bent or twisted. Check all threaded parts Snap ring
for damage. Steering link Cylinder rod
3. Replace all parts showing excessive wear or signs of 3. Rotate steering link into cylinder rod end and align
damage. bearing hole with rod end.
4. If parts are to be left exposed, coat all mating sur- 4. Tap pin through steer link bearing hole with snap
faces of parts with a light layer of engine oil. Keep all ring groove on lower end.
parts clean and covered. IMPORTANT
5. Remove and clean all grease fittings before reassem- Make sure bearing is properly aligned with
bling cylinder components. pin in the hole.
Refer to Section 6, “Steer Cylinder Overhaul”, if pressure 5. Install the snap ring to the steering link pin.
check or troubleshooting tips indicate a problem with
steer cylinder performance. 6. Repeat steps 1 to 5 for rod end-to-steering link con-
nection for opposite side.
7. Clean and replace hydraulic hoses on correct, clean,
Steer Cylinder Replacement cylinder fittings. See Group 40, Hydraulic Fitting
1. Remount the steer cylinder onto the steer axle dowel Tightening Procedure” for replacement procedures.
pins; set bolts and washers in place and torque
mounting bolts to 460-562 N⋅m (339-415 ft⋅lb).
Disconnect cylinder lines here.

Mounting Screw
8. Check to be sure all lube fittings are installed. Fill all

lubrication points with correct lubricant. See recom-
mended greasing procedure above.
! CAUTION
9. Test function of steer cylinder before returning the
Cylinder is somewhat heavy and bulky.
truck to service.
When remounting cylinder to steer axle
body, be prepared to lift and maneuver the
26-5-2 • Steer Cylinder Removal and Replacement

Section 6
Steer Cylinder Overhaul
IMP ORTANT
Cylinder Rod
Cylinder Tube
Gland
Steering Cylinder
Pneumatic-tire truck cylinder with “P” stamped on rod end.
SM 751, Dec ’06 Copyrighted Material Steer Cylinder Overhaul • 26-6-1

Preparation for Steer Cylinder Dis- 4. Remove gland from opposite end of steer cylinder.
assembly and Overhaul 5. Remove the seal and O-ring set from the piston. Dis-
card seals. Replace with new seal set at assembly.
Refer to Section 5 for removal of steer cylinder from the
steer axle body.
Piston Seal O-ring
IMPORTANT
Cleanliness is of extreme importance in the
repair and overhaul of this assembly.
1. Overhaul steer cylinder only in a clean, dust-free

location, using clean tools and equipment. Dirt or grit
will damage the highly-machined surfaces and will
result in leakage or premature failure of components.
Cleanliness of the hydraulic circuit is extremely
important to the proper operation and maintenance of
the system. Be sure the work area is clean.
6. Remove (inner) gland packing (O-ring) seal.
2. Before disassembly, the exterior of the steer cylinder Replace with new seals at assembly.
should be carefully cleaned to remove all dirt and
grease accumulation.
3. Be sure all hydraulic fluid has been removed from
the cylinder. Stroking the piston rod will help force
the fluid out.
Rod wiper
4. Before starting disassembly, the steer cylinder should Rod(U-cup)
be carefully examined to determine if there is any Seal
external damage.
Steer Cylinder Disassembly

1. Clamp the steer cylinder assembly in a vise. Wrap
the cylinder in a course cloth to prevent slipping and 7. Remove the rod (U-cup) seal and rod wiper from
scratching. Use extreme caution when tightening vise gland and discard. Note direction of seal and wiper
and do not overtighten ; cylinder can be bent, dis- seating for correct reassembly. Replace with new
torted, and potentially destroyed. seals and wipers at assembly.
2. Remove one gland by pulling it from cylinder barrel
and pulling it off the piston rod. Parts Inspection
Gland Gland 1. Carefully clean all parts in an approved solvent and
place on a clean surface.
Cylinder Barrel
2. Check the piston for chips, cracks, and looseness on
the rod. If loose, replace rod and piston assembly.
Piston Rod
3. Be sure the piston-seal groove in the piston is
smooth, true, and undamaged.
4. Check the piston rod for damage. Look for scratches,
grooves, gouges, pitting, corrosion or other evidence
Cylinder Section
of unusual wear. Minor surface damage may be
repaired by use of fine abrasion cloth or stoning.
3. Remove the piston and rod assembly from the cylin- Deeper damage will require replacement of piston
der. rod assembly.
26-6-2 • Steer Cylinder Overhaul Copyrighted Material SM 751, Dec ’06

5. Carefully inspect the cylinder internal bore for wear, 2. Install new piston seal over the O-ring seal.
scratches, corrosion or other damage. Check the out- Piston Seal
side for damage. Inspect all welds for cracks. O-ring
6. Inspect the cylinder ports and threads to be sure they

are free of contamination and that the threads are
clean and not damaged.
7. Check the gland for cracks or damage that could
cause failure.
8. Deep gouges or pitted surfaces require replacement
of parts.
9. Put a light coating of hydraulic fluid on all parts. If
parts are to be left disassembled for a period of time,
such as overnight, they should be covered with a 3. Install new gland packing (O-ring) seal on inner end
clean cloth. of gland.
Gland
Packing (O-
Steer Cylinder Reassembly ring) Seal
Check to make sure the overhaul kit you have is correct

and that all parts are included.
IMPORTANT
Be sure inside of cylinder and all parts are
clean before starting reassembly.
Assemble cylinder carefully to prevent dam-
age to seal lips and O-rings. Seals should be
lubricated with hydraulic oil to assist assem-
bly into cylinder barrel and gland.
Heating seal rings in boiling water before 4. Install new rod wiper and rod (U-cup) seal in outer
starting assembly will aid in assembly. end of gland.
1. Install new O-ring seal on the piston.
O-ring
Rod wiper
Rod(U-cup)
Seal
IMPORTANT
Be sure the rod wiper and rod (U-cup) seal
are installed in the correct directions.
5. Lightly lubricate the cylinder and gland mating sur-

faces with hydraulic oil before assembly.
SM 751, Dec ’06 Copyrighted Material Steer Cylinder Overhaul • 26-6-3

6. Install the gland onto the cylinder bore rim, making Operational Pressure Test
sure gland is fully seated on cylinder.
Once cylinder is remounted on axle (see Section 5), con-
7. Install piston and rod assembly into the cylinder. nect pressure source in turn at each port. Extend piston
NOTE rod at each side and test with internal pressure of 13790
A special part is included in the parts kit to kPa (2000 psi). At this pressure no leakage must occur.
allow you to slip the gland over the rod end Typical operating pressure is 10342 kPa (1500 psi).
without damaging the gland seals.
8. Repeat above procedure for installation of opposite

gland.
26-6-4 • Steer Cylinder Overhaul Copyrighted Material SM 751, Dec ’06

GROUP 29
GROUP 29
HYDRAULIC SUMP, FILTERS, AND PUMP
Main Hydraulic Sump, Filters, and Pump

Specifications and Description .............................. Section 1
Main Hydraulic Pump Troubleshooting .............. Section 2
Main Hydraulic Pump Removal and Installation Section 3
NOTE
This group covers the main hydraulic pump for the load
handling system.
Other hydraulic-related components and circuits are
described and illustrated in Group 25 “Steering Column and
Gear,” Group 26 “Steering System,” Group 30 “Hydraulic
Control Valve/Lift Circuit,” Group 32 “Tilt Cylinders,” and
Group 34 “Uprights.” Refer to these groups for hydraulic
components not covered in this group.
SM 751, Sep ’06 CopyrightedGroup 29, HYDRAULIC SUMP, FILTERS, AND PUMP
Material
NOTE :
Group 29, HYDRAULIC SUMP, FILTERS, Copyrighted

AND PUMPMaterial SM 751, Sep ’06
Group 29, Hydraulic Sump, Filters, and Pump
Section 1
Main Hydraulic Sump, Filters, and Pump

Specifications ......................................................... 2
Service Intervals ................................................. 2
System Description ................................................ 2
Sump Tank Fill Levels .......................................... 4
Hydraulic Fluid and Filter Change ..................... 5
Remove, clean and replace the strainer ............... 6
SM 751, Sep ’06 Main Hydraulic Sump, Filters,Material

Copyrighted and Pump Specifications and Description • 29-1-1
Specifications The hydraulic sump is located in the right side of the truck
frame. The sump is equipped with a suction line screen,
Hydraulic Pump Type: IntegraI gear-type pump and motor return line filter, oil cap/breather.
assembly.
The integral main hydraulic pump and motor assembly is
Sump Capacity: Usable oil = C60-70 :120 L (31.7Gal), mounted to the truck frame beneath the battery compart-
C80 : 140 L (37.0 Gal) ment.
Hydraulic Fluid Type: Clark Hydraulic Fluid MS-68 (or The main hydraulic pump draws oil from the sump and
other specification MS-68). sends oil to priority valve.
Filter Type: Disposable, 25 micron, return line oil filter, The priority valve variably divides oil between the steer-
100 mesh suction line screen and a 10 micron filter cap/ ing system and the main hydraulic system, with priority
breather filter. given to the steering system.
Serviceable items are the pump, motor, suction line screen
Service Intervals and the return line filter. Other components, such as hoses,
fittings, and clamps, are nonserviceable and should be
Hydraulic Fluid Level Checks: Every 8-10 hours or daily.
replaced if worn or damaged.
Hydraulic Fluid Change (Drain and Refill): Every 2000
hours of operation or every year.
Hydraulic Fluid Filter Replacement: After the first 50
hours of operation, then every year or 2000 hours of oper-
ation.
Description
NOTE
Se group 30 for a description of the complete
hydraulic circuit.
Sump brearher cap
Suction filter
Return line filter
29-1-2 • Main Hydraulic Sump, Filters, and Pump Specifications

Copyrighted Material and Description SM 751, Sep ’06
Steering gear
Hydraulic pump
Control valve

Sump Tank Fill Levels

Pull out the dipstick for the hydraulic oil.

Hydraulic Fluid and Filter Change tank is emptied. A steady stream of used oil should flow
from the drain line.
! CAUTION Continue operation until the sump tank is emptied. This
point will be reached when the pump starts to cavitate.
When cavitation occurs the pump speed will increase and
1. Park truck on a hard, level, and solid the speed sound will whine. Release the tilt lever immedi-
surface, such as a concrete floor with no ately when pump cavitation occurs.
gaps or breaks.
IMPORTANT
2. Put upright in vertical position and fully Be careful when sump is nearly emptied and
lower the forks or attachment. oil flow becomes erratic as the pump
3. Put all controls in neutral. Turn key approaches cavitation Do not operate pump
switch OFF and remove key. after cavitation occurs.
4. Apply the parking brake and block the Turn the key switch OFF.
wheels.
There is drain plug in the hydraulic sump tank. When the Disconnect drain line from truck. Replace the diagnostic
sump tank must be drained of all fluid, the procedure is to port cover and reinstall the cowl covers.
remove the drain plug and allow the fluid to drain into a NOTICE
suitable drain pan. Unless the sump tank is to be removed If old oil is excessively dirty or hydraulic sys-
for other repair or maintenance, the hydraulic fluid can tem is contaminated, it is recommended that
also be changed by one of the following methods: the sump tank be completely drained by
Remove the MCV cover for access to the hydraulic oil fil- removing the pump suction line from the
ter and diagnostic port on the control valve. sump outlet and flushed withy clean oil.
Pressure gauge to the diagnostic check port fitting.

NOTE: Use quick-disconnect adapter fitting.
You will need a drain pan of C60-70 :120 L (31.7Gal),

C80 : 140 L (37.0 Gal) minimum capacity. Be sure the
outlet end of the drain line is directed into the drain pan
and held from moving when pressurized.
Turn key switch ON.
Move tilt control lever to the back tilt position to start the
hydraulic pump. Hold tilt lever in this position until sump

Remove, clean and replace the strainer.
Sump breather cap
Refill the sump tank with Clark MS-68 Hydraulic Fluid.

Check truck operation. Turn key switch ON. Operate the
hydraulic system. Cycle the lift system serval times: raise
the lift carriage to full height and lower fully down. Check
Remove and discard old oil filter. Install new filter. Follow for leaks. Recheck sump tank fluid level.
the installation instructions printed on the filter body.
Also, check that the filter are tightened correctly. ! CAUTION
Be sure there is adequate overhead clearance
before raising upright.
Turn the key switch OFF.
Filter Head
Filter
Remove and replace the sump breather cap.

Section 2
Main Hydraulic Pump Troubleshooting
Noisy Pump ............................................................ 2
Pump Not Delivering Hydraulic Fluid ................ 2
Failure to Build Pressure ...................................... 2
Pump Not Developing Sufficient Pressure .......... 2
Pump Output Low ................................................. 2
Foaming Fluid ........................................................ 2
Overheated Pump and/or Fluid ........................... 2
External Leakage ................................................... 3
SM 751, Sep ’06 Main Hydraulic Pump Troubleshooting • 29-2-1

The following is a list of problems and solutions relating Pump Not Developing Sufficient
to the main hydraulic pump and associated components.
For other hydraulic system troubleshooting, refer to
Pressure
Groups 30 and 34. • Leak in hydraulic control system; check system for
and correct leaks.
Noisy Pump • Inlet line restriction; check for foreign material or
line kinks, check and clean sump suction screen.
• Hydraulic fluid level low; measure and correct
• Suction screen dirty; clean screen.
fluid level.
• Defective hydraulic pump; continue other trouble-
• Fluid viscosity too high; change to specified fluid.
shooting items, then consider servicing or replac-
• Sump strainer dirty; check and clean. ing pump.
• Air leak at pump inlet line; check plumbing tight-
ness.
Pump Output Low
• Inlet line restriction; check for foreign material or
line kinks, check and clean sump suction screen. • Cavitating pump; see “Noisy Pump.”
• Air leak at pump shaft packing; replace packing. • Air in fluid or wrong fluid; drain and fill with cor-
• Defective hydraulic pump; continue other trouble- rect fluid.
shooting items, then consider servicing or replac- • System relief valve set too low or too high, stuck or
ing pump. leaking; correct relief valve, pump may be OK.
• Overheated fluid; see “Overheated Pump and/or
Pump Not Delivering Hydraulic Fluid Fluid.”
• Contaminated fluid; eliminate contamination
• Hydraulic fluid level low; check and correct fluid source and replace fluid.
level.
• Gear face, body or cover nicked; repair or replace
• Sump suction screen dirty; check and clean. pump.
• Inlet line restriction; check for foreign material or • Excessive side loading, wear plate tight in body
line kinks, check and clean sump suction screen. bore, pinched thrust plate; inspect and service
• Air leak in suction line: check plumbing tightness. pump.
• Fluid viscosity too high: check fluid viscosity and
change to specified fluid. Foaming Fluid
• Defective hydraulic pump; continue other trouble-
shooting items, then consider servicing or replac- • Cavitating pump; see “Noisy Pump.”
ing pump. • Wrong fluid; drain and fill with correct fluid.
Failure to Build Pressure Overheated Pump and/or Fluid

• Hydraulic fluid level low; measure and correct • Low viscosity fluid; drain and fill with correct
fluid level. fluid.
• Defective relief valve or pump: perform pressure • Contaminated fluid; drain fluid, clean suction
check to test valve and pump. screen, replace filter and fill sump.
• Cavitating pump: see “Noisy Pump.”
• Pump drive shaft misaligned; check mounting and
alignment.
• Axial loading on drive shaft; check shaft end clear-
ance and shaft alignment; check for worn key/
spline.
• Relief valve usually in bypass; check relief setting.
29-2-2 • Main Hydraulic Pump Troubleshooting

Copyrighted Material SM 751, Sep ’06
External Leakage
• Excessive system pressure; replace pressure con-
trol valve on main hydraulic valve.
• Faulty or distorted pump seal gasket; replace seal
gasket.
• Damaged surfaces on pump body or cover; correct
and replace as required.
SM 751, Sep ’06 Main Hydraulic Pump Troubleshooting • 29-2-3

NOTE :

Section 3
Main Hydraulic Removal and Installation
Main hydraulic Pump Removal ........................... 2
Main Hydraulic Pump Installation ...................... 3
SM 751, Sep ’06 Main Hydraulic Removal and Installation • 29-3-1

Main Hydraulic Pump Removal NOTE

Capacity of hydraulic sump is C60/70 :
! 120L(31.7 Gal), C80 : 140 L(37 Gal).
CAUTION
1. Park truck on a hard, level and solid sur- 1. Place a drip pan under the hydraulic pump for oil that
face, such as a concrete floor with no will drain from the pump and hoses when they are
gaps or breaks. disconnected.
2. Put upright in vertical position and fully 2. Disconnect suction line from pump and plug the line.
3. Put ail controls in neutral. Turn key
4. Apply the park brake and block the
wheels.
The main hydraulic pump is located in front of transmis-
sion. The pump can be removed from the truck lift truck
after removing the floor.
Serviceable items are the pump, motor and the suction
line filter. Other components such as hoses, fittings and
clamps are non-serviceable and should be replaced if
faulty.
Pump suction line
Steering gear
Hydraulic pump
Control valve
29-3-2 • Main Hydraulic Removal and Installation

3. Disconnect the pressure line from the pump. Cap the 3. Slide suction hose and clamp into place and tighten.
hose and set aside.
4. Connect pump outlet hose and tighten. Use two
wrenches to tighten hose fittings to prevent twisting
of lines.
NOTE
Hydraulic line
Always clean or replace hydraulic sump suc-
tion screen fitting when installing new or
rebuilt pump. See Section 1, Main Hydraulic
Filters and Fluid Maintenance.
5. Refill sump as necessary using Clark Specification

MS-68 hydraulic fluid. See Section 1 for description
of sump tank fill levels.
6. Reinstall hose and cable support bracket.
Hydraulic pump
7. Check operation of hydraulic system. See Section 1,
Main Hydraulic Filters and Fluid Maintenance.
4. Remove the pump mounting fasteners.The ground 8. Check fluid level of sump again. Add fluid as neces-
strap will come off with the fasteners. sary.
NOTE
For Hydraulic Pump Overhaul Procedures
see Section 4.
Main Hydraulic Pump Installation

IMPORTANT
Keep all components clean during installa-
tion.
1. Be sure new or serviced pump is well lubricated

before installation.
2. Install pump onto motor. Install and tighten cap-
screws. Make sure ground wire is attached to lower
capscrews.
SM 751, Sep ’06 Main Hydraulic Removal and Installation • 29-3-3

NOTE :

GROUP 30
GROUP 30
HYDRAULIC CONTROL VALVE/LIFT CIRCUIT
Hydraulic Control Valve/Lift Circuit

Specifications and Description .............................. Section 1
Hydraulic System Schematic ................................ Section 2
Hydraulic System Troubleshooting ...................... Section 3
Hydraulic System Pressure Checks

and Adjustments .................................................... Section 4
Hydraulic Control Valve Removal

and Replacement .................................................... Section 5
Hydraulic Control Valve Overhaul ...................... Section 6
IMPORTANT
described and illustrated in Group 25, “Steering Column
and Gear”, Group 26 “Steer Axle”, Group 29, “Hydraulic
Sump, Filters and Pump”, Group 32, “Tilt Cylinders”, and
Group 34, “Uprights”. Refer to these other groups for
hydraulic components not covered in this group.
SM 751, Sep ’06 Group

Copyrighted 30, HYDRAULIC CONTROL VALVE/LIFT CIRCUIT
Material
NOTE :
Group 30, HYDRAULIC CONTROL VALVE/LIFT CIRCUIT

Group 30, Hydraulic Control Valve/Lift Circuit
Section 1
Hydraulic Control Valve/Lift Circuit

STRUCTURE
The control valve is designed as a load sensing type to optimize the energy consumption. The tilt lock valve
spool is equipped in the tilt spool, and the poppet is installed in the section to prevent falling down. The the tilt
and aux. speed can be adjusted. Also, the adjustable relief valve is installed in optional auxiliary valve section.
Install the maximum of two sections.
27
28
22
21
6 24
23
12 5 24
17
13
11
30
10
15 18
1
16
9 9
37
14 31
19
7 29
8 2
20 35
6
32 38
26
33 36
25
42
3 45
4 39 43
34 40 46
41 44
1 Inlet & Lift spool housing 17 Spool 33 Spring

2 Spool ass’y 18 Plate ass’y - Seal 34 Spool end group
3 Cap - spool 19 Poppet 35 O-ring
4 Cap screw 20 Spring 36 AUX.2 spool housing
5 Seal plate group 21 Poppet 37 Spool
6 Plug ass’y 22 Spring 38 Plate assy - Seal
7 Spool 23 O-ring 39 Poppet
8 Spring 24 Back - Up ring 40 Spring
9 Screw - restriction 25 Spool end group 41 Spool end group
SM 751, Nov ’06 Hydraulic Control Valve/Lift

Copyrighted Circuit Specifications and Description • 30-1-1
Material
10 Poppet - Lockout valve 26 O-ring 42 O-ring

11 Spring 27 Tang end 43 Outlet spool housing
12 Plug ass’y 28 O-ring 44 Relief valve ass’y
13 Spring seat 29 AUX.1 spool housing 45 Tie rod
14 Plug ass’y 30 Spool 46 Nut
15 O-ring 31 Plate assy - Seal
16 Tilt spool housing 32 Poppet
SPECIFICATION
C60-C80
Model
HUSCO
Main relief pressure kg/㎠(PSI) 210(3000)
Relief type Cartridge
Spool type Cantype spring return
Rated Q'ty l/min (gpm) 180(40)
30-1-2 • Hydraulic Control Valve/Lift Circuit Copyrighted

Material SM 751, Sep ’06
Section 2
Hydraulic Schematic
SM 751, Sep ’06 Copyrighted Material Hydraulic Schematic • 30-2-1

LIFT
CYLINDER TILT
CYLINDER STEERING CYLINDER
LOAD LOWERING SECONDARY RELIEF VALVE

FLOW VALVE
30-2-2 • Hydraulic Schematic

MAIN HYDRAULIC VALVE LIFT TILT AUX1 AUX2
LS DYN. STEER UNIT
MAIN RELIEF VALVE
BRAKE VALVE
UNLOADING
VALVE
ANTI-STALL
CHECK PORT FLOW CONTROL ORIFICE
ORIFICE
PRIORITY

VALVE
FILTER, BREATHER

& STRAINER
HYDRAULIC PRIORITY
COOLER VALVE
RETURN
FILTER
LIFT PUMP & MOTOR
HYD TANK STRAINER
SM 751, Sep ’06

Section 3
Hydraulic System Troubleshooting
The following is a list of problems and solutions relating • Cavitating pump; check hydraulic plumbing for
to the main hydraulic control valve and associated compo- airtight hoses and connections.
nents. For other hydraulic system troubleshooting, refer to • Pump driveshaft misaligned; check mounting and
Groups 29 and 34.
alignment.
No lift, tilt, or auxiliary function • Axial loading on drive shaft; check shaft end clear-
ance and shaft alignment; check for worn key/
• Hydraulic fluid very low; check and fill to correct spline.
level.
• Relief valve in bypass; check relief setting.
• Hose or fittings broken; replace component.
• Defective main lift valve; check other Trouble- Load cannot be lifted to maximum height
shooting items for possible cause, then consider
rebuilding or replacing main lift valve. • Hydraulic fluid low: check and fill to correct level.
• Hydraulic pump defective: check other Trouble- • Hydraulic pump defective; check other Trouble-
shooting items for possible cause, then consider shooting items for possible cause, then consider
rebuilding or replacing pump. rebuilding or replacing pump.
No motion, slow or jerky action of Oil leaks at top of lift (secondary) cylinder(s)
hydraulic system • Plugged vent line; check and clear line.
• Spool not moved to full stroke; check travel and • Worn or damaged piston seal: rebuild cylinder.
linkage adjustment. • Scored cylinder wall; replace cylinder.
• Relief valve not properly set, stuck in place, and/or See Group 34, “Cylinder Removal, Overhaul, and
worn; check and clean valve, replace if necessary. Replacement.”
• Dirt or foreign particles lodged between relief
valve control poppet and seat: check valve and Oil leak at tilt or auxiliary function cylinder
clean.
• Valve body cracked inside; check and replace • Worn or damaged seal; rebuild cylinder.
entire valve. • Scored piston rod; repair or replace rod.
See Group 34, “Cylinder Removal, Overhaul, and
Foaming hydraulic fluid Replacement.”
• Low oil level; check and fill to correct level.
• Wrong fluid; drain and refill with correct oil.
Load will not hold
• Oil too heavy; change to correct viscosity. • .Oil bypassing between lift spool and valve body; over-
• Pump inlet line restriction or line kinked; clean line haul valve and spool.
and suction screen or repair kinked hose. • Spool not centered; see spool remedies for correct-
• Hydraulic pump cavitating (pumping air with ing problems when spools do not return to neutral.
fluid); check hydraulic plumbing for airtight hoses • Oil bypassing piston in cylinder; repair or replace
and connections. cylinder.
Overheated hydraulic fluid Oil leaks at either end of main hydraulic

• Thin fluid; drain and fill with correct fluid. valve spool
• Fluid contaminated; drain sump, clean suction
screen, replace filter, and refill. • Defective O-ring seals; rebuild valve.
SM 751, Sep ’06 Copyrighted Material Hydraulic System Troubleshooting • 30-3-1

Spring-centered spools do not return to No relief valve action (high pressure)

neutral • Small particles of dirt in relief valve subassembly;
• Broken springs; rebuild valve. check, clean, and/or replace relief valve, clean
hole.
• Entrapped foreign particles; check and clean sys-
tem and valve. • Relief valve subassembly installed backwards;
reinstall correctly.
• Bent spool; replace with new valve section.
• Misalignment or binding of linkage; check and
align/adjust linkage. Load drops when spool is moved from
neutral to lift position
• Dirt or foreign particles lodged between check
valve ball and seat; check and clean.
• Sticking or scored check valve; clean if sticking,
replace if scored, replace poppet.
30-3-2 • Hydraulic System Troubleshooting Copyrighted Material SM 751, Sep ’06

Section 4
Hydraulic System Pressure Checks and Adjustments
! CAUTION 2. Remove the cap from the gauge port on the valve and
SAFE PARKING. Before working on truck: connect pressure gauge to the fitting.
gaps or breaks.
wheels.
Relief Pressure Checks

NOTE
Following is the procedure for checking main hydraulic
valve lift pressure and auxiliary relief pressure (if the Use quick-disconnect adapter fitting, Clark
truck is equipped with an auxiliary component). Part #913125.
Hydraulic system relief pressure setting may be checked 3. Check main relief pressure: Turn key switch on,
using a Mica Quadrigage (Clark Part No. 923770) or with move the tilt control lever to full back (or forward)
a conventional pressure gauge with suitable pressure tilt relief position. Hold tilt control in relief position
range calibration. To cover all models of the truck, a until pressure reading is obtained, and then release.
gauge with capacity range of 0 to 34,475 kPa minimum (0 Gauge should read 210 bar (3050 psi).
to 5000 psi) is recommended.
IMPORTANT
Do not operate system in relief any longer
! WARNING than required to read the pressure gauge.
HYDRAULIC FLUID SAFETY. Keep all
hydraulic ports and components clean. Wipe 4. Check auxiliary relief pressure: (Truck must have
the area on the pump around the diagnostic auxiliary component and auxiliary section added to
check port completely clean to prevent any main hydraulic valve.) Move the auxiliary control
contamination from entering the hydraulic lever to full back or forward relief position. Hold
system. auxiliary control in relief position until pressure
When checking the hydraulic system, do not reading is obtained, and then release. Gauge should
use your hands to check for leakage. Use a read 140 bar (2100 psi).
piece of cardboard or paper to search for
leaks. Escaping fluid under pressure can pen-
etrate the skin causing serious injury. Relieve
pressure before disconnecting hydraulic or
other lines. Tighten all connections before
applying pressure. Keep hands and body
away from pinholes and nozzles which eject
fluids under high pressure.
1. Remove the covers enclosing the main hydraulic
valve to access the hydraulic system pressure diag-
nostic check port.
SM 751, Sep '06 Hydraulic System

Copyrighted Material Pressure Checks and Adjustments • 30-4-1
Main Pressure Relief Adjustment Auxiliary Pressure Relief Adjustment

IMPORTANT IMPORTANT
Main pressure relief setting is set at the fac- The auxiliary relief setting only applies to a
tory. If the relief pressure does not measure hydraulic valve that has auxiliary sections
within the setting range, main pressure relief added.
setting is adjusted.
To adjust the hydraulic system auxiliary pressure relief
To adjust the hydraulic system main pressure relief valve: valve:
1. Loosen the jam nut on the main relief valve adjust- 1. Loosen the jam nut on the auxiliary relief valve
ment screw. adjustment screw.
Auxiliary relief
Lock nut valve
Lock nut
Main relief valve
Adjuster screw Adjuster screw
2. Turn the adjustment screw to set the auxiliary pres-

2. Turn the adjustment screw to set the main pressure sure relief setting to the normal range.
relief setting to the normal range.
3. Reset the jam nut on the auxiliary relief valve adjust-
3. Reset the jam nut on the main relief valve adjustment ment screw.
screw.
30-4-2 • Hydraulic System Pressure Checks Copyrighted

and Adjustments
Material SM 751, Sep ’06
Section 5
Hydraulic Control Valve Removal and Replacement
Hydraulic Control Valve Removal ...................... 2

Preparation for Valve Removal .............................. .2
Control Valve Linkage Disassembly ........................ 2
Valve Removal. ........................................................ 2
Hydraulic Control Valve Replacement ............... 3

Valve Replacement .................................................. 3
Control Valve Linkage Reassembly ......................... 3
Operational Checks ............................................... 4
! CAUTION
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.
remove key.
SM 751, Sep ’06 HydraulicMaterial

Copyrighted Control Valve Removal and Replacement • 30-5-1
Hydraulic Control Valve Removal Control Valve Linkage Disassembly

IMPORTANT Remove the cotter rings and clevis pins connecting the lift
Keep all hydraulic ports, components, and and tilt (and auxiliary, as applicable) lever rods from the
fittings completely clean during valve hydraulic valve spools.
removal and replacement to prevent any con-
tamination from entering the hydraulic sys-
tem.
Preparation for Valve Removal

1. Park truck in a safe position and fully lower the
upright.
2. Return all controls to neutral, apply the parking
Cotter
brake, and turn key switch OFF. Ring Clevis
3. Move all hydraulic control levers to all working posi- Pin
tions and return them to neutral. Be sure there is no
hydraulic pressure applied to the system by attach-
ments.
Valve Spool
4. Remove floor plate.
5. Remove the mcv cover at right side of operator's seat.
6. Air clean the hydraulic valve and fittings. Valve Removal
7. Place a drain pan under the truck and loosen and 1. Remove the three hex capscrews mounting the
remove all hydraulic lines from the valve. Plug the hydraulic valve to the hydraulic assembly bracket.
valve ports. Mark or tag each line as removed to Two of the capscrews thread into the valve itself; the
assure correct position of line at assembly. third is secured with a flange nut.
Return Line
to Sump
Feed Line
from Pump
Tilt Cylinder
Lines
2. Remove valve assembly from truck. See Section 6

To for valve overhaul instructions.
Upringt
NOTE
8. Cap ends of lines to keep them clean. Tie ends of
Be sure to clean up any oil spills and dry the
lines to truck to prevent loose ends dropping and
floor to prevent accidents.
leaking oil onto floor
30-5-2 • Hydraulic Control Valve Removal and Replacement

Hydraulic Control Valve Replacement Control Valve Linkage Reassembly

1. Insert the clevis pins through the rod-end clevises
Valve Replacement and valve spools of the lift and tilt spools (and auxil-
iary-lever rods and spools where applicable) and
1. Position the main valve on the hydraulic assembly
secure with the cotter rings. Rotation of the valve
bracket. Install valve mounting fasteners and tighten
spools is required to allow insertion of the clevis
hand tight so that valve mounting can be adjusted for
pins. Rotate spools back so all pins are in line.
alignment with the lever connecting rods.
Cotter
Ring Clevis
Pin
2. Install the hydraulic lines on the proper ports. Make

sure all lines are clean, arerouted correctly in the Valve Spool
truck, and are not kinked. Torque fittings according
to “Hydraulic Fitting Tightening Procedure” in
Group 40.
NOTE
The illustration above and system specifica-
tion torques also apply for auxiliary hydrau-
lic functions, such as a side-shifter or rotator.
2. When alignment between the lever rods and the valve

is set and levers are inline and level with one another,
Return Line
to Sump tighten the valve mounting capscrews and flange nuts
Feed Line to 40-50N⋅m(30-33 ft-lb).
from Pump
Tilt Cylinder
Lines
To
Upringt
3. Adjust the valve to align with the lever connecting

rods.
SM 751, Sep ’06 HydraulicMaterial

Copyrighted Control Valve Removal and Replacement • 30-5-3
Operational Checks
1. Operate the truck and hydraulic system. Check the
system for leaks.
! WARNING
Do not use your hands to check for hydraulic
leakage. Use a piece of cardboard or paper to
search for leaks. Escaping fluid under pres-
sure can penetrate the skin causing serious
injury. Relieve pressure before disconnecting
hydraulic or other lines. Tighten all connec-
tions before applying pressure. Keep hands
and body away from pinholes and nozzles
which eject fluids under high pressure.
If any fluid is injected into the skin, it must
be surgically removed within a few hours by
a doctor familiar with this type injury or
gangrene may result.
2. Check the operation of the valve and hydraulic sys-
tem by moving the valve control levers to the various
positions. The levers must operate smoothly with no
binding. When released from any working position,
the levers must return sharply to their neutral posi-
tions.
3. Refer to Section 4, “Hydraulic System Pressure-
Check” if valve was disassembled or overhauled.
4. Replace the cowl cover under the operator’s compart-
ment dash. See removal and replacement proce-
duresin Group 38.
30-5-4 • Hydraulic Control Valve Removal and Replacement

Section 6
Hydraulic Control Valve Overhaul
Preparation for Disassembly ................................ 1
Disassembly ............................................................ 2
Cleaning, Inspection, and Repair .......................... 3
Reassembly.............................................................. 4
Relief Valve Settings .............................................. 4
IMPORTANT
Before removing any component for overhaul, make sure the correct repair parts, seals, and gasket sets
are available.
The following overhaul instructions describe a two spool • Clean outside of valve with a good grade of solvent
assembly with the inlet/lift section, a tilt (or auxiliary) and dry thoroughly.
section, and outlet section (outlet section contains no • Before starting disassembly, the valve should be
spool). carefully examined to determine if there is any evi-
dence
Preparation for Disassembly
IMPORTANT
Overhaul valve only in a clean, dust-free
location, using clean tools and equipment.
Dirt or grit will damage the highly-ma-
chined surfaces and will result in leakage or
premature failure of components. Cleanliness
of the hydraulic circuit is extremely impor-
tant to the proper operation and mainte-
nance of the system. Be sure the work area is
clean.
SM 751, Dec ’06 Copyrighted Material Hydraulic Control Valve Overhaul • 30-6-1
Disassembly 2. Remove and label all parts between the sections for
correct reassembly. These include:
During disassembly, pay particular attention to identifica- a. Retainers and seals which are included in the
tion of parts for reassembly. Spools are selectively fitted replacement seal kit.
to valve bodies and you must return each spool to the b. O-rings, springs, and ball which are replaced sep-
same body from which it was removed. You must also be arately.
sure to reassemble the valve sections in the original order.
NOTE
NOTE Keep parts in order as removed and avoid
Valve sections may or may not require sepa- mixing the sections and parts.
ration for overhaul.
3. Disassemble each valve spool, one at a time, from
If only valve spools are being overhauled, you do not have bottom of valve as shown in the illustration.
to separate the sections. For a complete overhaul, includ-
ing replacement of the seals, retainers, O-rings, springs, 4. Remove the valve spools by tapping lightly on the
and balls used between the sections, follow steps 1 and 2. top end with a soft-faced hammer to drive them out
To overhaul only the valve spools, begin with step 3. of the valve body.
1. Remove the nuts and studs connecting the valve sec- 5. Arrange the parts in the sequence of removal.
tions.
Figure 1. InletlLift Body, Main Pressure Relief Valve, and Auxiliary Pressure Relief Valve.
Contents of spool assembly are shown in Figure 2.
30-6-2 • Hydraulic Control Valve Overhaul Copyrighted Material SM 751, Dec ’06
NOTE 3. Inspect valve spools and bores for burrs and scoring.
Remove the outlet port section only if there is If scoring is not deep enough to cause leakage, the
need for further inspection and cleaning of surfaces can be stoned or polished with crocus cloth.
contaminants in the valve. To remove, loosen If scoring is excessive, valve body and spool must be
and remove the nuts and studs and separate replaced. Check each valve spool for free movement
the outlet port section from the valve body. in its bore.
Label and keep all parts for correct reassem- 4. Inspect the main pressure relief valve for damage.
bly. Relief valve must be free from contamination, burrs,
and scoring. Plug, spring, and O-ring should be
Cleaning, Inspection, and Repair cleaned and inspected for damage.
1. Discard all old seals. Wash all parts in a clean min- NOTE
eral oil solvent and place them on a clean surface for Entire relief valve assembly must be replaced
inspection. if damaged. Relief valve pressure is set at the
factory. If pressure relief setting is not in rec-
2. Carefully remove any burrs by light stoning or lap- ommended range, relief valve pressure is
ping. Be sure there is no paint or burrs on mating sur- adjusted.
faces of valve bodies.
Figure 2. Valve Spool and Tilt (or Auxiliary) Body . Differences in lift (or tilt) and auxiliary components noted.
SM 751, Dec ’06 Copyrighted Material Hydraulic Control Valve Overhaul • 30-6-3
5. Inspect the lift and tilt relief valves for damage. If Reassembly
damaged relief valve assembly must be replaced.
Use the exploded view illustration of the valve section,
6. Inspect the valve body to make sure it has not been spools, and relief valves for reassembly.
physically damaged. Examine all threads to be sure
they are clean and not damaged or burred. Inspect all 1. Assemble valve in reverse order of disassembly.
bores and poppet seats. Poppet seat must be even all 2. Coat all parts with clean hydraulic oil to facilitate
around its circumference with no nicks, burrs, or assembly and provide initial lubrication. Petroleum
indentations in any of the seat face. jelly can be used to hold seal rings in place during
7. All springs should be free of corrosion and not bro- assembly.
ken or bent. 3. Use new O-rings and seals for all parts.
8. If parts must be left unassembled for a period of time 4. Install seal rings and the seal ring retainer in the
or overnight, cover with a lint-free clean material. grooves in body of each inlet and center section. Use
petroleum jelly to hold the seals in place. Carefully
place the sections together in the same order in which
they were removed.
5. Torque dust-cover screws to 10.8-13.5 N⋅m (8-10 ft-
lb).
6. Reinsert studs between valve sections and torque
nuts to 27-34 N⋅m (20-25 ft-lb).
Relief Valve Settings

Overhaul and reinstallation of the main hydraulic valve,
the hydraulic system relief pressure and auxiliary valve
relief pressure settings (if truck and valve are equipped
with an auxiliary component and section) must be
checked. See the hydraulic system checks and adjustments
Section of this Group (30) for procedures.
If the truck is not equipped with any auxiliary equipment,
no adjustments are necessary. If an auxiliary section has
been added to the hydraulic valve and auxiliary compo-
nents have been installed on the truck, check the relief
pressure. See the hydraulic system checks and adjust-
ments Section of this Group (30) for procedures.
Figure 3. Outlet Body
30-6-4 • Hydraulic Control Valve Overhaul Copyrighted Material SM 751, Dec ’06
GROUP 32
GROUP 32
TILT CYLINDERS
Tilt Cylinder Specifications and

Tilt Checks and Adjustments .................. Section 2
Tilt Cylinder Removal and

Tilt Cylinder Overhaul ............................ Section 4
IMP ORTANT
described and illustrated in Group 25, “Steering Column
and Gear,” Group 26 “Steer Axle,” Group 29, “Hydraulic
Sump, Filters, and Pump,” Group 30, Hydraulic Control
Valve/Lift Circuit,” and Group 34, “Uprights.” Refer to
these other groups for hydraulic components not covered in
this group.
SM 751, Jun ’06 Copyrighted Material Group 32, Tilt Cylinders

NOTE :
Group 32, Tilt Cylinders Copyrighted Material SM 751, Jun ’06

Group 32, Tilt Cylinders
Section 1
Tilt Cylinder Specifications and Description
Specifications Tilt Cylinder Rod-End Check and Tightening: Every 50-

See Group 30 for hydraulic system specifications.
Tilt Cylinder Rod-End Lubrication: Every 50-250 hours
Tilt Cylinder Type: Double-acting or each PM.
Maximum Operating Pressure: 21,000 kPa (3,000 psi)
Tilt Ranges*: Description
MAST BACK FORWARD The tilt cylinders provide backward and forward tilt of the
MFH mm(in) upright. The forward and back tilt angles are governed by
TYPE "B"( ˚ ) "F"( ˚ )
C60-C70 the cylinder stroke and by use of spacers and different
STD 2300(90.6)~3700(146) 10 15 length rod ends. The tilt cylinders are pin-mounted to the
STD 3800(147)~6400(252) 10 10 truck frame and upright using yokes, clevises, and pins.
TSU 3650(144)~4900(193) 10 10
Pins are held in place by a lock plate and fastener to pre-
TSU 6200(244)~8000(315) 6 6
vent the pins from working their way out.
C80 The tilt cylinders are serviced by removing them from the
STD 2300(90.6)~3700(146) 10 15 truck and disassembling them for complete overhaul,
STD 3800(147)~6400(252) 10 10 including installation of new seals and or other cylinder
TSU 3650(144)~4900(193) 10 10 components.
TSU 6200(244)~8000(315) 6 6
The tilt lock valve is integrated into the tilt section of the
Abbreviations: Std = Standard, high-visibility upright; main hydraulic control valve. The tilt lock valve prevents
TSU = Triple-stage upright; MFH = maximum fork the upright from tilting forward when the truck is not run-
height; B = back tilt; F = forward tilt. See truck data plate ning. The tilt lock valve is not serviceable and must be
for upright MFH. replaced as a valve section if defective.
Fastener Torques
Rod-End Yoke Bolts: 166-193 N.m (122-142 ft-lb)
Rod-End Pin Lock Plate Fasteners: 8-10 N⋅m (10.8-13.5
ft-lb).
Base Mount Pin Lock Plate Fasteners: 8-10 N⋅m (10.8-
13.5 ft-lb).
Service Intervals
Tilt Cylinder Drift Test: Every 50-250 hours or each PM.
Tilt Cylinder Check and Adjustment: Every 50-250 hours
or each PM.
Tilt Cylinder Rod Seal Condition Check: Every 50-250
hours or each PM.
Tilt Cylinder Mounting Check and Tightening: Every 50-
SM 751, Sep ’06 CopyrightedTilt Cylinder Specifications and Description • 32-1-1

Material
NOTE :
Group 32, Tilt Cylinders Copyrighted Material SM 751, Sep ’06

Section 2
Tilt Cylinder Checks and Adjustments
3. Raise the capacity load 2500mm (98.5 in) off the

! CAUTION ground and tilt the upright vertical, shut off the truck.

gaps or breaks.
2500mm(98.5in)
wheels.
4. Measure and write down the distance between the
cylinder-spacer face and the rod-end yoke.
Tilt Cylinder Drift Check
To check tilt cylinder drift, a rated capacity load is placed
on the forks, lifted up and held to determine if the tilt cyl-
inder rods moves (drifts) in a specified length of time.
Measure rod
It is recommended that a test load, made up of a full- distance here
capacity load equally distributed on a 1220×1220 mm (48

×48 in) pallet, be used. The material used to make up the
test load must be stacked to provide load stability and
must not extend beyond the pallet. It must be secured on
the pallet. Refer to the truck data plate for capacity rating.
1. Adjust fork width as wide as possible to distribute NOTE
the load. Refer to truck nameplate for capacity rating.
An alternate procedure is to measure the
change in the inclined angle of the upright,
! CAUTION using a protractor and level, or inclinometer.
Test load must be stacked stably, not extend
beyond the pallet, and be secured on the pal- 5. Wait five minutes and remeasure and write down the
let. Clamp the load on the load backrest or distance between the same two points.
fork bar to avoid sliping out from fork. 6. The decrease in the measure must not exceed the fol-
lowing measures :
2. Drive the forks into the load pallet until the test load
and pallet rest against the load backrest. Apply the Temperature Drift
parking brake and chock the wheels. 50°C (122°F) 0.5°, 3.1 mm@1min
5°, 31.1 mm@10min
SM 751, Jun ’06 Copyrighted MaterialTilt Cylinder Checks and Adjustments • 32-2-1
Drift Causes and Remedies Forward Adjustment

Tilt cylinder drift indicates the following possible prob- 1. Slowly tilt upright fully forward to the end of the tilt
lems : cylinder stroke.
• Tilt cylinder hydraulic circuit hoses or fittings are 2. As the cylinders approach the end of the stroke,
leaking. Check the circuit components and repair watch both piston rods for equal movement and
as necessary. upright for twisting. Note if upright “racks” (is
• Cylinder piston seals are worn, damaged, or defec- twisted at the end of its movement by unequal stroke
tive allowing fluid past the piston and causing the of tilt cylinders).
rod to drift. Consider rebuilding the cylinders if the NOTE
other remedies in this list are not successful. See
Correct the twisting effect by shortening the
Section 3 for cylinder removal and replacement
cylinder that is the longest length. Forward
and Section 4 for cylinder repair, if necessary.
twisting must be adjusted before backward
• The main hydraulic tilt valve is misadjusted, worn, twisting. If forward adjustment is not
or defective. Fluid is leaking past the valve and needed, continue with backward adjustment.
causing the tilt cylinders to drift. See Group 30 for
hydraulic valve troubleshooting. 3. To adjust, loosen rod-end yoke capscrew on the tilt
cylinder that extends the farthest, and turn piston rod
Tilt Cylinder Racking Check into rod-end yoke to shorten.
Upright racking occurs when tilt cylinder strokes are

unequal. Cylinders should be checked regularly during
operation to determine if cylinder strokes are the same. To Loosen capscrew
check for racking :
• Make sure truck is parked on level surface with Turn to adjust.
parking brake applied and wheels chocked.
• Check condition of the tilt cylinder, rod-end yoke,
mounting pins, piston rod, rod wiper, cylinder
gland, etc., for excessive wear or damage. Make
repairs before making twisting adjustment.
• Use a capacity load (see truck nameplate) centered
on the forks. Forward Adjustment : Pneumatic-tire truck rod-end yoke
orientation shown.
! CAUTION NOTE
Be sure to secure the load to the fork carriage Use wrench flat on rod under spacer (if
to keep it from falling off when tilted forward. installed). Move spacer for access.
Raise the upright only to the height that will
allow the fork tips to clear the floor when
tilted fully forward.
32-2-2 • Tilt Cylinder Checks and Adjustments

Copyrighted Material SM 751, Jun ’06
4. Continue to turn rod into rod end until tilt cylinder 4. Use rod shims to fill in the space between the rod-
strokes are equal. end yoke and spacer. Screw rod back into yoke the
same number of turns needed to remove.
IMPORTANT
The rod must be threaded onto the rod-end
yoke a distance at least as great as the diame-
ter of the rod plus 6.5 mm (0.25 in). Wrench Flat Rod shim
Rod end yoke
diameter
of rod Spacer
Cylinder rod
Thread rod into rodend
yoke the rod diameter
plus 6.5mm(0.25in)
5. Tighten capscrew of the rod-end yoke to 166-193

N⋅m (122-142 ft⋅lb), and repeat the racking test.
6. Repeat steps 1-5 for fine corrections if any racking 5. Tighten capscrew of the rod-end yoke to 166-193
remains evident. N⋅m (122-142 ft⋅lb), and repeat the racking test.
7. When no racking occurs, retighten capscrew of the 6. Repeat steps 1-5 for fine corrections if any racking
rod-end yoke to 166-193 N⋅m (122-142 ft⋅lb). remains evident.
8. Check all tilt functions before returning the truck to 7. When no racking occurs, retighten yoke capscrew to
service. 166-193 N⋅m (122-142 ft⋅lb).
8. Check all tilt functions before returning the truck to
Backward Adjustment service.
Perform forward check and adjustment first. Then :

Tilt Flow Control Adjustments
1. Slowly tilt upright fully backwards while watching
piston rods. They should both bottom out at the same See checks and adjustments Section of Group 30,
time. If they don’t, adjust backward tilt using the fol- “Hydraulic Control Valve/Lift Circuit,” for adjustment
lowing steps. procedure.
2. Stop the upright when the first tilt cylinder bottoms
out against its rod spacer.
3. Go to the opposite cylinder and remove the capscrew
on the rod-end yoke and screw rod out of yoke.
Count the number of turns required to remove the rod
from the yoke.
SM 751, Jun ’06 Copyrighted MaterialTilt Cylinder Checks and Adjustments • 32-2-3
NOTE :
Group 32, Tilt Cylinders Copyrighted Material SM 751, Jun ’06

Section 3
Tilt Cylinder Removal and Replacement
Tilt Cylinder Removal .......................................... . 2
Parts Inspection ..................................................... 3
Tilt Cylinder Replacement .................................... 3
SM 751, Sep ’06 Tilt Cylinder Removal and Replacement • 32-3-1

! CAUTION ! WARNING
SAFE PARKING. Before working on truck: The upright assembly is heavy. Use only
hoists with enough capacity to lift the entire
1. Park truck on a hard, level,-and solid
assembly. Keep hands and feet away from the
assembly. Use prybars to move the assembly
gaps or breaks.
into position for tilt cylinder replacement.
lower the forks or attachment. 3. Remove the floorboard.
3. Put all controls in neutral. Turn key 4. Put a drain pan under the truck at each tilt cylinder
switch OFF and remove key. position before removing the hydraulic lines. Discon-
nect and cap hydraulic lines from the tilt cylinders
(see illustration on facing page). Remove the hose
wheels.
connections on both sides of the tee fittings of theri-
ghtside cylinder. Keep all fittings and ports clean.
Tilt Cylinder Removal
1. Move tilt lever back and forth several times to relieve
any pressure.
2. Use an adequate chain and hoist to support the
upright so that it cannot fall when tilt cylinder pins
are removed.
Bearing
Rod end pin
Rod end yoke
Grease fitting
Base pin
Bearing
Tilt Cylinder Mounting Components

5. Support cylinder with a sling to prevent the cylinder from dropping when pins are removed.
32-3-2 • Tilt Cylinder Removal and Replacement

6. Remove lock-plate from tilt cylinder rod-end yoke. Tilt Cylinder Replacement
Use a soft drift and hammer to tap rod-end pin out of
yoke. 1. Position tilt cylinder base yoke on frame mounting
bracket.
7. Pop the cover from tilt cylinder base access port on
the step to the operator’s compartment. 2. Insert base pin in cylinder base yoke and through
frame mounting bracket, making sure slot in pin is in
8. Remove the lock-plate from cylinder base yoke. Use line with the lock-plate. Grease fitting must point
a soft drift and hammer to tap pin out of yoke. toward center of truck.
9. Remove cylinder assembly. IMPORTANT
Make sure the spherical bearing is aligned so
Parts Inspection that pin fits smoothly in yoke.
1. Clean all bearings, pins, and other components in an 3. Install base pin lock-plate in slot and fasten to yoke
approved cleaning fluid. with fastener and washer. Tighten fastener to a torque
2. Inspect all parts for scratches, nicks, dents, and wear. of 8-10 N⋅m (5.9-7.4 ft-lb).
Check the cylinder rods to be sure they are smooth 4. Position rod-end yoke on upright mounting bracket
with no scratches. Check all threaded parts for dam- and insert rod-end pin, making sure lock-plate slot is
age. in correct position. Grease fitting must be toward
3. Replace all parts which show damage. center of truck. Make sure the spherical bearing is
aligned so that pin fits smoothly in yoke.
4. If parts are to be left exposed, coat all mating sur-
faces of parts with a light layer of engine oil.
Tee fitting
Lines to
main valve
Till Cylinder Hydraulic Fittings
SM 751, Sep ’06 Tilt Cylinder Removal and Replacement • 32-3-3

NOTE 6. Install tilt cylinder hydraulic lines. Check Group 40

If the rod-end yoke has been removed from for hydraulic fitting tightening procedures. O-rings
the rod or loosened for adjustment, reinstall of fittings should be lightly coated with clean
the clamp bolts to a torque of 166-193 N.m hydraulic fluid or compatible oil.
(122-142 ft-lb). Nuts must be on inside of 7. Remove hoist chain from upright.
upright rails Orientation of the rod-end yoke
bolt hole is to be up as shown on the left side 8. See Section 2 for tilt cylinder adjustment procedures.
of the illustration on the previous page. When adjustments are made, check all upright com-
ponents under load before returning the truck to ser-
5. Install rod-end lock-plate in slot and fasten to yoke vice. Nuts must be on inside.
with fastener and washer. Tighten fastener to a torque
of 8-10 N⋅m (5.9-7.4 ft-lb).
32-3-4 • Tilt Cylinder Removal and Replacement

Section 4
Tilt Cylinder Overhaul
Preparation for Disassembly ............................... . 2

Disassembly ............................................................ 2
Inspection ............................................................... 2
Reassembly .............................................................. 3
IMPORTANT
Cylinder cap Cylinder Barrel O-ring

(Base mount) Gland
Wrench flat
Rod
Rod
Piston U-cup seal Rod wiper
Piston packing
Wear ring
Typical Tilt Cylinder Cross section
SM 751, Sep ’06 Copyrighted Material Tilt Cylinder Overhaul • 32-4-1

Preparation For Disassembly 2. Carefully pull the rod, piston assembly, and gland
from the cylinder barrel. Remove gland from rod.
IMPORTANT
Overhaul tilt cylinders only in a clean, dust- ! WARNING
free location, using clean tools and equip-
ment. Dirt or grit will damage the highly- The use of compressed air to blow the piston
machined surfaces and will result in leakage out of the barrel is not recommended. High-
or premature failure of components. Cleanli- pressure air can result in piston and rod
ness of the hydraulic circuit is extremely being ejected at high velocity (explosively),
important to the proper operation and main- causing severe injury to personnel and prop-
tenance of the system. Be sure the work area erty damage.
is clean.
3. Remove and discard the piston packing and wear
1. Before disassembly, the exterior of the tilt cylinder rings from the piston.
should be carefully cleaned to remove all dirt and
Piston packing Wear ring
grease accumulation.
2. Be sure all hydraulic oil has been removed from the
cylinder. Stroking the piston rod will help force the
oil out.
3. Before starting disassembly, the tilt cylinder should
be carefully examined to determine if there is any
evidence of external damage.
Disassembly
The tilt cylinder can be held by clamping the base end or 4. Remove and discard the rod U-cup seal, O-ring, and
the barrel in a vise while disassembling. piston rod wiper from the gland.
IMPORTANT
O-ring U-cup seal
Do not use excessive force when clamping on Rod wiper
the barrel.
1. Remove the gland with a hook wrench. Carefully

pull the gland assembly from the cylinder tube and
slide it off the cylinder rod.
O-ring
Inspection
1. Carefully clean all parts in an approved solvent and
place on a clean surface.
2. Check the piston and rod for damage. Look for
gouges, scratches, corrosion, or evidence of unusual
wear. Minor surface damage may be repaired by use
of fine abrasion cloth or stoning. Deeper damage will
require replacement of piston rod assembly.
3. Be sure the threads on rod are undamaged.
32-4-2 • Tilt Cylinder Overhaul Copyrighted Material SM 751, Sep ’06

4. Inspect the tilt cylinder barrel internal bore for wear, 3. Install gland on piston rod. Use gentle pressure and
scratches or other damage. Check the outside for careful movements to avoid damage to the U-cup
damage. Inspect all welds for cracks. seal and rod wiper when these parts are moved over
Deep gouges or pitted surfaces require replacement the piston rod end.
of parts.
NOTE
Check the gland, base end, and ports for cracks or
damage that could cause failure. Inspect the ports to Reassemble cylinder carefully to prevent
be sure they are free of contamination and that the damage to seal lips and O-rings.
threads are clean and not damaged.
4. Install piston into cylinder barrel. Be careful not to
5. Put a light coating of hydraulic fluid on all parts. If damage the piston seals when installing the piston
parts are to be left disassembled for a period of time, into end of cylinder.
e.g., overnight, they should be covered with a clean
cloth. 5. Install gland into cylinder them screw the gland into
the cylinder barrel with a hook wrench. When tight-
ing, do not damage the seal. Tighten torque : 60±6
Reassembly kgf⋅m
Be sure inside of cylinder and all parts are clean before O-ring
starting reassembly. Seals may be lubricated with hydrau-
lic oil to assist assembly into cylinder barrel.
1. Install piston dust wiper, rod seal, and O-ring on the
gland. Make sure rod seal and dust wiper are
installed in proper orientation as shown in the illus-
tration.
O-ring U-cup seal

Rod wiper
6. Check the assembly by making sure the piston slides

freely in and out of the cylinder.
See Section 3 for replacement procedures ; see Section 2
for checks and adjustments before returning the truck to
service.
2. Replace the piston packing and wearing.
Piston packing Wear ring
SM 751, Sep ’06 Copyrighted Material Tilt Cylinder Overhaul • 32-4-3

NOTE :
Group 32, Tilt Cylinders Copyrighted Material SM 751, Sep ’06

GROUP 34
GROUP 34
UPRIGHTS
Upright Specifications and Description ........................ Section 1
Troubleshooting ............................................................... Section 2
Upringht Inspection ......................................................... Section 3
Carriage and Upright Roller Clearance

Checks and Shim Adjustments ...................................... Section 4
Cylinder Removal, Shimming,

Overhaul, and Replacement ........................................... Section 5
Upright Chain Inspection, Adjustment,

and Replacement .............................................................. Section 6
Fork and Carriage Removal and

Replacement ..................................................................... Section 7
Upright Removal and Replacement ............................... Section 8
IMPORTANT
Related service information is covered in Group 29, “Hydrau-
lic Sump, Filters, and Pump,” Group 30, “Hydraulic Control
Valve/Lift Circuit,” and Group 32, “Tilt Cylinder.”
SM 751, Oct ’06 Copyrighted Material Group 34, Uprights

NOTE :
Group 34, Uprights Copyrighted Material SM 751, Oct ’06

Group 34, Uprights
Section 1
Upright Specifications and Description
General Specifications
Upright
Upright Weight: (Approximately 999 kg (2202 lb) to Upright Type Number Cylinder Type
approximately 2280 kg (5027 lb) without carriage. <C60-70>
Carriage Weight: Approximately 485 kg (1069 lb) to 574 STD pneu V6704 Piston-type Lift Cylinder
kg (1265 lb) with a 80 inch carriage. TSU pneu M6704 Piston-type Secondary Cylinder
<C80>
Fork Weight: Approximately 115-301 kg each (254-664 STD pneu V8001 Piston-Type Secondary Cylin-
lbs). der
IMPORTANT TSU Pneu M8001 Piston-Type Secondary Cylin-
Before hoisting, the weights of upright, car- der
riage, forks and attachments being lifted
must be combined to determine what lifting Drift:
capacity is required of the hoisting equip-
ment. With the upright substantially vertical the descent of the
rated load caused by an internal leakage in the hydraulic
Capacities and Lift Heights: Upright, carriage, and fork system shall not exceed 100mm (4in) during the first
capacity and upright lift heights are listed on the truck’s 10min with the oil in the hydraulic system at normal oper-
data plate. ating temperature. If drift over 100 mm (4 in) in ten min-
utes is evident, cylinder should be checked for internal
Lubricants: leakage. See Section 3 for drift test procedures.
• All Purpose Grease (MS-9)
Fastener and Fitting Torque Specifications
• Innerslide Lubricant (Clark P/N 886396)
• Chain and Cable Lube (Clark P/N 886399) Upright Mounting Bolts: 340-380 N⋅m (249-279 ft-lb)
Chain Anchor Bolt Jam Nut: 340-380 N⋅m (249-279 ft-lb)
Cylinder Types Carriage Side-Thrust Roller Bolts: 1150-1300 N⋅m (843-
953 ft-lb)
Standard uprights use two lift cylinders. Triple stage
uprights use four cylinders, two primary (center-mounted) Hose Fittings: See Group 40, “Hydraulic Fitting Tighten-
cylinders, and two secondary cylinders. All primary cylin- ing Procedure.”
ders used on triple-stage uprights (TSUs ) are piston cylin- Rod End Bolts: 170-190 N⋅m (125-140 ft-lb)
ders. The lift and secondary cylinders used on standard,
TSUs can be piston cylinders.
The types of cylinders used on the truck are listed below.
Check the first five characters of the upright number
stamped on the upright of the truck to determine the type
of cylinder, piston used on the upright.
IMPORTANT
Before removing any component for over-
haul, make sure the correct repair parts,
seals, and gasket sets are available.
SM 751, Dec ’06 Upright Specifications and Description • 34-1-1

Group 34, Uprights
Service Intervals The lift and secondary cylinders on standard uprights and
• All upright components should be visually checked triple-stage uprights (TSUs) are piston type cylinders. The
every day during the Operator’s Daily Inspection. primary cylinder on TSUs are piston-type cylinder. See
the chart under “Specifications” to determine the type of
• A thorough visual inspection should be performed
cylinder used on the upright you are servicing.
by a trained service professional every 50-250
hours. Piston-type cylinders contain a by-pass check valve in the
• Lift chains should be inspected and lubricated piston that allows air and fluid that have accumulated in
every 50-250 hours or monthly. the rod end of the cylinder to return to the system. The
• Lift chain tension should be checked every 50-250 check valve can be removed and cleaned if indicated by
hours or monthly. troubleshooting. A non-serviceable check-ball-type cush-
ioning function is built into ram and piston cylinders for
• Upright and carriage roller checks should be per-
smooth staging during the lowering cycle. The primary
formed every 50-250 hours or monthly.
cylinder on TSUs incorporates cushioning on the lift
• Roller patterns should be checked every 6 months cycle. A velocity fuse in the hydraulic port of the lift cyl-
or after 1000 hours of service. inders (secondary cylinders on TSUs) prevents the mast
• Racking and drift tests should be performed every from falling rapidly in case of sudden fluid pressure loss
50~250 hours or monthly. due to line breaks or other malfunction of the hydraulic
• The complete extended inspection should be per- circuit.
formed at least every year or 2000 hours of opera-
As the cushion system is added to lift cylinder of standard
tion.
upright and the primary cylinder of TSU, the speed will
Description get slow for a moment before the fork touches the ground.
It is helpful to protect the ground.
The upright assembly includes the lift chains, lift cylin-
As explained in more detail in Group 30, the main pump
ders, carriage, forks, and mast or rail sets. Each of the
sends fluid to the main hydraulic control valve, which
components can be serviced using the tests, checks,
contains spools that route fluid to the lift cylinders and tilt
adjustments, and removal and replacement procedures in
cylinders. The valve assembly also contains a counter-
the following Sections.
balance valve that prevents upright tilt when the truck is
The upright uses the hydraulic cylinders and chain sets to not operating.
lift the carriage and rail sets. On standard, two-stage
Fluid flow rates for lift functions are factory set and not
uprights, the lift cylinders lift the carriage with chains and
adjustable. Flow rates for tilt and auxiliary functions are
directly lift the inner rail set. On triple-stage uprights, the
controlled by adjustments on the main hydraulic valve. A
primary (free-lift) cylinder lifts the carriage by chains.
non-adjustable “load-lowering” flow valve mounted on
When the primary cylinder reaches its maximum exten-
the upright limits upright lowering speed.
sion, fluid is diverted to the secondary lift cylinders,
which lift the inner rails using a second set of chains and Groups 29 and 30 contain general hydraulic information
lift the intermediate rails by direct lift. including upright hydraulic functions. Other hydraulic
checks for the upright appear in “Troubleshooting,” Sec-
Friction and play between the nesting rails is controlled by
tion 2.
roller sets mounted on the rails and carriage. When rails or
rollers become worn, the gap between the rollers and rails
becomes larger, creating more play in lifting and lowering
operations. The rail web to roller side clearances can be
reduced by shimming the rollers to close the gap between
the roller and rails. The gap between the rail flange and
roller bearing surface can be reduced by the use of over-
size rollers on a one-time basis.
Forks use a hanger design for mounting on the carriage.
Auxiliary attachments may be added to the upright for
specialized handling operations. The hydraulic circuit is
modified with a hose adapter kit and an auxiliary section
is added to the main hydraulic valve to operate the attach-
ment.
34-1-2 • Upright Specifications and Description

Group 34, Uprights
Upper Roller
Lift Cylinder
DETAIL B
Chain
Chain Anchor
Load lowering
flow valve
Outer Rail set Inner Rail set
Lower Roller
DETAIL A
Typical Standard (Two-Stage) Upright Assembly

Group 34, Uprights
Chain Anchor
Upper roller
Upper roller
Secondary Hose sheave
cylinder
Chain sheave
Primary cylinder
Carriage chain
Carriage
Outer rail set

Load lowering
flow valve Intermediate rail set
Lower roller
Lower roller
Inner rail set
Primary Load lowering

cylinder flow valve
Typical Triple-stage Upright Assembly

Group 34, Uprights
Typical Triple Stage Upringht-Overhead View
Carriage
Roller
Adjustment shims
Carriages and Roller Sets

Group 34, Uprights
Four-Hose Adaptation for the Triple-Stage Upright

(Only Right hand Adaptation for the Two-Hose )
Four-Hose Adaptation for the Standard Upright

(Only Right hand Adaptation for the Two-Hose )

Group 34, Uprights
Section 2
Troubleshooting
The visual inspection and the operational checks pre- • Dry hose sheave or rollers; check condition of all
sented in Section 3 should be used to determine problems sheaves and rollers and lubricate as necessary.
with the upright. Possible problems, causes, and remedies • Damaged chain sheaves; check condition of chain
are listed below. sheaves and repair or replace.
Other troubleshooting information about the hydraulic cir- • Excessive fork hanger or carriage fork bar wear;
cuit and components appears in the troubleshooting Sec- inspect and replace as necessary.
tions of Groups 29 and 30. Use these other • Seals dry; lubricate rod.
troubleshooting Sections for more detailed problem isola-
• Seals dry - all primary cylinders; remove gland and
tion with Upright hydraulic functions.
add 100 ml (3.4 oz) of hydraulic oil to rod side of
piston, see “Cylinder Removal, Shimming, Over-
! WARNING haul, and Replacement.”
The procedures for troubleshooting uprights,
carriages, and forks involve movement of the No lift, tilt, or auxiliary function
components. Failure to follow these warnings
can result in serious injury. • Hydraulic fluid level low; check level and fill.
Make sure overhead clearances are adequate • Broken hoses or fittings; check and repair.
before raising the upright to full lift height.
• Damaged or blocked sump strainer; check and
Do not walk or stand under raised forks.
clean.
Block carriage and upright whenever making
checks with the upright elevated. • Hydraulic pump defective; see Group 29 for pump
Keep clear of load and carriage when making troubleshooting.
any check or adjustment. • Defective main hydraulic control valve; see Group
Keep your arms and fingers away from mov- 30 for valve troubleshooting.
ing parts of the upright. • Defective upright load-lowering flow valve; disas-
Do not reach through open areas of the semble valve, check and clean or replace.
upright.
No lift function but tilt operates

Upright noise
• Broken hoses or fittings; check and repair.
• Bent or broken components; inspect upright thor-
• Cylinder is damaged; inspect and repair.
oughly and repair or replace components as
required. • Main hydraulic control valve, lift section defective;
see Group 30 for valve troubleshooting and ser-
• Damaged upright roller; check condition of rollers
vice information.
and replace defective rollers.
• Upright load-lowering flow valve damaged; disas-
• Roller scuffing rails; clean and lubricate rails.
semble valve, check and clean or replace.
• Roller (carriage or upright) shimming needs
adjustment; check and adjust as required.
• Fit between roller edge and rail flange excessively
loose in rails; replace with oversized, “Select-Fit”
rollers. See “Upright Roller Clearance Check and
Shim Adjustment.”
• Dry lift chain; lubricate chain.
SM 751, Oct ’06 Copyrighted Material Troubleshooting • 34-2-1

Group 34, Uprights
Load cannot be lifted to maximum height • Defective priority valve; see Group 30 for valve
troubleshooting information.
• Hydraulic fluid level low, check level and fill. • Defective upright load-lowering flow valve;
• Debris in upright; check and clean. remove valve clean, inspect, and replace if neces-
• Hydraulic hose fittings loose or damaged; check sary.
and torque correctly (see Group 40 for specifica-
tions) or replace. Lowering speed sluggish
• Check cylinder for external leakage; replace cylin- • Damaged or binding upright roller; check condi-
der if cracked. tion of roller and replace if necessary.
• Cylinder shimming is incorrect; check and adjust • Damaged or kinked hydraulic hose or tube; check
shimming. condition of hose and tube, repair or replace as
• Internal leakage on lift or secondary piston cylin- necessary.
ders; remove rod and piston and clean check • Defective upright load-lowering flow valve; check,
valves; also clean and inspect/replace piston seals. clean and replace valve if necessary.
See Section 5.
• Defective velocity fuse; remove fuse from cylinder
• Cylinder check valve on lift or secondary piston hydraulic port, clean and recheck for proper opera-
cylinders not functioning properly; remove rod and tion.
piston and clean check valves; also clean and
inspect/replace piston seals. See Section 5. Load bounces excessively when lowering
• Hydraulic pump defective; see Group 29 for pump
troubleshooting information. • Air in hydraulic system, TSU and Hi-Lo ram-type
cylinders; set capacity load on upright and lift form
• Upright rails binding:
fully collapsed to full lift height for 10-15 cycles.
a. Perform a visual inspection and check for worn,
or distorted parts, broken or cracked rails or tie- • Defective upright load-lowering flow valve; check,
bars, correct chain and hosing placement and clean and replace valve if necessary.
operation • Defective main lift valve; see Group 30 for valve
b. Check rollers for contamination and proper oper- troubleshooting and service information.
ation, perform roller clearance check and adjust- • Defective velocity fuse; remove fuse from cylinder
ment hydraulic port, clean and recheck for proper opera-
tion.
Lift speed sluggish
Upright mis-staging (TSU lifting)
• Hydraulic fluid level low; check level and fill.
• Debris in upright roller area of carriage; check and
• Broken hoses or fittings; check and repair.
clean.
• Pump inlet line restricted; remove from pump and
• Interference between carriage and inner rail or cyl-
clean.
inder; check staging alignment and adjust or repair
• Damaged or binding upright roller; check condi- as necessary.
tion of roller and replace if necessary.
• Bent or broken carriage or inner rail; replace part -
• Internal leakage on piston-type lift and secondary do not try to repair by welding.
cylinders (with load); perform cylinder checks
• Damaged or binding carriage roller; check condi-
listed under “Load cannot be lifted to maximum
tion of roller and replace if necessary.
height.”
• Carriage roller shimming or thrust roller out of
• Hydraulic pump defective; see Group 29 for pump
adjustment; perform roller checks on carriage and
troubleshooting information.
make adjustments as necessary.
• Defective main lift valve; see Group 30 for valve
• Damaged or kinked primary cylinder hose; check
troubleshooting and service information.
condition of hose, repair or replace as necessary.
• Primary cylinder chain or chain sheave binding or
hydraulic port, clean and recheck for proper opera-
damaged; inspect and repair.
tion.
34-2-2 • Troubleshooting Copyrighted Material SM 751, Oct ’06

Group 34, Uprights
• Internal leakage in primary lift cylinder; perform • Bent or broken carriage or inner rail; replace part -
cylinder checks listed under “Load cannot be lifted do not try to repair by welding.
to maximum height.” • Carriage and upright roller shimming or thrust
• Damaged primary lift cylinder causing binding in roller out of adjustment; perform roller checks on
the cylinder; inspect and repair or replace cylinder. upright and/or carriage and make adjustments as
• Defective velocity fuse; remove fuse from cylinder necessary.
hydraulic port, clean and recheck for proper opera- • Defective velocity fuse; remove fuse from cylinder
tion. hydraulic port, clean and recheck for proper opera-
tion.
Upright mis-staging (TSU lowering)
External leakage on primary cylinder
• Debris in upright roller area or tie bar area; check
and clean. • Gland loose; check and tighten primary cylinder
• Bent or broken carriage or inner rail; replace part - gland and glands on lift (secondary) cylinders to
do not try to repair by welding. 706 N⋅m (517 ft-lb).
• Damaged or binding roller on upright; check con- • Cracked cylinder tube; replace tube.
dition of roller and replace if necessary. • Rod seal damage; replace seals and check for:
• Carriage and upright roller shimming or thrust − Damaged rod seal groove in gland; check for
roller out of adjustment; perform roller checks on damage to groove and replace seal or gland if
upright and/or carriage and make adjustments as necessary
necessary. − Scored cylinder wall; repair or replace cylinder
tube if necessary
• Damaged or kinked lift cylinder hose; check condi-
− Leaking check valve; clean and replace if nec-
tion of hose, repair or replace as necessary.
essary
• Lift cylinder chain or chain sheave binding or dam- − Leaking O-ring seal on check valve; replace
aged; inspect and repair. check valve.
• Bent cylinder rod; inspect and replace rod and/or • Gland static seals (O-rings and back-up ring) dam-
cylinder as necessary. aged; replace back-up ring.
• Internal leakage in piston-type cylinders; perform • Gland static seals sealing surface damaged; check
cylinder checks listed under “Load cannot be lifted groove and bore and repair or replace as necessary.
to maximum height.”
• Damaged lift cylinder causing binding in the cylin-
External leakage on lift (Standard) and
der; inspect and repair or replace cylinder.
secondary cylinder (TSUs)
hydraulic port, clean and recheck for proper opera- • Gland loose; check and tighten gland on cylinders
tion. to 706 N⋅m (517 ft-lb).
• Cracked cylinder tube; inspect and replace tube.
Upright mis-staging (Standard upright • Seal damage in piston-type cylinders; replace pis-
lowering) ton seals and rod seals.
• Damaged seal groove, piston-type cylinders; check
• Damaged or binding roller on upright; check con-
for scratches, nicks, or burrs and repair or replace
dition of roller and replace if necessary.
rod and piston.
• Top carriage roller retaining cap screw loose;
• Scored cylinder wall, TSU piston-type cylinders;
check and replace cap screw.
replace tube and all seals.
• Lift cylinder chain or chain sheave binding or dam-
• Scored or damaged rod; replace rod and all seals.
aged; inspect and repair.
• Damaged gland back-up seal; inspect and replace
• Debris in upright roller area or tie bar area; check
seal.
and clean.
SM 751, Oct ’06 Copyrighted Material Troubleshooting • 34-2-3

Group 34, Uprights
• Gland static seals sealing surface damaged; check • Cylinder hydraulic fittings loose or worn; check
grooves and bore. fitting O-rings, tighten fittings according to Group
40, “Hydraulic Fitting Tightening Procedure.”
Oil leak at top of lift cylinder • Check valve worn or damaged; remove rod and
• Scored cylinder wall; see Section 5. piston, clean check valve and replace if necessary.
• Worn or damaged gland rod-seal; see procedures • Control valve spool linkage malfunctioning, dam-
for piston-type cylinders under “Cylinder leaking aged, or worn; see Group 30, Section 5 for linkage
internally.” adjustment and/or replacement.
• Counterbalance function in main hydraulic control
Unsatisfactory lift or tilt cylinder drift test results valve malfunctioning, damaged, or worn; inspect
• Cylinder leaking internally; remove cylinder gland and clean or replace if necessary.
and check:
a. Primary cylinder should have only 3.4 ounces
(100 ml) on rod side of the piston
b. Piston-type lift and secondary cylinders should be
dry on rod side of piston.
If fluid is leaking past piston:
On piston-type cylinders, remove rod and piston,
clean check valves and clean and inspect/replace pis-
ton seals
See Section 5.
34-2-4 • Troubleshooting Copyrighted Material SM 751, Oct ’06

Group 34, Uprights
Section 3
Upright Inspection
! CAUTION
1. Park truck on a hard, level, and solid sur-
face, such as a concrete floor with no gaps or
breaks.
3. Put all controls in neutral. turn key switch
OFF and remove key.
wheels.
Upright
Carriage
Fork
SM 751, Oct ’06 Copyrighted Material Upright Inspection • 34-3-1

Group 34, Uprights
Basic Visual Inspection • Good condition of the chain links and pins. No
rust, corrosion, stiffness, or cracking should be evi-
Use the following steps to conduct an initial visual inspec- dent. Pins should not be turned or protruding.
tion of the upright. This is the same type of inspection • Excessive side wear or edge wear on the chain
operators should be conducting on a daily basis. plates.
If you note problems with any component during the basic • Correct, equal tension on chain sets.
visual inspection, continue with “Extended Inspection” • Secure anchor bolt, adjustment nut, and jam nut
for checks and service. mounting.
• Correct alignment of the chain anchors to the chain
! WARNING and chain sheaves. Adjust turned chain anchors.
The procedures for checking, maintaining, • Loose, broken, or damaged anchor bolt pins and
and adjusting uprights, carriages, and forks cotter pins. Replace defective pins and cotter pins.
involve movement of the components. Failure
to follow these warnings can result in serious
injury. Always use extreme caution. Rollers
Inspect the upright and carriage rollers for:
Keep clear of load and carriage when making
any check or adjustment. • Broken or loose rollers.
Keep your arms and fingers away from mov- • Loose, broken, or misadjusted thrust roller on the
ing parts of the upright. carriage.
Do not reach through open areas of the
• Obvious signs of failed bearing seals.
upright.
NOTE
General Some grease will purge from the bearings in
the first 100-200 hours of operation.
• Check to make sure all fasteners are secure.
• Check to make sure the upright lifts and lowers • Excessive looseness in carriage or upright roller
smoothly with and without a capacity load. shimming.
• Check for visible damage to components.
Upright and Carriage Weldments
Forks Inspect the upright and carriage for:
• Check function and security of the fork latch. • Debris or foreign objects on the components.
• Inspect the forks for cracks, especially the hanger • Bent, cracked, or broken components.
and heel areas. • Undesirable wear on or contact between compo-
• Check for wear in the fork heel. If heel wear is evi- nents.
dent, perform the extended inspection. • Irregular roller patterns and signs of excessive
• Inspect the fork hanger and carriage fork bar for wear or scraping on the rails.
excessive wear.
• Inspect for bent forks.
Lift Chains
Inspect the chains for:
• Proper lubrication. The links should have a coat of
oil on all surfaces. Lubrication oil should penetrate
completely into chain joints.
34-3-2 • Upright Inspection Copyrighted Material SM 751, Oct ’06

Group 34, Uprights
Hydraulic System Fork Bending

Overloading, glancing blows against solid objects, or
Inspect the upright hydraulic system components for: picking up loads unevenly can bend or twist a fork. Use
• Damage or wear on all hoses and hydraulic tubes. the following procedure to check for fork bending.
• Leaks on hoses, fittings, or valves. 1. Place a 50 x 100 x 610 mm (2 x 4 x 24 in) wood
• Leakage on the cylinders. block flat on the fork. Make sure the block is not rest-
• Excessive drift in lift or tilt operations. ing on the heel radius.
Extended Inspection
The extended inspection should be performed whenever
the basic visual inspection indicates upright problems, as
specified for PMs, or at least every 2000 hours.
Forks
Forks have a limited service life because of wear and
fatigue. Forks should be tested every 50-250 hours using a
visual inspection, a fork thickness check, a fork bending
check, and a fork gap check. If replacement is necessary, Fork Bending Check
always replace the pair to ensure fork integrity. 2. Set a carpenter’s square on the block against the fork
Fork Alignment shank
1. Park the truck on a flat, even surface, tilt upright to 3. Check the fork 508 mm (20 in) above the blade to
vertical position, and set forks 25-50 mm (1-2 in) make sure it is not bent more than 14.5 mm (0.6 in) at
above the ground. the maximum.
2. Compare fork arms to be sure they are straight, on 4. If blades are bent over the 14.5 mm (0.6 in) allow-
the same plane (level), and the same length. ance they should be replaced as a set.
See Section 7, “Fork and Carriage Removal and Replace-
3. Measure the distance from the fork tips to the ment,” for procedures to remove and replace the forks.
ground. The height difference between the forks tips
should be no more than 6mm(1/4in). Fork Fatigue
Fatigue cracks normally start in the heel area or on the
Fork underside of the top hanger. If cracks are found, the fork
Hanger Shank should be replaced. Dye penetrants or magnaflux can be
used for a more accurate inspection.
Fork Wear and Heel Wear
Industrial Truck Association (ITA) standards require that
a fork be removed from service when the blade or heel
thickness is reduced by 10% over its original thickness. If
the heel is 10% smaller than the arm, the load capacity
could be reduced by 20%. A 5,000-pound (2272 kg)
capacity fork with 10% wear can only safely handle 4,000
6mm(1/4in ) max. pounds (1818 kg).
Fork Arm Height
Use of fork wear calipers are recommended (Clark part
4. If the fork tips are not aligned within the specified number 1803641) to gauge fork wear as follows:
6mm (1/4in) difference, the cause of the problem
1. Use the outside jaws of the caliper to measure fork
must be determined and corrected before returning
thickness in the shank area of the fork.
the truck to service. If replacement is necessary,
always replace the forks in a set.

Group 34, Uprights
Chain Wear (Stretch) - All Lift Chains

Lift chain stretch due to wear in the joints can be mea-
sured using a measuring tape or Clark’s chain check ruler.
Chain Check Ruler - Clark Part Number 59-960-9908

NOTE
When any section of the chain has worn and increased its
Hold the caliper square and use light pres-
original length by 3% or more, the chain must be replaced.
sure to squeeze the outer jaw tips against the
When checking chain wear, always measure a segment of
fork shank. Take care not to accidentally
the chain that rolls over a sheave.
alter the reading of the calipers.
2. Check the fork blade area to the inside jaws of the

caliper.
3. If the inside jaws fit over the fork in the blade area,
wear exceeds allowable 10% wear and a new set of
forks should be installed.
Fork Hanger Wear and Carriage Fork Bar Wear
Inspect the fork hangers and carriage fork bar. Excessive
wear can cause the fork to disengage the fork bars or
reduce fork hanger life. IMPORTANT
Fork hanger hole Never replace a single chain in a set. Always
replace the two chains in a set for consistent
lift operation. Always replace anchor pins
when replacing chains.
Carriage 1. For example, measure a 305 mm (12 in) segment of

Shaft fork
the chain that does not roll over a sheave and count
the number of links in the segment.
• If fork hangers are excessively worn, replace the 2. Find an area of the chain that normally runs over the
forks as a set. sheave. This can usually be identified by wear on the
• If carriage fork bar is excessively worn, replace the plate edges that roll over the sheave.
carriage.
3. If the same number of links measures over 315 mm
IMPORTANT (12.36 in) the chain must be replaced.
Welding is not recommended for repairing If using a chain check ruler, see instructions on the ruler.
forks or carriage. Replace the worn parts Chain replacement procedures appear in Section 6.
with new parts.
Chain Length
Lift Chains IMPORTANT

Perform a chain length check and adjust-
The following checks should be performed every 50-250 ment every 50-250 hours. Checks and adjust-
hours to ensure correct chain performance See Section 6 ments should also be performed to adjust for
for more complete chain inspection and maintenance pro- chain stretch and tire wear.
cedures.

Group 34, Uprights
Chain length must be adjusted if: • Bent components indicate excessive loading or
high impacts to the weldments. Bent components
• The fork-to-ground clearance is less than 5 mm
are usually structurally damaged and should be
(.20 in) or more than 25 mm (1.0 in) when the
replaced.
upright is vertical.
• Inspect roller contact patterns on the rail sections.
• The center of the bottom carriage roller comes
Roller contact patterns should be smooth and regu-
within 20 mm (0.80 in) of the bottom edge of the
lar.
inner rail.
− In some applications, it may take up to 500
• The carriage safety stop hits the inner rail stop at hours of operation to develop a roller contact
full lift height. pattern on the flange of the rail.
• On TSUs, the difference between the bottom of the − In applications where heavy loads are common,
inner rail and the outer rail is greater than 10 mm a rail lubricant may be required to allow proper
(0.40 in). wear-in on the roller.
See Section 6 for chain length adjustment procedures. • Check rails and carriage for wear due to undesir-
Chain Tension able contact between components. Such contact
can be an indication of broken rollers, loose com-
IMPORTANT ponents, foreign objects or debris on the upright, or
Center any auxiliary attachments before a broken weldment.
beginning tension check − If contact or rubbing exists, the condition must
be corrected immediately.
1. Raise the upright enough to put tension on the chains − Rail and carriage weldments with damage
to be checked. should be replaced.
2. Push the chains forward and pull them backward; the • Tie bar areas should be free of foreign objects and
amount of tension should be equal on both sides. debris. The roller area of the rail should be cleaned
every 500-1000 hours in a normal application.
! − In applications where excessive amounts of
WARNING
contaminants settle in the rail channels, clean-
Do not reach through the upright to push ing may be required on 50-250 hour intervals.
chains for tension check. − If excessive contamination exists, the rollers
should be exposed and the bearing seal areas
3. If one chains moves more than the other; cleaned thoroughly.
a. Lower the forks to ease tension on the chains. See Section 4 for carriage roller and upright
b. Adjust chain adjustment nuts for equal tension on roller removal and installation.
both chains. See Section 6 for chain adjustment
procedures
Carriage and Upright Rollers
4. Repeat the tension test and make adjustments until
the tension is equal on both chains when the carriage Carriage Thrust Rollers
and upright are raised. The carriage uses two types of thrust rollers.
Carriage and Upright Weldments

The carriage and upright should be checked for fatigue
cracks and bent components every 2000 hours or every
year..Fatigue cracks start in areas of stress after a high
number of load cycles. Stress concentrations typically
exist in welded joints, in the area around a welded joint, or
in the corners of parts. Dye penetrant, magnaflux, or other
crack detection methods can be used to find or trace
cracks. If cracks are found in any structural weldment, the
component should be replaced before returning the truck
to service.

Group 34, Uprights
• The external thrust roller runs along the outside Carriage and Upright Main Load Rollers
flange of the inner rail to control lateral load on the Inspect the carriage and upright main load rollers for bro-
carriage. ken, loose, or rough bearings. Defective rollers should be
replaced.
Shoulder
Roller shaft
shims
Bearing outer race
External
thrust Indications of broken or damaged rollers include:
roller
Internal • Part of all of roller bearing missing
thrust
roller • Bearing outer race loose
• Scraping noise from the upright
Both types of thrust rollers should be checked for smooth
rotation, seal integrity, radial bearing tightness, and a tight • Scraping of carriage fork bar on inner rail (carriage
cap screw. A roller should turn smoothly without sticking rollers)
and be grit free. Replace the roller if any defect is found. • Upright rail sections scraping together (upright
rollers)
External thrust roller cap screws have a locking patch to
prevent the cap screw from backing out. Repeated • Upright misstaging
removal will deteriorate the ability of the patch to hold the • Excessive looseness of the rail section or carriage
cap screw. If the cap screw is backing out without holding, demonstrated by the following load test.
a new cap screw is recommended. The cap screw can also
be cleaned and set using thread locking compound Loctite NOTE
271 (Clark Part 1802302). The internal thrust rollers use a Some grease will purge from the bearings in
jam nut to ensure that the bearing remains secure. the first 100-200 hours of operation. This is
not necessarily a sign of a failed roller bear-
NOTE ing seal.
Some grease will purge from the bearings in
the first 100-200 hours of operation. This is Load Test
not necessarily a sign of a failed roller bear- A load test helps you to determine the amount of clear-
ing seal. ance between the moving upright parts. The upright
requires some lateral movement between the interlocking
The external thrust rollers are not adjustable. The internal rails and the carriage. But, too much or too little clearance
thrust roller adjusts using a locking cam on the mounting can be the cause of binding and uneven operation.
cap screw. See Section 4 for roller replacement and inter-
nal thrust roller adjustment procedures. ! WARNING
An upright or carriage can move unexpect-
edly during service procedures causing
severe injury:
any check or adjustment.
Keep your arms and fingers away from mov-
ing parts of the upright.
Do not reach through open areas of the
upright.

Group 34, Uprights
Failure to follow these warnings can result in Signs of loose shimming include:
serious injury.
1. Excessive lateral (side-to-side) movement in the
upright rail sections
1. Place a capacity load on the forks and secure it to the
carriage. 2. Excessive lateral shift in the upright at, or near, full
maximum fork height (MFH)
! CAUTION 3. Irregular roller patterns on the rail.
Test load must be stacked stably, not extend Signs of over shimming include:
beyond the pallet, and be secured on the pal-
let. Operate the truck only from within the 1. Mis-staging or hanging up of the upright
operator’s compartment. 2. Excessive wear in the rail web
2. Tilt the upright back slightly and raise the upright to 3. Premature bearing failure.
its maximum extension several times. Note the Perform the following roll pattern check and the load test
smoothness of operation, the carriage play, and play if the need for roller shimming is suspected. See Section 4
between the rails. for detailed clearance measurement procedures.
3. Move the load 102 mm (4 in) off center on the forks Roll Patterns
and resecure it to the carriage. Impressions made by rollers on upright rails are called roll
patterns. Roll patterns can provide indication of the need
4. Raise the upright to its maximum extension and for upright or carriage adjustment.
lower the load to the floor several times.
5. Repeat the step, moving the load 102 mm (4 in) off ! WARNING
center to the other side.
6. Raise the upright to its maximum extension and any checks or adjustments.
lower the load to the floor several times.
Carefully observe the smoothness of operation, particu- 1. Elevate the carriage about 4 feet (1.3 m).
larly in carriage play, and play between the rails. If any
2. Apply a light, thin layer of grease to the roller con-
unusual movement, staging, or noise occurs during the
tact area.
test, correct the problem before returning the truck to ser-
vice. Continue with the following roller shimming checks 3. Lower the forks and pick up a capacity load. Raise
if too much play is evident in the carriage and rails in the and lower the upright several times.
load test. The troubleshooting guide may also help to
4. Back out from the load and raise the carriage.
identify specific problems with upright operation.
Compare the impressions of the rollers on each side of the
Roller Side-Clearance upright rails. The impressions should look the same on
The carriage and upright rollers are shimmed between the both sides. Look for signs of metal scoring or gouging
inner race and the roller shaft shoulder to maintain mini- which can indicate excessive pressure caused by damaged
mal clearance between the side of the roller and the web or misadjusted rollers.
of the adjacent rail. Shim adjustments help accommodate
Carriage rollers, including side-thrust rollers, and all
manufacturing tolerances and wear in the upright rail sec-
upright rollers can be checked by examining roll patterns.
tions.
If irregular impressions result from the checks, perform
the “Lift Cylinder Shimming Check” and the “Load Test”
to further diagnose problems.
See Section 4 for procedures to measure clearances and
adjust carriage or upright rollers.

Group 34, Uprights
Cylinders 4. After cleaning the top of the gland and the barrel,
cycle the upright 5-10 times. If a ring of oil forms to
Use the Drift Test, presented under “Hydraulic Checks” run 3 mm (0.125 in) down the rod, the cylinder must
below, for additional diagnosis of cylinder condition. See be overhauled or replaced.
Section 5 for cylinder repair.
Internal Leakage on Primary Cylinder
External Leakage (All Cylinders)
To check for internal leakage on the primary cylinder:
To check for external leakage on the primary cylinder:
1. Lift the upright to maximum height then lower forks
1. Clean the top of the gland and rod to remove any completely.
buildup of debris.
2. Cycle the upright 5-10 times through the first 2/3
2. Check rod surface for defects or unusual wear. length of the primary stroke and lower forks com-
• Nicks, burrs, or other sharp defects can cause dam- pletely.
age to the seal and will lead to leaks. The rod
should be repaired or replaced. 3. Slowly lift the carriage 305-610 mm (1-2 ft) into the
secondary lift stage then lift to full extension.
• For piston-type cylinders, small blunt defects in the
top and midsection of the rod can be tolerated in 4. If the carriage does not lift to full height, the problem
this cylinder design. The high pressure sealing is is likely an internal leak and the cylinder should be
over the last several inches of stroke. This type of overhauled.
defect is acceptable if leakage is not evident.
5. If the carriage does lift to full height, but you still
3. Check for external leakage from the cylinder barrel, suspect an internal leak, repeat the procedure with a
gland O-rings and backup ring, and the rod seal. 40-70% capacity load.
NOTE
The primary cylinder normally has approxi-
mately 100 ml (3.4 oz) of hydraulic fluid on
the rod side of the piston as a pre-charge.
Use the Drift Test, presented under “Hydraulic Checks”

below, for additional diagnosis of cylinder condition. See
Section 5 for cylinder repair.
Internal Leakage on Piston-Type Lift and Secondary
Cylinders
To check for internal leakage in Standard lift and TSU
secondary cylinders:
1. Lift the upright to MFH then lower forks completely.
2. Cycle the upright 5-10 times through the first 2/3
length of the lift cylinder stroke and lower forks com-
pletely.
• The gland O-rings and backup ring are near-zero
leakage seals. If, after cleaning the gland and tube, 3. Lift the upright to full MFH.
oil accumulates to form a run, the O-rings and Watch for the lift cylinder to increase lift speed. If you see
backup ring should be replaced (see Section 5). an increase in lift speed, one or both of the lift cylinders
• External leakage from the barrel requires replace- have an internal leak and requires overhaul.
ment of the barrel.
If the upright does not increase lifting speed, but you still
NOTE suspect an internal leak, repeat the procedure with a
The seals are installed with lubricant and a capacity load. If the upright does not extend to full MFH,
trace amount will be in the gland/tube inter- the problem is likely an internal leak and the cylinder
face area. should be overhauled.

Group 34, Uprights
Lift Cylinder Shimming Upright Drift

The lift cylinders on both standard uprights and TSUs bot-
tom out at the end of the stroke to limit upright extension. Drift tests check cylinder, main valve, and hydraulic cir-
The upright has dual lift cylinders and the cylinders’ cuit integrity under load pressures. A load is held elevated
extension length must be equal. If not, “racking,” or side- for an extended period to determine how much the upright
to-side shifting, results. Rod extension length is made “drifts” (moves) over a specified time period. A tilt cylin-
equal by using shims under the rod end of the cylinder. To der drift test appears in Group 32, Section 2, “Tilt Cylin-
determine if shimming of the cylinders is required to pre- der Checks and Adjustments.”
vent racking, perform the following operational check:
! WARNING
! CAUTION An upright or carriage can move unexpect-
Make sure truck is parked on level surface edly during service procedures causing
with parking brake applied and wheels severe injury:
chocked; make sure overhead clearance is Do not walk or stand under raised forks.
adequate to extend upright to its full height. Keep clear of load and carriage when making
any check or adjustment.
1. Center the forks or attachments on the upright. Keep your arms and fingers away from mov-
ing parts of the upright.
2. Check for equal chain tension. Do not reach through open areas of the
3. Raise the upright from the retracted position to full upright.
lift height. Note the point when the lift cylinders Failure to follow these warnings can result in
reach the end of their stroke. serious injury.
• If the upright shifts right or left noticeably, shim-
1. Raise upright with the rated capacity and carriage to
ming is required.
its full extension and lower to a point halfway down
• Repeat the check three times before adding shims. from full extension with the upright substantially ver-
NOTE tical.
Offset or unbalanced loads and off-center 2. Shut off the truck. Apply the parking brake and
attachments can cause the upright to shift chock the wheels.
even with proper lift cylinder shimming.
3. With a pencil or chalk, make a mark across the rails
See Section 5 for lift cylinder shimming procedure. Rack- on one side of the upright.
ing adjustments for tilt cylinders appear in Group 32, Sec-
tion 2, “Tilt Cylinder Checks and Adjustments.”
Hydraulic Plumbing
Use the Lift Cylinder Shimming Check, the Load Test,
and the following Drift Test to check the performance of
the hydraulic system.
1. Check all fittings for leakage. Disassemble fittings
and inspect the seals. Replace seals as required. See
Group 40 for hydraulic fitting tightening procedures.
Mark upright
2. Check all hoses and tubes for wear and damage. rails here
a. Hoses or tubes with scrapes or kinks should be
replaced.
b. Hoses with outer cover wear exposing the rein- ! WARNING
forcement braiding should be replaced.
any checks or adjustments. Do not use the
upright to climb; use an approved platform.

Group 34, Uprights
4. Wait ten minutes and recheck the mark. Measure and Consider rebuilding the cylinders if the first two remedies
write down the distance the marks on the inner and in this list are not successful. See Section 5 for removal,
intermediate rails have drifted from the mark on the overhaul, and replacement procedures for primary and
outer rail. secondary cylinders.
5. If the rated load drift 50 mm (2 in) or more in the ten
minutes, read and follow the procedures presented in Trunnion Bearings
“Drift Causes and Remedies.”
To check the Upright mounting:
! CAUTION 1. Check for missing, broken, bent, or loose mounting
fasteners. Replace any damaged parts.
Test load must be stacked stably, not extend
beyond the pallet, and be secured on the pal- 2. Lift the upright 305-610 mm (1-2 ft) and tilt the
let. upright fully forward.
Drift Causes and Remedies

3. Check for sprical bearing or cap wear by inserting a
feeler gauge between the mount and the axle-mount-
If drift of 50 mm (2 in) or more is evident under the rated
ing bearing surface.
load, consider the following causes and remedies:
• The main hydraulic valve is misadjusted, worn, or
defective. Fluid is leaking past the valve and caus-
Grease nipple
ing the upright cylinders to drift. See Group 30 for
hydraulic valve troubleshooting and service.
• Upright hydraulic circuit hoses or fittings are leak-
ing. Check the circuit components and repair as
necessary. Spacer
• Cylinder piston seals are worn, damaged, or defec- Bearing
tive allowing fluid past the piston causing drift. Pin
• Primary cylinder or piston-type lift or secondary

cylinders have a check valve that allows oil to flow
back to the rod side of the cylinder. This check
valve may be clogged or defective. Inspect the
check valve for proper sealing and operation.

Group 34, Uprights
Section 4
Carriage and Upright Roller Clearance Checks and Shim

Adjustments
IMPORTANT
! WARNING
haul, make sure the correct repair parts and/ Use an approved safety platform to reach the
or kits are available. upper areas of the upright. Never use the
upright as a ladder.
! WARNING
Introduction
An upright or carriage can move unexpect-
edly: Standard upright assemblies have two lift roller sets
• Do not walk or stand under raised forks mounted on the rails, three lift roller sets mounted on the
• Kee clear of load and carriage when mak- carriage, and two external thrust roller set mounted on the
ing any check or adjustment carriage.
• Keep your arms and fingers away from
The triple-stage upright assemblies have four lift roller
moving parts of the upright.
sets mounted on the rails, three lift roller sets mounted on
• Block the carriage or upright when work-
the carriage, and thrust roller sets mounted on the car-
ing with the components in a raised posi-
riage. (see the “Roller Side Clearance Chart” on next
tion.
page.)
• Do not reach through open areas of the
upright. Each carriage and upright lift roller is nested within its
• Never attempt to move or align the rails adjacent rail set. The front “face” of the lift roller handles
by hand. Use a prybar. front-to-back friction and play between the nesting seg-
Failure to follow these warnings can result in ments of the upright assembly, the side “face” of the roller
serious injury. radius handles side-to-side friction and play. The rollers
SM 751, Oct ’06 Carriage and Copyrighted

Upright Roller Clearance Checks and Shim Adjustments • 34-4-1
Material
Group 34, Uprights
are canted (tilted) to allow the side face to bear properly tainty that the clearance is excessive, you perform the
on the web. checks given below.
Rail flange wear can cause excess play between the lift To correct excessive lift roller side clearance, you add
rollers and the rail flange. The only way to correct this is shims as described later in this Section. To correct internal
to install oversize rollers-only one size of which is avail- thrust roller clearance, you adjust thrust roller position as
able. If oversize rollers were fitted previously, the only described later in this Section.
remedy for excessive front-to-back play is to replace the
rail set. (carriage middle rollers are always standard-size
rollers; see “Oversize Rollers” later in this Section for
details on roller replacement.)
The gap between the roller “side” and the web of adjacent
rail set affects the side-to-side motion of the upright-
which should be as small as possible without causing the
sliding segments to bind. The same is true of the internal
thrust rollers.
You check the performance effect of the lift roller side
clearance and internal thrust roller clearance by means of
the load test described in Section 3. To evaluate with cer-
Roller Side Clearance Chart
Roller Set #1 Carriage

Roller Set #2
Roller Set #3
Inner Rail Set
Roller Set #4
Roller Set #5
Intermediate Rail Set
(TSU only)
Roller Set #6
Roller Set #7
Outer Rail Set
Web Area Gap at Mimimumm Span of Rail Set Gap at Maximum Span of Rail Set
Roller Set# Forming Gap Targeta Allowedb Targeta Allowedb
(mm) (in) (mm) (in) (mm) (in) (mm) (in)
#1 Front, Inner railc 0.5-1.5 0.02-0.06 0.05-1.25 0.02-0.05 d d 2.25 0-0.09
#2 Front, Inner rail 0-0.75 0-0.03 0-1.5e 0-0.06 d d 2.25 0-0.09
#3 Back, Inner rail 0-0.75 0-0.03 0-1.0 0-0.04 d d 2.25 0-0.09
#4 Back, Inner rail 0-0.75 0-0.03 0-1.0 0-0.04 d d 2.25 0-0.09
#5 Back, Intermd rail 0-0.75 0-0.03 0-1.0 0-0.04 d d 2.25 0-0.09
#6 Back, Intermd rail 0-0.75 0-0.03 0-1.0 0-0.04 d d 2.25 0-0.09
#7 Back, Outer rail 0-0.75 0-0.03 0-1.0 0-0.04 d d 2.25 0-0.09
a. Target is the desired gap after reshimming the roller set. d. Ideal is same as final measured gap at minimum width point of rail set.
b. Allowed is the acceptable gap when checking roller set. e. Measured at top of inner rail.
c. Internal side thrust rollers should extend 0.25-0.50mm(0.01-0.02 in)
beyond #1 rollers.
34-4-2 • Carriage and Upright Roller ClearanceCopyrighted

Checks and Shim Adjustments
Material SM 751, Oct ’06
Group 34, Uprights
Roller Side Clearance Checks 2. Position the carriage or rails so that the roller set you
want to check is at the mark for the narrowest span
The same basic procedure is used for checking all the lift on the adjacent nesting rail set.
rollers. That general procedure is given in the subsection
directly below. Special instructions for specific rollers fol-
low that subsection. Follow those directions (in the sub-
section called “Directions for Checking Specific Rollers”) Narrowest
span
and you will be directed to general and specific informa-
tion you need.
General Roller Side Clearance Checking Widest

Procedure span
For each roller set, you need to measure the gap between
the outside face of a roller and its adjacent nesting rail. In
general, the lift roller side clearance check procedure is as Example of Aligning Roller Set with Widest and
follows: Narrowest Spans Marked on Adjacent Rail Set.
Rail sets are shown separated for clarity.
1. With the spanner tool, find and mark the narrowest
and widest spans in each rail set at the roller-contact 3. Clamp the rails together opposite the roller you
areas in the rail webs: intend to check. Use wooden shim blocks to protect
• Inner Rail Set-Mark narrowest and widest spans the rails. Place clamp as close to roller as possible.
for both the front and back web areas. Torque clamp to 25 N⋅m (20 ft-lb).
• Outer and Intermediate Rail Sets-Mark narrowest
and widest spans for the back web area only.
Back
Area
Web 4. Measure the gap with a feeler gauge. Make sure

roller is tight against its shoulder. Write down the
result.
Front
Area
Web Areas on Typical Rail Set

Gap
Measure
here.
5. Repeats steps 2 through 4 for the widest span marked

on the rail set.
Spanner Tool. Clark Part #180109

Material
Group 34, Uprights
6. If the clearance at the widest rail set span is more Top Carriage Rollers and Internal Thrust Rollers
than 2.25 mm (0.09 in), the roller set needs shim-
1. Move the top carriage lift roller to the narrowest span
ming.
on the inner rails set.
If the clearance at the narrowest rail set span is more
than 1.0 mm (0.04 in), the roller set should be 2. Clamp rail to one side as in general procedures.
shimmed; however, it is OK for the middle carriage Check clearance of lift roller on clamped side.
roller gap to be up to 1.5 mm (0.06 in).
7. Repeat entire procedure for each roller set, following Measure gap here Measure gap here
(step2). (step3).
the instructions in “Directions for Checking Specific
Rollers” below.
Directions for Checking Specific Rollers

Use these directions to supplement the general procedures
given above.
Carriage Rollers
Bottom Carriage Rollers
Follow the general procedure above.
Middle Carriage Rollers Contact the web and cause the lift roller to stand off
The middle rollers are difficult to access and require the from the web by .01 to 1 mm (0.001-0.03 in).
following special procedures.
3. Check clearance on lift roller opposite clamped side
1. Raise the carriage until the middle rollers are at the as in the general procedures. If clearance is greater
top of the inner rails. than 1.25 mm (0.05 in), the roller set should be
shimmed.
2. Measure roller side clearance at the top of the inner
rails. Note measurement here: 4. Move clamp to opposite side and check clearance on
_____________________. clamped side as in step 2 directly above. Gap should
If gap is less than 1.5 mm (0.06 in), shimming is not be 0.01-1.0 mm (0.001-0.03 in).
required.
5. Move the top carriage lift roller to the widest span on
If gap is more than 1.5 mm (0.06 in), check clearance
the inner rail set and check clearance as in general
at narrowest span by comparison with the top of the
procedures.
rail set as follows:
Upright Rollers
a. With spanner tool, measure span of inner rail set
at top of the front web area. Note measurement 1. Remove the carriage as described in Section 7 of this
here: _____________________. Group.
b. With spanner tool, measure span of inner rail set
2. Fully extend the upright making sure carriage hoses
at narrowest span of front web area. Note mea-
and chains are secured out of the way to prevent
surement here: _____________________.
damage.
c. Subtract measurement in step b from measure-
ment in step a, Write result here: ! WARNING
b-a= _____________________.
If the calculated gap is less than or equal to the An upright or carriage can move unexpect-
gap measured in step 2, the roller set does not edly:
require shimming. Otherwise, the roller set • Do not walk or stand under raised forks
should be shimmed. • Keep clear of load and carriage when
making any check or adjustment
upright.

Group 34, Uprights
• Never attempt to move or align the rails Oversize Rollers

by hand. Use a prybar.
• Use an approved safety platform to reach At the time of roller shimming, you may
the upper areas of the upright. Never use want to replace the lift rollers with oversize
the upright as a ladder. rollers to counter rail flange wear as
Failure to follow these warnings can result in detected by inspection and the load test.
serious injury. Because there is only one size of oversize
rollers, you can install them only if they
3. Follow the “General Roller Side Clearance Checking were not installed previously.
Procedure” given earlier in this Section.
The clamping procedure is as illustrated below. Identify oversize rollers as follows: If a
roller is oversize, it has an indented radius
in the outer edge of its mounting side, as
shown below.
Lift Roller Shimming

You need to shim lift rollers if the roller side clearance
checks indicated that clearance was excessive at either the
narrowest or widest span of the roller set’s adjacent rail
set.
Your objective in shimming is to add only enough shims
to bring the clearances at both the widest and narrowest
spans into tolerances. In practice, you achieve this by
shimming to obtain the smallest possible clearance at the
narrowest span of the rail set.
Carriage Roller Shimming

Using the measurement you recorded in previously in the
“Roller Side Clearance Checks,” determine the number of
shims required to reduce the carriage roller clearance at
the narrowest span on the inner rail to 0-0.75 mm (0-0.03
in):
1. Remove the carriage as described in Section 8, “Fork
and Carriage Removal and Replacement.”
2. Remove the rollers (note the number of shims
already on the roller shafts, if any).
• Clean and inspect roller bearings, shims, and

shafts.
• Replace any defective parts.

Material
Group 34, Uprights
3. Add shims to the top and bottom rollers as deter- Upright Roller Removal
mined in the previous steps. 1. After the carriage has been removed, lower the
• Install shims with the same number on each side. upright rails until both of the secondary (final) lift
• When an odd number of shims is required, always cylinders are completely collapsed.
place the odd shim on the same side on all roller 2. Jack the truck and block under the frame so that the
sets. bottom of the upright is approximately 254 mm (10
4. Use a straight bar to determine the number of shims in) off the floor. See “Lifting, Jacking, and Blocking”
to add to the middle roller shaft as shown in the fol- in Group SA for safe procedures.
lowing illustration. This shimming may be asymmet- 3. Set the parking brake and block the steer wheels.
ric, meaning the numbers of shims do not have to 4. Tilt the upright to as near vertical as possible.
match those of the top and bottom rollers.
5. Using a hoist and lifting strap of adequate capacities,
connect the lifting strap to the inner rail on standard
and Hi-LO uprights or intermediate rails on triple-
stage uprights. Lift hoist to remove slack from the
-0.25 to +0.25 mm strap.
(-0.01 to +0.01 in) gap
5. Reinstall all bearings; torque top roller fasteners to

40-45 N⋅m (30-33 in-lb).
6. Disconnect the flow control valve manifold from the
Carriage internal thrust rollers must be adjusted after the upright bracket.
carriage is shimmed. Adjust as described previously.
Upright Roller Shimming

Use the following procedures to remove, shim, and
replace rollers. Use the preceding checks to determine the
number of shims required to reduce the roller clearances
to 0.75 mm (0.03 in) or less.
! WARNING
Use an approved safety platform. Never use
the upright as a ladder.
! CAUTION
The carriage should be removed for shim-
ming or when any service is performed on the
upright. See Section 8, for removal and
replacement procedures.

Group 34, Uprights
7. Secure the cylinder to prevent its falling and discon- Roller Removal, Shimming, and Replacement
nect the cylinder rod retaining bolts. To add shims to, or replace the rollers:
1. Use a puller to remove the rollers from the posts. Or,
gently pry the rollers off the posts. Pry at different
points around the bearing to work it off. Do not dam-
age the bearing seals on the backside of the roller.
2. Inspect all roller components when removed:
NOTE
For 4-hose adapters, you must disconnect the
hose sheave and bracket. This is not neces-
sary for 2-hose adapters.
a. Clean and inspect the rollers, shims, and roller
8. Move the sheave with the hoses and any other con-
shafts.
nected components out of the way.
b. Bearings should be in good condition and allow
9. Disconnect the rail cylinders by raising the rails to the roller to spin smoothly with a true rotation.
free the cylinder rod ends from the tie bar. Tilt the c. Clean rail sections and add lubricant if necessary.
cylinders inward and secure out of the way of the tie d. Replace any worn or damaged component.
bars.
3. If the clearance check indicated an even number of
10. Lower the assembly completely to expose the rollers. shims needed, split the number evenly between the
rollers on either side of the upright.
The lower roller set of the inner rail and upper roller set of
the outer rail on standard and triple-stage uprights are now 4. If the clearance check indicated an odd number of
exposed for shim adjustment. shims needed, keep the odd number to the same side
on all rails of the upright. If three shims are needed,
for example, add one to the rollers on the left side.
Add the other two on the rollers on the right side.
5. Reposition the rollers onto the roller shaft and use a
plastic or hard-rubber mallet to gently tap the roller.
Seat the roller evenly by continuing to tap gently
until it is fully seated and snug against the added
shims.

Material
Group 34, Uprights
Upright Reassembly 3. Reconnect the cylinder rod retaining bolts. Torque

The following steps detail the procedures for reassem- rod retaining bolts to 40-45 N⋅m (30-33 ft-lb).
bling the upright.
! WARNING
The upright can move unexpectedly:
upright.
• Never attempt to move or align the rails
by hand. Use a prybar.
Failure to follow these warnings can result in
serious injury.
4. Reconnect the load lowering flow valve to the
1. Connect the lifting strap to the inner rail on standard upright bracket. Torque nuts to 20-25 N⋅m (14.8-18.5
uprights or intermediate rails on triple-stage uprights ft-lb).
and raise the rails just high enough to clear the lift
cylinders. Use a prybar to guide the rails and allow
the rollers to reenter the rail channel.
5. Jack up the truck only enough to remove the blocking

and slowly lower the truck so that its full weight is on
the floor.
6. Replace the carriage and forks.
7. Test the upright lift and tilt functions; make sure all
2. Reposition the rail cylinders and slowly and carefully
upright components work correctly and smoothly.
lower the rails to seat the rod end into the mounting.
Check for overshimming as described in the next
subsection. Repeat the load test to make sure the
upright works correctly under load. When you are
sure all components are operating correctly, perform
the chain adjustment checks in Section 3 before
returning the truck to service.

Group 34, Uprights
Overshimming
Use these steps to check for overshimming:
1. With the forks removed, lift the upright to maximum
fork height.
2. Slowly lower the upright.
• The carriage should not bind or hang up at any
point along the rails.
• If the carriage binds or hangs up, and the rails are
not clogged with grease or debris, the carriage
requires reshimming. See “Troubleshooting” for
other mis-staging problems.

Material
NOTE :

Group 34, Uprights
Section 5
Cylinder Removal, Shimming, Overhaul, and Replacement
Cylinder Types 2. Attach a hoisting strap to the tie bar of the inner rail
or intermediate rail tie bar of TSUs.
Standard uprights use two lift cylinders. Triple stage
uprights use four cylinders, two primary cylinders, and
two secondary cylinders. All primary cylinders used on
triple-stage uprights (TSUs) are piston cylinders. The lift
and secondary cylinders used on standard, TSUs are either
piston cylinders.
IMPORTANT
haul, make sure the correct repair parts,
seals, and gasket sets are available.
Upright Upright
Type Number Cylinder Type ! CAUTION
<C60-70>
Standard pneu V6704 Piston-Type Lift Cylinder Make sure hoisting equipment is of adequate
TSU pneu M6704 Piston-Type Secondary Cylin- capacity and in good working order.
der
<C80> 3. Remove the cylinder rod retaining bolt.
Standard pneu V8001 Piston-Type Lift Cylinder
TSU pneu M8001 Piston-Type Secondary Cylin-
der
! CAUTION
To remove, or partially remove, the cylinders
from the upright for shimming or overhaul,
start with the truck in a safe position:
• Ignition off
• Parking brake applied
• Directional lever in neutral 4. Slowly lift the inner (or intermediate) rails off the top
• Forks lowered completely of the cylinder to expose the cylinder rod top.
• Wheels blocked.
! CAUTION
Block rail in up position.
Lift Cylinder Shimming Procedure
To shim the lift cylinders to correct unequal cylinder 5. Insert shim(s) over rod end of cylinder with the
stroke: shorter stroke to compensate for unequal stroke
length.
1. Fully lower upright until both lift cylinders are col-
lapsed. 6. Slowly lower the inner or intermediate rail back onto
the rod ends.
SM 751, Oct ’06 Cylinder Removal,

Copyrighted Shimming, Overhaul, and Replacement • 34-5-1
Material
Group 34, Uprights
4. Remove the pins, draw the chain through the sheave,

! WARNING and drape the chain over the carriage.
Do not try to maneuver the cylinder or rails
with your hands. Use a prybar.
7. Replace cylinder rod retaining bolt to secure rod end

into inner or intermediate rail mounting hole. Torque
the cylinder rod retaining bolts to 40-45 N⋅m (30-33
ft-lb).
8. Repeat the racking test and adjustment until no rack-
ing is evident during upright lift extension.
9. Check all upright functions before returning the truck
to service.
5. Remove the snap ring holding the chain sheave (and
hose bracket, if equipped) on the rod end and move
Primary Cylinder Removal and assembly off top of rod.
Replacement (TSU)
Remove the primary cylinder for replacement only. Cylin- Snap ring
der can be overhauled without removing it from the
upright. See “Cylinder Overhaul” for procedures.
1. Make sure the cylinder is completely collapsed and
pressure is released.
2. Disconnect and cap the hydraulic line at the base of
the cylinder.
Primary
cylinder
6. Disconnect cylinder mounting bolts and cylinder

base mounting bolts.
To load lowering
flow valve
3. Remove and discard cotter pins from chain anchor

bolt pins on the cylinder.
Use these steps in reverse to replace the cylinder. Check

Group 40 for hydraulic fitting tightening procedures.
34-5-2 • Cylinder Removal, Shimming, Overhaul, and Replacement

G ro u p 3 4 , U p r ig h ts
Lift and Secondary Cylinder & Hi-Lo uprights and inner and intermediate rails on
triple-stage uprights.
Removal and Replacement
Only piston-type lift and secondary cylinders must be
removed from the upright for overhaul. The cylinder gland
and rod can be removed for overhaul while leaving the
cylinder tube mounted on the truck.
1. Make sure the cylinders are completely collapsed and
pressure is released.
2. Tilt the upright to as near vertical as possible.
lift the carriage to access the hydraulic lines at the
base of the cylinders.
7. Disconnect the cylinder rod retaining bolts.
! CAUTION
Make sure hoisting equipment is of adequate
capacity and in good working order.
4. Disconnect and cap the hydraulic line from the base

of each cylinder. Remove the mounting bolts from
the manifold block.
8. Remove the cylinders by raising the inner rail (and

intermediate rail on the triple stage upright) to free
the cylinder rod ends from the tie bar.
9. Remove any shims and note number and location.
10. Lift the cylinders off the base mount.
Use these steps in reverse to replace the cylinders. Torque
the cylinder rod retaining bolts to 40-45 N⋅m (30-33 ft-lb).
5. Lower the carriage
Cylinder Overhaul
connect the lifting strap to the inner rail on standard Use these steps to overhaul the primary and lift and sec-
ondary (TSU) cylinders.
NOTE
During overhaul, set rod or cylinder on a
work bench with adequate support for safe
and convenient disassembly. Two sets of 4x4
in (100x100 mm) “V”-notched blocks are
helpful; one set for the cylinder barrel and
one set for the piston rod. The blocks prevent
nicks and scratches from harming the piston
or rod.

Material
Group 34, Uprights
Cylinder Disassembly a. Remove the check valve from the piston for
inspection and cleaning by removing the snap
• To overhaul the primary cylinder, it is not neces- ring from the piston bore.
sary to remove the cylinder from the upright.
Instead, free the rod end of the cylinder as
explained in “Cylinder Removal.”
• To overhaul piston-type cylinders, you should
remove the cylinders from the upright as explained
in “Cylinder Removal.” The cylinders have seals
on the piston, and the rods must be removed for
seal replacement.
Check Valve. Arrow shows direction of flow
1. Clean the rod-end and gland thoroughly to prevent
contamination from falling into the cylinder during b. Use a blunt hook to pop the check valve out.
disassembly. IMPORTANT
2. With a blunt punch or chisel, bend the lock ring out Use extreme care that you do not make nicks
of the locking grooves of the gland. and burrs on the interior surface area of the
cap or cylinder or the piston.
3. Use a spanner wrench to remove the gland. Reuse the
lock ring if undamaged.
Parts Inspection and Service
4. Carefully lift the rod out of the cylinder and place in
a clean area. 1. Clean all parts completely in a suitable solvent. Dry
all parts with a soft clean cloth.
5. Inspect the tube and tube end for damage and cover
the cylinder tube end to prevent contamination. 2. Inspect cylinder barrel and bore for cracks, pining,
scoring, or other irregularities that may require
6. Remove all rings and seals from the piston and the
replacement of the barrel.
gland.
Dust Wiper 3. Inspect the piston and rod for nicks, scratches, scor-
ing, or other defects that may demand new parts.
Wear Ring
4. Check all gland and piston seal grooves for nicks,
Rod(U-cup) burrs, and scratches that can damage seals during
Seal Rod reinstallation.
Gland Piston 5. Inspect and clean the check valves.
Wear Ring 6. Inspect all seals, including the check valve O-ring.
Piston Seal
NOTE
O-Ring Wear Ring Minute imperfections inside the cylinder bar-
O-Ring Check Valve rel or on the piston or rod may be improved
for acceptable use by careful honing. How-
O-Ring
Spacer ever, removal of material that produces a
Washer notch, groove, or out-of-roundness may cause
Rod Snap Ring excessive leakage during operation and a
shortened life.
7. For piston-type cylinders: 7. Use new parts as necessary. Always use the Packing
Kit listed in the parts manual. New kits include all
the seals, wiper rings, wear rings and O-rings neces-
sary for the particular cylinder.

Group 34, Uprights
Cylinder Reassembly the piston. Install the cylinder seal from the top of
the rod.
Take care when installing these parts to make sure that no
parts are damaged.
Cylinder Seal
1. Coat all packing, seals and rings in clean, hydraulic Back-Up Ring
oil (Clark part number 1800236 qt., 1802155 gal.) Spacer Wear Ring
prior to reassembly. Coat the inside of the gland nut
bore with hydraulic oil.
2. Replace the U-cup seal (groove toward bottom of
cylinder), rod wiper, and O-ring and back-up seals on
the gland.
4. For protection against corrosion, lubricate spacers
(where used) with petroleum-based hydraulic fluid.
O-Ring and
Back-Up Seal O-Ring Slide the spacer onto the rod.
5. Insert the piston and rod into the cylinder. Be careful
not to scratch or damage the cylinder gland nut
Rod U-Cup Seal
Rod Wiper threads.
6. For primary cylinders, add 3.4 oz (100 ml) of hydrau-
lic oil into the cylinder on the rod side of the piston.
NOTE 7. Install the lock ring onto the gland. Lubricate cylin-
der threads and screw gland onto cylinder. Be careful
O-rings should be carefully installed to elimi-
not to damage gland seal. Make sure the gland is
nate cuts or twisting.
fully seated on the cylinder barrel. Deform the lock
ring into slots in the tube and the gland.
3. Replace the piston seals:
a. Primary cylinder pistons require a piston seal and 8. Check the assembly by making sure the piston slides
wear ring. Install the piston seal from the top of freely in and out of the cylinder.
the rod. Use a ring compressor to compress the
9. Tighten the gland nut:
piston seal. This prevents damage to the seal dur-
ing reassembly. • On primary cylinders, tighten the gland nut to 706
N⋅m (517 ft-lb).
Piston Seal • On lift and secondary cylinders, tighten the gland
Check Valve Wear Ring nut to 706 N⋅m (517 ft-lb).
O-Ring
b. Piston-type lift and secondary cylinder require a

cylinder seal, a back-up ring, and a wear ring on

Material
Group 34, Uprights
This competes the cylinder repair procedure. Replace the for correct carriage and rail position. When all adjust-
cylinders as described in “Cylinder Removal and Replace- ments are completed, return the truck to service.
ment.” Complete the chain length adjustment in Section 3
Dust Wiper
Wear Ring
Rod(U-cup)
Dust Wiper Seal
Rod(U-cup) Gland
Seal
Wear Ring Wear Ring
Gland
O-Ring
Wear Ring Back-Up Ring
O-Ring
O-Ring O-Ring
Spacer Spacer
Back-Up Ring
Rod
O-Ring
Rod
Barrel
Barrel
Piston Piston
Back-Up Ring
Piston Seal
Piston Seal
Wear Ring
Wear Ring
Check Valve
O-Ring Check Valve
O-Ring
Washer
Snap Ring Washer
Snap Ring
Typical Piston-Type Standard Upright Lift and TSU Triple-Stage Upright Primary Cylinder
Secondary Cylinder

Group 34, Uprights
Section 6
Upright Chain Inspection, Adjustment, and Replacement
Chain Configuration-Standard Uprights
SM 751, Oct ’06 Upright ChainMaterial

Copyrighted Inspection, Adjustment, and Replacement • 34-6-1
Group 34, Uprights
Chain Configuration-Triple Stage Uprights
34-6-2 • Upright Chain Inspection, Adjustment, and Replacement

Group 34, Uprights
Periodic Inspections in this condition, a pin, or series of pins, can begin to twist
out of a chain resulting in failure. The pin head rivets
Each 50-250 hours of operation (more frequently in severe should be examined to determine if the "VEE" flats are
or extreme environments), chains should be inspected and still in correct alignment. Chain with rotated/displaced
lubricated. Inspection should focus on the following: heads or abnormal pin protrusion should be replaced
immediately. Do not attempt to repair the chain by weld-
Elongation ing or driving the pin(s) back into the chain. Once the
press fit integrity between outside plates and pins has been
When a length of 12.00 inches (305 mm) of new chain has altered, it cannot be restored. Any wear pattern on the pin
elongated to a length of 12.360 inches (315 mm), it should heads or the sides of the link plates indicates misalign-
be discarded and replaced. It is important to measure the ment in the system. This condition damages the chain and
chain in the section that moves over the sheaves because it increases frictional loading, and should be corrected.
receives the most frequent articulation. Measuring the
chain near its clevis terminals could give an erroneous
reading as it would not have flexed as frequently, if indeed
at all, as nearer the middle of the assembly.
Turned pins and abnormal pin protrusion.
Chains should be replaced when wear exceeds 3% or Cracked Plates

when 12 inches (305 mm) of chain is stretched 3/8 inch
(10 mm). The chains should periodically be inspected very care-
fully, front and back as well as side to side, for any evi-
dence of cracked plates. If any one crack is discovered, the
Edge Wear chain(s) should be replaced. It is important, however, to
determine the causes of the crack before installing new
Check the chain for wear on the link plate edges caused by
chain so the condition does not repeat itself.
running back and forth over the sheave. The maximum
reduction of material should not exceed 5%. This can be • Fatigue Cracking - Fatigue cracks are a result of
compared to a normal link plate height by measuring a repeated cyclic loading beyond the chain's endur-
portion of chain that does not run over the sheave. Dis- ance limit. The magnitude of the load and fre-
torted or battered plates on leaf chain can cause tight quency of its occurrence are factors which
joints and prevent flexing. determine when fatigue failure will occur. The
loading can be continuous or intermittent (impulse
load).
Worn contours and worn surfaces on the outside links or

pin heads should not exceed 5% of new link height. Fatigue cracks generally run from the pin hole toward the
edge of the link plate approximately 90o from the line of
Turning or Protruding Pins pull.
Highly loaded chain operating with inadequate lubrication Fatigue cracks almost always start at the link plate
can generate abnormal frictional forces between pin and pin hole (point of highest stress) and are perpendic-
link plates. In extreme instances, the torque could surpass ular to the chain pitch line. They are often micro-
the press fit force between the pins and the outside plates, scopic in their early stage. Unlike a pure tensile
resulting in pin rotation. When chain is allowed to operate failure, there is no noticeable yielding (stretch) of
the material.

Group 34, Uprights
• Stress - Corrosion Cracking - The outside link Ultimate Strength Failure

plates, which are heavily press fitted to the pins,
are particularly susceptible to stress corrosion This type of failure is caused by overloads far in excess of
cracking. Like fatigue cracks, these initiate at the the design load.
point of highest stress (pin hole) but tend to extend
in an arc-like path between the holes in the pin
plate.
Broken plate caused by overload.
Arc-like cracks in plates are a sign of stress corrosion. Tight Joints

More than one crack can often appear on a link All joints in leaf chain should flex freely. Tight joints
plate. In addition to rusting, this condition can be resist flexure and increase internal friction, thus increasing
caused by exposure to an acidic or caustic medium chain tension required to lift a given load. Increased ten-
or atmosphere. sion accelerates wear and fatigue problems.
Stress corrosion is an environmentally assisted fail-
ure. Two conditions must be present: a corrosive
agent and static stress. In the chain, static stress is
present at the pin hole due to the press fit pin. No
cyclic motion is required, and the plates can crack
during idle periods. The reactions of many chemi-
If lubrication does not loosen a tight joint, the chain may
cal agents (such as battery acid fumes) with hard-
have corrosion and rust problems or bent pins and must
ened steel can liberate hydrogen which attacks and
be replaced.
weakens the steel grain structure.
See Section 3 for detailed chain stretch, length, and ten-
For this same reason, never attempt to electroplate
sions checks.
a leaf chain or its components. The plating process
liberates hydrogen, and hydrogen embrittlement
cracks will appear. These are similar in appearance Chain Length Adjustments
to stress corrosion cracks.
If a plated chain is required, consult Clark. Plated ! WARNING
chains are assembled from modified, individually An upright or carriage can move unexpect-
plated components which may reduce the chain edly:
rating.
• Do not walk or stand under raised forks
• Corrosion Fatigue - Corrosion fatigue cracks are • Keep clear of load and carriage when mak-
very similar (in many cases identical) to normal ing any check or adjustment
fatigue cracks in appearance. They generally begin
at the pin hole and move perpendicular (90°) to the
chain pitch line.
Corrosion fatigue is not the same as stress corro- • Block the carriage or upright when work-
sion. Corrosion fatigue is the combined action of ing with the components in a raised posi-
an aggressive environment and a cyclic stress (not tion.
a static stress alone, as in stress corrosion). • Do not reach through open areas of the
upright.
• Never attempt to move or align the rails by
hand. Use a prybar.
serious injury.

Group 34, Uprights
Standard Upright Chain Length Adjustment inner rail. Distance should not be less than 20 mm
(0.80 in) or chain length adjustment is required.
To adjust chain length on the standard upright use the fol-
lowing illustration and procedures: 3. Carriage stop-to-upright:
a. Lift upright to its full height and check for clear-
ance on the carriage safety stop.
b. If the carriage stop hits the upright stop, adjust
the chain anchor adjustment nuts out until there is
at least 3 mm (0.12 in) clearance between the
stops.
IMPORTANT
The carriage stop must not be allowed to con-
tact the upright stop under any circumstance
Adjust chain
length here during normal operations.
To carriage
If all three chain length requirements listed above cannot
1. Fork-to-ground clearance: be met, the tire diameter may be out of the design range
a. Set the upright to vertical position. allowance. Also, excessive tire wear will decrease carriage
b. Break the jam nuts loose on the chain anchors. stop clearance.
Oversized tires will reduce the bottom carriage roller
engagement on the inner rail when the carriage is in the
lowered position. The fork-to-ground clearance can devi-
ate from the 10-20 mm (0.40-0.80 in) allowance by a
small amount if necessary to maintain the safe 20 mm
(0.80 in) clearance of the bottom carriage roller to the
lower edge of the inner rail.
Adjustment Nut
Jam Nut Triple-Stage Upright Chain Length
c. Turn the chain adjustment nuts until clearance Adjustments
between forks and ground is 10-20 mm (0.40- Triple-stage uprights use two chain sets; one set for car-
0.80 in). riage lift and one set for rail lift. Adjustment anchors for
IMPORTANT the lift cylinder stage are located at the back of the outer
For all chain anchor adjustments: rail. Adjustment anchors for the primary lift stage are
• Threaded chain anchors must be left free to behind the primary cylinder. Carriage chain anchors are
pivot in mounting hole. not intended for adjustment.
• Anchor cotter pin heads must be to the For TSU inner rail lift chains, chain length must be
inside of the upright. adjusted if the difference between the bottom of the inner
• Torque jam nuts to adjustment nuts to 340- rail and the outer rail is greater than 10 mm (0.40 in).
380 N⋅m (249-279 ft-lb).
For the TSU primary cylinders lift chain, the chain length
• Make sure chain anchors are secured so
must be adjusted if:
that no twist is evident in the chains.
2. Carriage roller position: • The fork-to-ground clearance is less than 5 mm
a. Raise carriage about 1 m (3.2 ft) and smear a (0.20 in) or more than 25 mm (1.0 in) when the
bead of grease on the bottom 75 mm (3 in) inner upright is vertical.
rail in the area of the roller pattern. • The center of the bottom carriage roller comes
b. Tilt upright fully back and completely lower. within 20 mm (.80 in) of the bottom edge of the
c. Raise carriage about 1 m (3.2 ft) and measure the inner rail.
distance from where the center of the bottom car- • The carriage safety stop hits the inner rail stop at
riage roller stopped to the bottom edge of the full lift height.

Group 34, Uprights
To adjust the cylinder lift chains on a TSU use the follow- IMPORTANT
ing illustration and procedures: For all chain anchor adjustments:
• Threaded chain anchors must be left free to
pivot in mounting hole.
• Anchor cotter pin heads must be to the
inside of the upright.
• Torque jam nuts to adjustment nuts to 340-
380 N⋅m (249-279 ft-lb).
Adjust chain • Make sure chain anchors are secured so
length here
that no twist is evident in the chains.
To Inner Rail
2. Carriage roller position:
a. Raise carriage about 1 m (3.2 ft) and smear a
bead of grease on the bottom 75 mm (3 in) of the
1. Set the upright in the vertical position. inner rail in the area of the roller pattern.
b. Tilt upright fully back and completely lower.
2. Break the jam nuts loose on the chain anchors. c. Raise carriage again about 1 m (3.2 ft) and mea-
3. Adjust the chain anchor adjustment nuts until the sure the distance from where the center of the
bottom of the inner rail is within 2.5 mm (0.10 in) of bottom carriage roller stopped to the bottom edge
the bottom of the outer rail. of the inner rail. Distance should not be less than
To adjust the primary cylinder lift chain on TSU use the 20 mm (0.80 in) or chain length adjustment is
following illustration and procedures: required.
3. Carriage stop-to-upright:
a. Lift upright to its full height and check for clear-
ance on the carriage safety stop.
b. If the carriage stop hits the upright stop, adjust
the chain anchor adjustment nuts out until there is
at least 3 mm (0.12 in) clearance between the
stops.
Adjust chain
length here IMPORTANT
The carriage stop must not be allowed to con-
tact the upright stop under any circumstance
To carriage during normal operations.
If all three chain length requirements listed above cannot

be met, the tire diameter may be out of the design range
1. Fork-to-ground clearance: allowance. Also, excessive tire wear will decrease carriage
a. Set the upright to vertical position. stop clearance.
b. Break the jam nuts loose on the chain anchors.
c. Turn the chain adjustment nuts until clearance Oversized tires will reduce the bottom carriage roller
between forks and ground is 10-20 mm (0.40- engagement on the inner rail when the carriage is in the
0.80 in). lowered position. The fork-to-ground clearance can devi-
ate from the 10-20 mm (0.40-0.80 in) allowance by a
small amount if necessary to maintain the safe 20 mm
(0.80 in) clearance of the bottom carriage roller to the
lower edge of the inner rail.

Group 34, Uprights
Chain Lubrication Failure to follow these warnings can result in

serious injury. See “Lifting, Jacking, and
Like all bearing surfaces, the precision-manufactured, Blocking” for safe blocking procedures.
hardened-steel, joint-wearing surfaces of leaf chain
require a film of oil between all mating parts to prevent
accelerated wear. General Guidelines
Maintaining a lubricant film on all chain surfaces will: • Chain Movement - Make sure that the chain oper-
ating path is clear and that the chain articulates
• Minimize joint wear. freely through its full range of operation.
• Improve corrosion resistance. • Lubrication - Assure that the chain is well lubri-
• Reduce the possibility of pin turning. cated with the heaviest oil that will penetrate the
• Minimize tight joints. void between the link plate apertures and the pins.
• Promote smooth, quiet chain action. • Paint - Make sure the chain does not get painted
over at any time.
• Lower chain tension by reducing internal friction
in the chain system. • Protection - Where necessary, as a protection from
atmosphere or sliding wear, the chain may be cov-
Laboratory wear tests show #40 oil to have greater ability ered with a layer of grease. It should be noted,
to prevent wear than #10 oil. Generally, the heaviest however, that the grease will have to be removed at
(highest viscosity) oil that will penetrate the joint is best. a later date for chain inspection and relubrication.
Whatever method is used, the oil must penetrate the chain • Chain Mountings - Double check to be sure all
joint to prevent wear. Applying oil to external surfaces chain fastening devices are secured and all adjust-
will prevent rust, but oil must flow into the live bearing ments have been made to assure uniform loading
surfaces for maximum wear life. of multiple chain applications. Check chain
To prepare the chain for oiling, the leaf chain plates anchors and pins for wear, breakage, and misalign-
should be brushed with a stiff brush or wire brush to clear ment. Damaged anchors and pins should be
the space between the plates so that oil may penetrate the replaced.
live bearing area. • Sheaves - Sheaves with badly worn flanges and
outside diameter should be replaced. This wear
Oil may be applied with a narrow paint brush or directly may be due to chain misalignment or frozen bear-
poured on. Chain should be well flooded to be sure the oil ings.
penetrates the joint.
In locations difficult to reach, it may be necessary to use a Lift Chains (Standard and TSUs)
good quality oil under pressure such as an aerosol can or
pump pressure spray. To remove and replace the lift cylinder and/or carriage
chain set on standard and triple-stage uprights (TSU):
Chain Removal and Replacement 1. Attach a hoist strap on the carriage of the standard
upright or inner rail of the TSU.
! WARNING 2. Lift the carriage or inner rail slightly to create slack
The procedures for removing and replacing in the chains. Block the carriage or inner rail up for
chain sets involve hoisting and blocking com- safety.
ponents.
• Do not walk or stand under raised forks.
upright.

Group 34, Uprights
3. Remove the chain anchor pins on the outer rail and chains. The carriage may also be lifted and blocked
pull the chains off of the sheaves on the inner or in position and the primary cylinder completely col-
intermediate rails. lapsed to create slack in the chains.
2. Remove the chain anchor pins from the back of the
primary cylinder. Pull the chains through the chain
sheave and lay over the carriage load backrest.
4. Remove the chain anchor pins from the carriage on

the standard upright or the inner rail on the TSU. On
the TSU, the inner rails must be lowered to the floor
to access the chain anchor pins.
3. Remove the chain anchor pins from the back of the

carriage.
Lift Chain Removal from Carriage (standard upright)
4. Use these steps in reverse to replace the primary cyl-

inder/carriage chain.
Lower rail to floor
Perform the chain length adjustment and chain tension
check before returning the truck to service.
Triple-Stage Upright Lift Chain Removal from Inner Rail
NOTE Other Chain Service Notes
If a hose adapter assembly is used, the chain
sheaves must be loosened and removed to • Use lengths of factory assembled chain. Do not
prevent the hoses from stretching when the build lengths from individual components.
inner rails of the TSU are lowered to access • Do not attempt to rework damaged chains by
the chain anchor pins. replacing only the components obviously faulty.
The entire chain may be compromised and should
5. Use the steps in reverse order to replace the lift chain be discarded.
set. • Never electroplate assembled leaf chain or its com-
ponents. Plating will result in failure from hydro-
Primary Cylinder/Carriage Chains (TSU) gen embrittlement. Plated chains are assembled
from modified, individually plated components.
1. Tilt the upright forward, lower it, and completely col- • Welding should not be performed on any chain or
lapse the primary cylinder to create slack in the component. Welding spatter should never be

Group 34, Uprights
allowed to come in contact with chain or compo-

nents.
• Leaf chains are manufactured exclusively from
heat treated steels and therefore must not be
annealed. If heating a chain with a cutting torch is
absolutely necessary for removal, the chain should
not be reused.

NOTE :

Group 34, Uprights
Section 7
Fork and Carriage Removal and Replacement
3. Lift tip of each fork and put parret under the fork arm
! CAUTION near the heel.
]SAFE PARKING. Before working on truck:
1. Park truck on a hard, level, and solid sur- ! CAUTION
face, such as a concrete floor with no gaps Forks weight 115-301 kg (254-664 lbs) each.
or breaks. Take care when lifting.
wheels.
Fork Removal
NOTE
Forks do not need to be removed to remove
Blocking the Fork
the carriage.
4. Disassemble the carriage stopper bar and the fork
1. Release the fix pin. shaft.
! CAUTION
Forks are not stable sitting free in upright
position. Use care when working around the
forks.
5. Back the truck away from the forks.
Pin Operation Fork Replacement

2. Move each fork to the notch on the bottom of the 1. Carefully drive truck up close to forks.
lower carriage cross bar.
! CAUTION
Forks are not stable sitting free in upright
position. Use care when working around the
forks.
2. Drag forks into position close to carriage and to line

up with the notche on the lower carriage cross bar.
3. Arrange the fork and the carriage in position.
Notch
4. Assemble the shaft between carriage and fork, and
then lock them with stopper.
SM 751, Oct ’06 Fork

Copyrighted and Carriage Removal and Replacement • 34-7-1
Material
Group 34, Uprights
5. Check fork pins when repositioning forks to upper

carriage fork notches. ! WARNING
You may need to pull on the hoses/cables and
chains while lowering the primary cylinder to
Carriage Removal get it all the way down. This is done to create
The carriage should be removed for shimming or when slack in hoses/cables and chains and to dis-
any service procedure is performed on the upright. place as much oil as possible, which will
reduce oil loss when disconnecting hydraulic
! WARNING lines for auxiliary components.
The procedures for checking, maintaining, You may need a helper to hold the control
and adjusting uprights, carriages, and forks handle in the lowering position while you pull
involve movement of the components. on the carriage chains to fully collapse the
primary cylinder (on Hi-Lo & TSUs). When
• Do not walk or stand under raised forks.
pulling on the chains to lower the primary
• Keep clear of load and carriage when mak- cylinder (on Hi-Lo & TSUs), the ignition
ing any check or adjustment. must be off.
4. Once the carriage is fully lowered, clamp the front of
one fork to the pallet to prevent the carriage from
• Do not reach through open areas of the falling over backwards when removed.
upright.
• Always use a prybar to move the upright or
carriage.
serious injury.
1. Set upright tilt to 0 degrees (vertical). Raise the car-
riage about 12 in (305 mm).
2. Place a heavy pallet under the forks. Turn the key off.
3. Lower the carriage onto the pallet and keep lowering
(until the primary cylinder is all the way down on
TSUs and Hi-Lo). Before proceeding with the next
step read the following warning.
5. For carriage auxiliary components, the hose sheave

bracket must be unbolted from the primary cylinder
chain sheave bracket. Move the hose bracket off the
chain bracket.
Remove hose
sheave using
these bolts
34-7-2 • Fork and Carriage Removal and Replacement

Group 34, Uprights
6. Disconnect the carriage chains at the base of the car- 10. Remove steer wheel blocks. Release the parking
riage. Pull chains back off primary cylinder sheave. brake and slowly back the truck away from the car-
riage.
11. Lower the upright rails until both of the secondary
cylinders are completely collapsed.
Carriage Replacement
To replace the carriage:
1. First check to be sure the carriage is securely
clamped to the pallet.
2. Move the truck up to the carriage assembly with the
7. For carriage auxiliary components, disconnect hoses inner rail centered on the carriage.
(2- or 4-hose assemblies) from carriage. Remove the
bolts and strap fixture also. 3. Raise the upright until the inner rail is high enough to
clear the upper carriage rollers.
4. Tilt the upright until it is at the same angle as the car-
riage assembly.
5. Now slowly move the truck forward until the inner
rail is centered over the carriage rollers.
• Cap all lines to prevent leaks.

• Label all lines and fittings for correct reassembly.
8. Elevate the primary cylinder to its maximum height.
Be sure all hoses and loose parts are secured out of
the way to prevent damage.
9. Continue elevating the upright until the inner rail
clears the carriage.
SM 751, Oct ’06 Fork

Copyrighted and Carriage Removal and Replacement • 34-7-3
Material
Group 34, Uprights
10. Reconnect the hoses and mounting strap to the car-

! WARNING riage auxiliary component if the carriage is so
Never attempt to move or align the carriage equipped.
or bearings by hand. Use a pry bar.
6. Lower the upright until the inner rail clears all of the
carriage rollers.
NOTE
If the rail or bearings bind, raise the upright,
back away from the carriage and check to be
sure the carriage rollers are installed prop-
erly.
7. When the inner rail has cleared the carriage rollers,

continue to lower the upright until the lift cylinders
are lowered completely.
8. Reset the truck in a safe position: • Lubricate all O-rings with a light coating of system
hydraulic fluid or a compatible oil.
• Ignition off
• Use two wrenches to tighten hose fittings to pre-
• Parking brake applied
vent hoses from twisting.
• Directional lever in neutral
• See Group 40 for hydraulic fitting tightening pro-
• Forks completely lowered cedures.
• Block steer wheels.
11. Adjust carriage height according to Section 6 and
9. Reinstall the carriage lift chains to the base of the chain tension according to Section 3.
carriage.
12. Remove the “C” clamp from the pallet and check the
operation of the carriage and the upright. Carefully
check for oil leaks. Make sure the carriage and
upright work smoothly and correctly before returning
the truck to service.
• Set anchor bolts so that no twist develops in the

chains.
• Anchor pin heads must be pointing to the inside of
the upright.
• Use new cotter pins.
IMPORTANT
Always use new anchor pins when replacing
chain sets.
34-7-4 • Fork and Carriage Removal and Replacement

Group 34, Uprights
Section 8
Upright Removal and Replacement
This Section describes how to remove the entire upright

assembly from the truck. The carriage and forks must be ! CAUTION
removed from the upright assembly before the upright is SAFE PARKING. Before working on truck:
removed. (For uprights with an auxiliary component, a
side-shifter for example, the two hydraulic hoses power- 1. Park truck on a hard, level, and solid sur-
ing the auxiliary component must be removed before the face, such as a concrete floor with no gaps
carriage is removed.) See Section 7, “Fork and Carriage or breaks.
Removal and Replacement,” for procedures to remove the 2. Put upright in vertical position and fully
carriage and fork assembly from the upright. lower the forks or attachment.
wheels.
Outer rail set
Tilt cylinder mount
Transaxle bearing
bearing
Typical Upright Installation
SM 751, Oct ’06 Copyrighted Material Upright Removal and Replacement • 34-8-1
Group 34, Uprights
Upright Removal 2. Disconnect and cap hydraulic line at the load-lower-

ing flow valve. Secure the hose out of the way of the
The following procedures are for uprights with carriage upright.
and forks, or auxiliary components removed. See Section
7, “Fork and Carriage Removal and Replacement,” for
instructions on removing the forks and carriage.
! WARNING
The upright assembly is heavy. Use only
hoists with enough capacity to lift the entire
assembly. Keep clear of the assembly as it is Disconnect and
cap line from main
being hoisted and set down. Keep hands and hydraulic control valve
feet away from the assembly. Use prybars to
move the assembly into position for reattach-
ment.
1. Attach a hoist and strap of adequate capacity to the NOTE

upright as shown below. Tension the hoist so that the
For two-hose adapter assemblies, the hydrau-
upright cannot fall when upright mounting pins and
lic lines to the upright must also be discon-
tilt cylinder pins are removed.
nected and capped.
Disconnect
lines here.
34-8-2 • Upright Removal and Replacement Copyrighted Material SM 751, Oct ’06
Group 34, Uprights
3. Remove tilt cylinder rod-end lock plates and rod-end Upright Replacement
pins from upright.
1. Use an overhead chain hoist of adequate capacity and
an approved lift chain to lift upright into position.
4. Remove pin fix bolts and lift upright off frame. See
illustration on page 1.
! WARNING
Use prybars to move the assembly into posi-
5. Slowly set upright down on the floor, 100 x 100 mm
tion for reattachment.
(4 x 4 in) blocking, or sturdy pallets set end-to-end.
2. Match the position of mounting pin to the trans axle.
Install the lock pin bolts and tighten them with
Torque to 340-380 N⋅m(249-279ft⋅lb).
SM 751, Oct ’06 Copyrighted Material Upright Removal and Replacement • 34-8-3
Group 34, Uprights
3. Install rod end pins, lock plates, and fasteners. NOTE

Tighten lock plate fasteners to a torque of 121-136 Reconnect two-hose adapter assembly
in-lb (19.3-21.5 N⋅m). hydraulic lines to the upright-mounted
bracket.
Reconnect hose
adapter lines here.
4. Attach hydraulic lines to the upright flow control

valve:
5. Remove the lift chain between the upright and hoist.
6. Completely check all upright and hydraulic compo-
nents under load before returning the truck to service.
7. See Section 8, “Fork and Carriage Removal and
Reconnect
Replacement,” for steps to replace the carriage and
hydraulic fork assembly.
line here
• Lubricate all O-rings with a light coating of system

hydraulic fluid or a compatible oil.
• Use two wrenches to tighten hose fittings to pre-
vent twisting lines.
• See Group 40 for hydraulic fitting tightening pro-
cedures.
34-8-4 • Upright Removal and Replacement Copyrighted Material SM 751, Oct ’06
GROUP 38
GROUP 38
COUNTERWEIGHT AND CHASSIS
Counterweight Specifications and

Counterweight Removal and

Overhead Guard/Operator’s Cell Removal

and Replacement .................................. Section 3
Floorboard, Radiator Cover, and Seat Deck

Removal and Replacement .................. Section 4
Operator’s Seat Removal and

SM 751, Dec ’06 Copyrighted Material Group 38, Counterweight and Chassis
NOTE :
Group 38, Counterweight and Chassis Copyrighted Material SM 751, Dec ’06
Group 38, Counterweight and Chassis
Section 1
Counterweight Specifications and Description
Counterweight weights : The counterweight is a solid, cast-iron piece mounted to
the back of the lift truck to counter-balance the loads
C60:3180 Kg (7010 lbs)
placed on the upright at the front of the truck. The weight
C70:3600 Kg (7736 lbs)
C80:4000 Kg (8820 lbs) must be great enough to counteract forward tipping when
lifting or stopping with a capacity load. The weight of the
counterweight is determined by the lifting capacity of the
Fastener Torques truck.
Counterweight Mounting Bolt : 392-490 N⋅m (289-361 The counterweight is cast with mounting niches molded
ft⋅lb) in. The niches fit the truck frame mounting and allow the
counterweight to “hang” on the truck frame bracket.
Large, hard steel bolts hold the counterweight to the frame
General Maintenance
and prevent the counterweight from being dismounted
The counterweight must be maintained in good condition accidentally.
and securely attached to the lift truck. Because of its
heavy weight and bulky mass, the counterweight must be ! WARNING
carefully supported and handled. When removed from the
The counterweight is extremely heavy. Do not
truck, store at floor level in a stable position to be sure it
remove the counterweight unless you have
will not fall or tip, causing damage or injury.
training and are familiar with the correct
procedures. Counterweights can fall if not
handled correctly and can cause severe
injury or death. Keep your hands, feet, and
body clear of the counterweight at all times.
Hoisting equipment must be capable of han-
dling the weight of the counterweight when
removing or replacing. Make sure your hoist
is of adequate capacity to handle the weight.
SM 751, Dec ’06 Counterweight

Copyrighted Material Specifications and Description • 38-1-1
NOTE :
Group 38, Counterweight and Chassis Copyrighted Material SM 751, Dec ’06
Section 2
Counterweight Removal and Replacement
5. Slowly lower the counterweight onto a sturdy pallet.

! CAUTION Set the counterweight on its flat side if possible. If
SAFE PARKING. Before working on truck : set on its curved side, use chocks to prevent the coun-
terweight from shifting or rolling.
gaps or breaks.
Counterweight Replacement
1. Bring counterweight vertically near the rear of the
truck and positioned so that it is within 25-50 mm (1-
2 in) of the frame.
2. Move the counterweight forward and lower it, mak-
ing sure that the support hooks on the frame engage
4. Apply the parking brake and block the with the counterweight.
wheels.
! WARNING
! WARNING During mounting, always use prybars for
Observe proper, safe lifting practices when location adjustments. Do not place any part
lifting counterweight onto or off truck. of your body between the counterweight and
Counterweight should only be lifted by truck.
appropriately-sized eye bolts installed
through both top lifting holes. 3. Make sure that the bolt holes in the counterweight
Use only overhead lifting equipment having a align properly with the mating holes in the frame.
safe lifting capacity in excess of that of the
4. Inspect the counterweight mounting bolts to make
counterweight.
sure they are in good condition before re-installing.
Use only Clark replacement parts. Torque the mount-
Counterweight Removal ing bolts to 392-490 N⋅m (289-361 ft⋅lb).
1. Install eye bolts into the counterweight. Eyebolts 5. Remove the hoist and eyebolts.
must be able to lift 3200-4500 kg (7100-10000 lb)
IMPORTANT
depending on truck model (see illustration next
Never allow a truck to be put into service
page).
without the counterweight mounting bolt(s)
2. Using an overhead hoist with sufficient lifting capac- in place. Check the bolt(s) and torque regu-
ity, chain the eyebolts to the hoist ; slowly hoist larly.
chains until slack is removed.
3. Remove the tow bar and the counterweight anchor
bolt(s).
4. Slowly lift the counterweight from the truck frame.
! WARNING
Stand clear of the counterweight as it is being
hoisted, moved, or mounted.
SM 751, Dec ’06 Counterweight Removal and Replacement • 38-2-1

Towbar
Anchor bolts
Counterweight Installation. A standard truck counterweight and frame is shown. Removal and replacement
38-2-2 • Counterweight Removal and Replacement

Section 3
Overhead Guard/Operator’s Cell

Removal
! CAUTION
SAFE PARKING. Before working on truck: 1. Remove jack of cowl and headlight wire.
2. Remove driver deck with driver seat.
surface, such as a concrete floor with no 3. Release parking break.
gaps or breaks. 4. Remove four floor plate.
2. Put upright in vertical position and fully 5. Secure overhead guard safely using hoist and remove
lower the forks or attachment. cushion and bolt.
switch OFF and remove key. Replacement
4. Apply the parking brake and block the 1. Set cell into place on the truck chassis using an over-
wheels. head hoist.
2. Replace the four mounting bolts and nuts. Torque the
Overhead Guard/Operator’s nuts to 70-80 N⋅m (52-59 ft⋅lb).
Removal and Replacement NOTE
Overhead Guard If the cell is a new replacement or has been
repaired, install new cushion mounts.
Mounting bolt
3. Assemble parking brake and driver’s deck.

4. Assemble floor plate.
5. Connect each wire.
SM 751, Dec ’06 Overhead Guard/Operator’s

Copyrighted Material Cell Removal and Replacement • 38-3-1
6. Reconnect the air induction tubing to the cell leg.

7. Reconnect all wiring for cell-mounted lights or other
electrical devices according to the labels made during
removal.
8. Replace the operators seat deck ; see Section 4.
9. Replace the operator’s compartment floor plate and
readjust, if necessary, using the procedures in Section
4.
38-3-2 • Overhead Guard/Operator’s Cell Removal and Replacement

Section 4
Floorboard, Cowls, and Driver Deck

SM 751, Dec ’06 Floorboard, Cowls,

Copyrighted and Driver Deck Removal and Replacement • 38-4-1
Material
8. Align and fasten the tilt cylinder cover installed on

! CAUTION cowl surface and middle floor plate to the hole.

gaps or breaks.
wheels.
Floor Plate/Driver Deck Removal

and Replacement
1. Remove rubber mattress of floor plate.
9. Fasten loose bolt to torque 20-25N.m(14.7-18.4lb.ft).
2. Remove control lever cover and tilt cylinder cover.
10. Install parking lever bracket to rear floor plate and
3. Remove driver deck.
fasten control lever cover to 6-7N.m(4.4-5.2lb.ft).
11. Install driver deck.
4. Remove and tilt parking brake bracket.

5. Release bolt securing 4 floor plates and remove the
floor plates.
6. Place floor plate guard on the hole securing 4 floor
plates for floor plate installation.
7. Fasten floor plate mounting bolt loosely.
38-4-2 • Floorboard, Cowls, and Driver Deck Removal and Replacement

Section 5
Operator’s Seat
! CAUTION wheels.

Seat Removal
surface, such as a concrete floor with no 1. Remove the four nuts securing the seat rails to the
gaps or breaks. seat deck.
lower the forks or attachment. ! CAUTION
3. Put all controls in neutral. Turn key Make sure to support seat on deck so it does
switch OFF and remove key. not fall when bolts are removed. Seat may be
damaged or injury can result.
Remove nuts and

washers here
SM 751, Dec ’06 Copyrighted Operator’s

Material Seat Removal and Replacement • 38-5-1
Seat Replacement 2. Check seat for correct, smooth adjustment when slid-
ing forward or back. Make sure the seat locks in
1. Replace the four nuts securing the seat rails to the place on the rails when adjusted for different posi-
seat deck and torque to 23-25 N⋅m (210-230 in⋅lb). tions.
38-5-2 • Operator’s Seat Removal and Replacement

GROUP 40
GROUP 40
SPECIFICATIONS
Nameplates and Decals ............................ Section 1
General Specifications .............................. Section 2
Hydraulic Fitting Tightening

Procedures ............................................ Section 3
SM 751, Nov ’06 Copyrighted Material Group 40, Specifications

NOTE :
Group 40, Specifications Copyrighted Material SM 751, Nov ’06

Group 40, Specifications
Section 1
Nameplates and Decals
Nameplates and Decals ating on elevators, elevated floors, etc. to be sure

they are safe.
This Section shows the nameplate (data and capacity
plate) and decals required to be on all operating Clark 5. Capacity rating, load center, and lifting height data
industrial trucks. The nameplate lists the data on the truck — Shows the maximum load capacity of this truck
- type and serial number - and the capacities of the truck. with relation to load centers and fork heights (see
Decals depict or explain the hazards the operator must diagram on plate). Personal injury and damage to the
avoid when operating the truck. The nameplate and decals truck can occur if these capacities are exceeded. Do
are placed in specific locations on the truck and are not exceed the maximum capacity specified.
intended to warn others working around the truck of its
hazards as well. These nameplates and decals MUST BE ! CAUTION
IN PLACE on all trucks. When attachments are added or if the truck
If any decals or the nameplate are missing from the truck, is modified, the capacity of the truck may be
check with your local Clark dealer for replacements. affected. Contact your authorized Clark
dealer for a new nameplate showing the
IMPORTANT revised capacity.
Do not allow a lift truck with damaged or
missing decals or data plates to be placed in
service. Replace them immediately. They 1 2
3
contain important information as described
on the following pages. The location of all 5
decals is also shown on the following pages.
The truck data and capacity plate provides essential infor-

mation about the truck. This information is important for
both operators and service personnel. Operators can see 4
what the truck’s capacities and load ratings are. Service
personnel must identify the truck model, type, and serial
number when ordering parts. Refer to example data plate
illustration for callout numbers. Truck Data and Capacity Plate
1. Truck model number or registered name.
2. Truck serial number — An identification number
assigned to this particular truck and should be used
when requesting information or ordering service 1
2
parts for this truck from your authorized Clark dealer. 3
The serial number is also stamped on the frame.
3. Attachment description (if any installed) — The user 5
must see that the truck is marked to identify the

attachment(s), including the weight of the truck/
attachment combination and truck capacity with the
4
attachment.
4. Truck weight — The approximate weight of the
truck without a load on the forks. This weight plus
the weight of the load must be considered when oper-
SM 751, Nov ’06 Copyrighted Material Nameplates and Decals • 40-1-1

Operator Safety Warning Plate General Safety Decal

The Operator Safety Warning Plate describes basic, safe The General Safety Decal
operating procedures that should be used when operating depicts important points
WARNING
the truck. about truck operation and
Read the
warns operators about truck manual
safety hazards. The General

WARNING Safety Decal is meant as a
reminder for operators and is Buckle up!
BEFORE OPERATING lift truck, operator must: placed where operators can
• Be trained and authorized.
• Read and understand operator's review the points daily as
manual. they conduct a visual inspec- Apply brake
• Not operate a faulty lift truck. tion and prepare the truck for when leaving
truck
• Not repair lift truck unless trained and authorized.
• Have the overhead guard and load backrest work.
extension in place. Watch Out
For Other
DURING OPERATION, lift truck operator must: People
• Wear a seat belt.
• Keep entire body inside truck cab.
• Never carry passengers or lift people.
• Keep truck away from people and obstructions.
Most lift truck
• Travel with lift mechanism as low as possible. INJURIES
and tilted back. are to other
people near
the lift truck.
TO PARK lift truck, operator must:
• Completely lower forks or attachments.
• Shift into neutral.
• Turn off key.
• Set parking brake.
P Prevent
Overturns!
Clark Material Handling Co. Sit Down Rider 2798233
AVOID :
• slippery,
IMPORTANT sloping,
or uneven
Safety and warning decals are placed in con- surfaces
spicuous locations on the truck to remind • loads over
capacity on
operators of essential procedures or to pre- nameplate
vent them from making an error that could • unstable or

high loads
damage the truck or possibly cause personal • low tire
pressure
injury. Safety and warning decals should be
• poorly
replaced immediately if missing or defaced maintained
lift truck
(damaged or illegible). • fast or
sharp turns
In Case of
Tip-Over:
Don't
jump
Hold on
tight
Brace feet
Lean
away
2798235
40-1-2 • Nameplates and Decals Copyrighted Material SM 751, Nov ’06

Seat Belt/Tip-Over Warning Decal Keep Away from Forks Decal

This decal is located on the seat deck, to the left of the This safety decal is placed on the upright to warn of the
operator. It’s purpose is to remind the operator that staying danger of injury from forks when they are in the raised
in the seat provides the best chance of avoiding injury in position. Operators and others should never ride on or
the event of a truck-tipping mishap. stand under forks or attachments. The forks can fall and
cause injury or death.
2372604
Lift trucks can be tipped over if operated improperly.

Experience with lift truck accidents has shown that the
Fan Warning Decal
driver cannot react quickly enough to jump clear of the
truck and overhead guard as the truck tips. To protect The fan warning decal reminds operators and service per-
operators from severe injury or death in the event of a tip- sonnel not to touch or work around a spinning radiator
over, make sure this decal is in place to remind them to cooling fan. The decal is placed on the radiator fan
always use their seatbelts. shroud.
Hand Safety Warning Decal

This safety decal is placed on the upright to warn of the
danger of injury from movement between rails, chains,
sheaves, fork carriage, and other parts of the upright
assembly. Operators and others should never climb on or
reach into the upright. Personal injury will result if any
part of someone’s body is put between moving parts of the
upright. IMPORTANT
The Engine Coolant Fan, on all internal com-
bustion engines, can cause extensive injury
and bodily harm. Keep hands, arms and
clothing away from a spinning fan. Also,
don’t stand in line with a spinning fan.
SM 751, Nov ’06 Copyrighted Material Nameplates and Decals • 40-1-3

Nameplate, Decal Locations The Keep Away from Forks decal is placed on both sides
of the upright on the outer rail just above the tilt cylinder
The following illustrations show decal locations for the yoke mount.
nameplate and safety decal required on all Clark indus-
trial lift trucks.
The Data Plate is located on the seat deck to the left side
of the operator seat deck.
2372604
The Fan Warning decal is placed on the cooling fan

shroud as shown.
The Operator’s Safety and Warning Plate is located on the
seat deck to the right side of the operator seat.
The General Safety Decal is located on the operator’s cell

leg as shown.
The Hand Safety Warning Decal is located on the outer

rail upper tie bar.
40-1-4 • Nameplates and Decals Copyrighted Material SM 751, Nov ’06

Section 2
SM 751, Nov ’06 Copyrighted Material General Specifications • 40-2-1

Weights and Performance Specifications

Capacities
For standard transaxle trucks.
At 600mm At 24 in
Models Load Center Load Center
C60 6000 kg 13500lb
C70 7000 kg 15500lb
C80 8000 kg 17500lb
Note : Rated capacity applies when using standard upright : 3000mm [118 inches] for C60-70, 2800mm [100 inches] for
C80 pneumatic tire.
Truck Weights and Axle Weights

Weights for standard transaxle trucks with standard C60-70 : 3000mm[118 inches], C80 : 2800mm[110 inches] MFH
upright.
Loaded Vehile Empty Vehile Loaded Drive Empty Drive Empty Steer
Weight Weight Axle Weight Axle Weight Axle Weight
(kg/lbs) (kg/lbs) (kg/lbs) (kg/lbs) (kg/lbs)
Diesel
C60 15260(33642) 9260(20415) 13296(29313) 4050(8928) 5210(11486)
C70 16630(36663) 9630(21230) 14717(32445) 3931(8666) 5699(12564)
C80 18360(40477) 10360(22840) 15989(35250) 4034(8893) 6326(13946)
Note : Refer to the truck data plate for exact service and axle weights.
40-2-2 • General Specifications Copyrighted Material SM 751, Nov ’06

Maximum Gradeability Group 32, Tilt Cylinders Specifications

At stall in forward with standard upright on surface of 0.6
Tilt cylinder type : double-acting with shims.
friction coefficient.
Maximum operating pressure : 21000 kPa (3045 psi ; 210
Without load With load
(%) (%) bar)
Pneumatic tire type Diesel In case of standard trucks (C60-70 : MFH3000, C80 :
C60 21.2 43.8 MFH2800), they have been set to 56.8 LPM (15 GPM) on
C70 19.8 41.6
C80 19.2 36.7 delivery.
Parking Brake Test Tilt Ranges
For standard transaxle trucks. (Abbreviation — Std = Standard, high-visibility upright ;

The brake must be capable of holding the truck with a full TSU = Triplestage upright ; MFH = Maximum fork height
rated-capacity load on a 15% grade. ; B = back tilt ; F = Forward tilt)
Tilt Ranges* ::
Group 30, Hydraulic Valve/Lift Circuit
MAST BACK FORWARD
Specifications TYPE
MFH mm(in)
"B"( ˚ ) "F"( ˚ )
Rated Flow : C60-C70
STD 2300(90.6)~3700(146) 10 15
Lift spool (spool #1) : 170LPM (45GPM) STD 3800(147)~6400(252) 10 10
Tilt spool (spool #2) : 75.7LPM (20GPM) TSU 3650(144)~4900(193) 10 10
Auxiliary spool (spool #3) : 75.7LPM (20GPM) TSU 6200(244)~8000(315) 6 6
Flow Setting : C80
STD 2300(90.6)~3700(146) 10 15
Flow Setting Parts number of Cartridge
STD 3800(147)~6400(252) 10 10
L/min (gpm)
TSU 3650(144)~4900(193) 10 10
<Tilt/Aux>
TSU 6200(244)~8000(315) 6 6
15.1 4 8041431
20.8 5.5 8041432
26.5 7 8041433 Group 34, Upright Specifications
37.9 10 8041434
56.8 15 8041435 Upright Weight : Approximately 999 kg (2202 lb) to
75.7 20 8041436 approximately 2280 kg (5027 lb) without carriage
Carriage Weight : approximatelly 485 kg (1069 lb) to
approximately 574 kg (1265 lb)
Fork Weight : approximatelly 115 kg (254 lb) to approxi-
mately 301 kg (664 lb)
IMPORTANT
Before hoisting, the weights of upright, car-
riage, and forks must be combined to deter-
mine what lifting capacity is required of the
hoisting equipment.
Capacities and Lift Heights : Upright, carriage, and fork

capacity and upright lift heights are listed on the truck’s
data plate.
Lubricants :
All Purpose Grease (Clark specification MS-9)

Innerslide Lubricant (Clark part #886396) Critical Fastener Torque Specifications

Chain and Cable Lube (Clark part #886399) Tightening Torque. Dry
N⋅m ft⋅lb
Group 38, Counterweight and Chassis For standard transaxle truck
Engine Mounting Bolts 245-294 181-217
Specifications
Transaxle to Engine Bolts 60-65 44-48
Counterweight weights : Torque Converter to Drive Plate Bolts 60-65 44-48
Transaxle/Drive Axle to Frame 240-270 177-199
C60 : 2852 kg (6287 lbs) Mounting Bolts
C70 : 3434 kg (7570 lbs) Drive wheel Lug nut 539-588 397-433
C80 : 4040 kg (8906 lbs) Steer Axle Mounting Bolts 235-288 173-213
Steer Wheel Lug Nuts 441-490 325-361
Drift, Lift and Tilt Cylinders Steering Handwheel Retaining Nut 35-45 25.8-33.2
Tilt Cylinder Yoke Clamp Bolts 170-190 125-140
For standard transaxle truck.
Tilt Cylinder Pin Retainer Bolts:
Upright Fork Downdrift : Should not exceed 100 mm (4 Front 40-45 30-33
in) in a 10-minute period. Rear 8-10 5.9-7.4
Tilt Cylinder Drift : Should not exceed 5° in a 10-minute Counterweight Mounting Bolts (Bot- 441-490 325-361
period. tom)
Determined by marking and measuring carriage descent Overhead Guard Mounting Bolts 100-121 74-89
and upright forward tilt from raised, non-tilted position Upright Trunnion Mounting Bolts 340-380 250-280
with hydraulic fluid at operating temperature ; and a
capacity load held evenly distributed on lift forks. (If a Transmission and Bracket Mounting 450-500 332-369
pallet is used, load should not extend beyond pallet ; load Bolts
should be stacked to provide maximum stability.) Fork
completely engaging load and adjusted as wide as possi-
ble to provide even distribution of weight. Group 06(S), Standard Transaxle
Lift Speeds, Upright Specifications
For the standard two-stage upright, with standard tran- General Specifications
saxle or hydraulic transmission.
Note : Hydraulic fluid should be at operating temperature Model : ZF 3WG-116 Transmission.
when testing these specifications.
No. Ratios : 3-speed, forward and reverse.
Lift Speed Lowering Speed
No. Ratios Gear ratio
m/s(ft/min) m/s(ft/min)
1 ST 4.578 : 1
Pneumatic tire type Diesel
2 ND 2.396 : 1
Loaded 0.43m/s 0.45m/s
C60 3 RD 0.994 : 1
Empty 0.45m/s 0.43m/s
Loaded 042m/s 0.45m/s Torque Converter Size : 280 mm (11 in).
C70
Empty 0.45m/s 0.43m/s Torque Converter Stall Ratio : 2.382
Loaded 0.39m/s 0.45m/s
C80 Hydraulic Pump Drive ratio : 1.0 × engine rpm.
Empty 0.45m/s 0.43m/s
Dry Weight : 242 kg (534 lb).
Oil Capacity : 20 L (21.1 qt).
Transaxle Fluid : Clark # 2776236.
NOTE
1. All rpm’s noted are engine speed.
2. All clutch pressures are engine idle speed
with clutch engaged.
3. Oil at operating temperature (82-93°C)
180-200 °F.

Group 13, Instrument Pod & Electrical Sys- Group 01, Cooling System Specifications
tem Specifications Radiator Type : Crossflow radiator with coolant recovery
Indicator lights : LCDs integral with circuit board. system.
Fuel gauge : LCD. System Pressure (Radiator cap) : 83-109 kPa (12-16 psi).
Engine Coolant Temperature Gauge :LCD. Thermostat :
Hour Meter :LCD. Diesel : open (cracking) at 83°C ± 1.5° (181°F ± 2.7°)
fully open 98°C (208°F).
Pinout Locations : See Group 13, “Electrical System,” for
schematic. Coolant Mixture : 50% water and 50% low-silicate, ethyl-
ene glycol, permanent-type antifreeze with rust and corro-
Voltage and Ground sion inhibitors.
System Voltage : 24 volt. Cooling System Coolant Capacity :
System Ground : Negative. Diesel truck with 4-row radiator capacity is 24L (25.4
qt).
Alternator Fan Type : Pusher type
Type : 24 volt. Fan Drive Belt : Flat 6 Grove type belt
Battery Water Pump Type : Centrifugal
Diesel Engine : Hose Clamp Sizes :
Type : 12 volt 80AH X2 Diesel : 51mm (2 in).
Cold Crank Current : 800 amps at 0 °F (-18 °C)

Group 03, Air Induction and Exhaust Systems
Reserve Capacity : 130 minutes at 80 °F (27 °C).
Specifications
Starter
Diesel Engine : Air Cleaner Type : Canister style with replaceable paper
element and air-restriction indicator.
Type : Positive engagement, offset gear reduction.
Voltage : 24 volts
Output : 4.0 kW.
System Protection
Fuse : 10A Direction Control.
Fuse : 10A Ignition.
Fuse : 10A STOP Switch.
Fuse : 10A Horn.

Group Specifications Group 22, Wheels and Tires Specifications

Steer Tire Types : Pneumatic Rubber and urethane.
Group 00, F4GE0454A Diesel Engine
Drive Tire Type : Pneumatic Rubber and urethane.
Specifications
Pneumatic Truck Wheel and Tires
Tire Sizes and Ratings
Engine Type : IVECO F4GE0454A Vertical, in-line, 4-
cycle water-cooled diesel engine. Drive Tires :
Number of Cylinder : 4 C60/70 Dual : 8.25X15-14 ply rating

C80 Dual : 8.25X15-18 ply rating
Combustion Chamber : Direct injection
Total Displacement : 4500 cu⋅cm (275 cu⋅in) Steer Tires :
C60/70 8.25X15-14 ply rating
Rated Output : 74 kw (99ps) @ 2300rpm C80 8.25X15-18 ply rating
Maximum Torque : 398 N⋅m(294 lb⋅ft) @ 1400 rpm Tire Pressures
Engine Speed (rpm) :
Drive Tires :
Idle : 800±30 rpm
C60/70 Dual : 820kPa(119psi)
Converter Stall : 1850±30rpm C80 Dual : 1000kPa(145psi)
Maximum No-Load : 2480±30 rpm
Steer Tires :
Fuel Consumption (rated) : 217 g/kw-h
C60/70 820kPa(119psi)
Firing Order : 1-3-4-2 (No.1 cylinder on flywheel side) C80 1000kPa(145psi)
Output Shaft : Flywheel
Direction of Rotation : Counterclockwise(viewed from Group 23 Brake/Inching System
flywheel) Specifications
Fuel Oil : Diesel oil
Service Brake
Engine oil : 15W 40, API CD, CF-4 Engine oil.
Type : Wet disc brake. Step-bore master cylinder.
Engine weight (dry) : About 440 kg (970 lb)
Fluid : Fluid (RANDO HD32 or NUTO H32
Start Motor : 24V-4.0 kW in accordance with CLARK specification MS-68
Alternator : 24V-70A (CLARK #2776239)) by reservoir.
Pedal Freeplay : 4~6mm (0.16~0.24 in).
Parking Brake
Type : Cam-structure type that each wheel is connected to
the service brake piston.
Holding Test : Rated load on 15% grade.
Inching (also see transaxle specs)

Type : Inching pedal mechanically linked to brake pedal
and to inching sensor on transaxle.
Pedal Freeplay : None.
Overlap Adjustment : 0-5 mm (0-0.2 in).

Group 25, Steering Column and Gear Drawbar Pull

Specifications With standard upright and standard transaxle.
Steering System Type : Hydrostatic power steering with with load without load
load sensing, dynamic signal circuit. Pneumatic tire type Diesel kg(lbs) kg(lbs)
Steering System Relief Pressure Setting : 13000 kPa
(1885 psi). C60 6397(14103) 6173(13609)
C70 6440(14198) 6182(13629)
C80 6370(14043) 6135(13525)
Group 26, Steer Axle Specifications
Travel Speeds
Pneumatic-Tire Truck Maximum speeds with standard upright and standard tran-
saxle.
Steering System Relief Pressure Setting:13000 kPa (1885
psi). with load without load
Steer Cylinder Type : Double-acting, piston-type. km/h(MPh) km/h(MPh)
Pneumatic tire type Diesel
Turning Arc : 72° max. inside turning angle
51° max. outside turning angle. C60 29.3(18.2) 34.4(21.4)
C70 28.1(17.5) 33.7(20.9)
The number of handwheel turns required for lock-to-lock C80 27.4(17.0) 32.2(20.0)
turning differs between the cushion and pneumatic-style
axles.
Turning Radius (outside)
Group 29, Hydraulic Sump, Filters, and Pump For standard transaxle truck.
Specifications
mm in
Hydraulic Pump Type : Transmission-driven, gear-type Pneumatic tire type Diesel
with integral load sensing priority flow valve and pressure C60 3420 134.6
relief valve ; pump is connected to, and works in conjunc- C70 3450 135.8
tion with the transmission charging pump. C80 3775 148.6
Sump Type and Capacity : Tank is built into truck frame
with capacity of 120 L (31.7 gallones) for C60-70, 140 L
(37.0 gallones) for C80.
Hydraulic Fluid Type : Clark Hydraulic Fluid specifica-
tion MS-68.
Tank top Return Filter Type : Disposable, glass micro-
fiber element.
Suction Screen : 100 mesh stainless steel screen.

NOTE :

Section 3
Hydraulic Fitting Tightening Procedure
1. Tighten fitting finger tight until it stops turning, 2. Using finger tips only, lightly snug fitting with a
while moving the fitting lightly side to side to pre- wrench until it bottoms out on the seat or port. Do
vent cocking or thread damage. not overwighten.
SM 751, Nov ’06 Hydraulic Fitting Tightening Procedure • 40-3-1

NOTE :

700 Enterprise Drive
Lexington, KY
40510
Printed in Korea
Intended for CLARK dealers only Jan, 2007

Service Manual c60 c80 Compressed

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C60-80 D

RATED CAPACITY: 6000– 8000kg

Part No. 8051043

700 Enterprise Drive

Arrangement and Use of this Manual

Copyrighted Material SM751, Dec ’06

Group 34. Uprights

Group 32. Tilt Cylinders

Group 20. Drive Axle

Group 00. Engine

Group 01. Engine Cooling System

Group 22. Wheels and Tires

Group 38. Counterweight Group 26. Steer Axle

SM 751, Nov ’06 Copyrighted Material CONTENTS-1

CONTENTS Copyrighted Material SM751, Nov ’06

When new or revised information is published to Dec. 2006

SM 751, Nov ’06 Copyrighted Material REVISION HISTORY - 1

Revision Revision Revision Revision

2 - REVISION HISTORY Copyrighted Material SM 751, Nov ’06

Revision Revision Revision Revision

SM 751, Nov ’06 Copyrighted Material REVISION HISTORY - 3

REVISION HISTORY Copyrighted Material SM 751, Nov ’06

Safety ................................................................... Section 1

Lifting, Jacking, and Blocking the Truck ....... Section 2

SM 751, Oct ’06 Copyrighted Material Group SA, Safe Maintenance

Group SA, Safe Maintenance Copyrighted Material SM 751, Oct ’06

Safety Signs and Messages Safe Maintenance Practices

SM 751, Oct ’06 Copyrighted Material Safety • SA-1-1

SA-1-2 • Safety Copyrighted Material SM 751, Oct ’06

Lifting, Jacking, and Blocking the Truck

Safe Parking Raising Drive Wheels Off Floor

Lifting, Blocking, and Jacking Points Steel

Under Under Frame Under Upright

SA-2-2 • Lifting, Jacking, and Blocking the Truck

7. Check for stable condition of the truck. Be sure that ! WARNING

Blocking the Upright In Raised

For standard uprights, block may need

1. Park truck safely as described in “Safe Parking.” Put

6. Hold the shorter block against the outer rail and

SA-2-4 • Lifting, Jacking, and Blocking the Truck

Raising Entire Truck

The reverse is also true. If the counterweight

Put an equal amount of blocks under each side of the truck

8. When maintenance work is completed, lower the

b. Without an Upright and Carriage Installed

SA-2-6 • Lifting, Jacking, and Blocking the Truck

Direction of towing for distances of

SM 751, Oct ’06 Copyrighted Material Towing • SA-3-1

LIFT TRUCK PARKING

SA-3-2 • Towing Copyrighted Material SM 751, Oct ’06

Maintenance Schedules ............................ Section 1

The Planned Maintenance Program ....... Section 2

SM 751, Oct ’06 Copyrighted Material Group PS, Periodic Service

Group PS, Periodic Service Copyrighted Material SM 751, Oct ’06

“Periodic Service” and “Planned Determining Maintenance Intervals

Since the operating environments of lift

SM 751, Oct ’06 Copyrighted Material Maintenance Schedules • PS-1-1

Service Chart/Lubrication Points

API,MORE THAN A CLASS SJ GRADE

PS-1-2 • Maintenance Schedules Copyrighted Material SM 751, Oct ’06

Recommended Periodic Service Schedule

Every 450- Every 900- Every 2000

SM 751, Oct ’06 Copyrighted Material Maintenance Schedules • PS-1-3

Every 450- Every 900- Every 2000