Clark C60D C70D C80D Forklift Service Manual SM-751 – PDF

Description

Clark C60D C70D C80D Forklift Service Manual SM-751 – PDF

The Clark C60D C70D C80D Forklift Service Manual SM-751 – PDF is a detailed service reference for the C60, C70 and C80 diesel lift trucks covered by this book. It brings together scheduled maintenance, troubleshooting, system testing, adjustment, removal, installation and overhaul procedures for the major truck systems in one 518-page manual. The cover identifies the book as Service Manual SM-751, Part No. 8051043, dated Jan. 2007, with a rated-capacity range of 6000-8000 kg.

This manual is written for trained service personnel. Its procedures are organized by CLARK service groups, so a technician can move from a symptom or system to the relevant inspection, specification, adjustment or repair procedure. The manual also includes extensive illustrations, electrical circuits, hydraulic schematics, component layouts, service-data tables and tightening information that support workshop diagnosis and repair.

File Details

• Manual type: Service Manual
• Brand: CLARK
• Models covered: C60D, C70D and C80D
• Manual identification: Book No. SM-751; Part No. 8051043
• Date: Jan. 2007
• Language: English
• Page count: 518 pages
• File format: PDF
• Rated capacity shown on the cover: 6000-8000 kg

What This C60-80 D Service Manual Covers

The Clark C60D C70D C80D Forklift Service Manual SM-751 – PDF goes well beyond routine maintenance. It includes complete service groups for the diesel engine, 3 WG-116 transmission, drive axle, wet-disc braking system, steering, hydraulic load-handling system, tilt cylinders, uprights, chassis and electrical system. Troubleshooting sections are integrated with repair procedures so the manual can be used both to locate faults and to carry out the corrective work.

Engine and Fuel System Service

The engine group covers the N45-MNS application and the IVECO F4GE0454A diesel engine information used in the truck specifications. The material includes lubrication and cooling-system layouts, mechanical rotary-pump fuel feed, injection components, turbocharger-related service, electrical components, maintenance planning, troubleshooting and extensive engine-overhaul information. Procedures cover engine removal and replacement, cylinder-head work, valve and rocker-arm service, timing components, pistons and connecting rods, crankshaft and bearing checks, injection-pump timing, fuel-system bleeding and the special tools referenced by the manual.

The engine troubleshooting tables address starting faults, low-temperature starting, engine cut-out, overheating, irregular running or lack of power, abnormal knocking and abnormal exhaust smoke. The overhaul material provides measurements, clearances, wear limits and tightening sequences alongside illustrated disassembly and reassembly steps.

Transmission, Drive Axle and Brakes

The transmission group is specifically identified as the 3 WG-116 transmission. It covers transmission layout, disassembly, reassembly, AEB setting of the transmission controller clutch, inching calibration and troubleshooting. The drive-axle group adds differential service, axle disassembly and assembly, specifications and fault diagnosis.

Brake coverage includes the brake/inching system description, service-brake troubleshooting, pedal and linkage adjustments, brake bleeding, master-cylinder service and parking-brake service. The general specifications identify a wet-disc service brake system and provide adjustment and holding-test data used during service.

Hydraulics, Steering and Load Handling

A substantial part of SM-751 is dedicated to hydraulic and load-handling systems. The hydraulic sump, filters and pump group covers system description, pump troubleshooting and pump removal and installation. The hydraulic control valve and lift-circuit group contains system specifications, a hydraulic schematic, troubleshooting, pressure checks and adjustments, control-valve removal and replacement, and valve overhaul.

Separate groups cover tilt-cylinder specifications, checks, adjustment, removal, replacement and overhaul; the steer axle and steer cylinder; and the hydrostatic power-steering system. Upright service is especially detailed, with specifications, troubleshooting, inspection, carriage and upright roller-clearance checks, shim adjustments, cylinder service, lift-chain inspection and adjustment, fork and carriage removal, and complete upright removal and replacement.

Electrical and Instrument Diagnosis

The electrical group contains precautions for electrical work, system specifications, electrical circuit diagrams, component arrangement and instrument-pod information. This is useful when tracing starting, charging, warning, interlock, sensor or harness-related faults because the manual shows system circuits as well as component locations and diagnostic information. The specifications section also consolidates system-voltage, battery, starter and alternator information used elsewhere in the book.

Chapters Covered

• Group SA – Safe Maintenance: Safety; lifting, jacking and blocking the truck; towing.
• Group PS – Periodic Service: Maintenance schedules; Planned Maintenance Program.
• Group 00(D) – Engine (N45-MNS): General specifications; fuel; industrial application/mechanical-injection engine service; overhaul and technical specifications; tools; engine replacement.
• Group 01 – Engine Cooling System: Specifications and description; troubleshooting; testing and maintenance; radiator removal and replacement.
• Group 03 – Air Induction and Exhaust System: Specifications and description; troubleshooting; air-induction service; exhaust systems.
• Group 06 – Transmission (3 WG-116): Layout; disassembly; reassembly; AEB setting of T/M controller clutch and inching calibration; troubleshooting.
• Group 13 – Electrical System: Electrical-work cautions; system specifications and features; electrical circuit diagrams and parts arrangement; instrument pod.
• Group 20 – Drive Axle: Specifications and description; differential; drive-axle disassembly and assembly; troubleshooting.
• Group 22 – Wheels and Tires: Specifications and description; pneumatic wheels and tires.
• Group 23 – Brake System: Brake/inching specifications and description; service-brake troubleshooting; pedal and linkage adjustment; brake bleeding; master-cylinder service; parking-brake service.
• Group 25 – Steering Column and Gear: Specifications and description; steering troubleshooting; steering-column/component removal and replacement; relief-pressure check and adjustment; steering-gear overhaul.
• Group 26 – Steer Axle: Specifications and description; wheel-bearing maintenance and adjustment; axle removal and replacement; axle overhaul; steer-cylinder removal and replacement; steer-cylinder overhaul.
• Group 29 – Hydraulic Sump, Filters and Pump: Specifications and description; main hydraulic-pump troubleshooting; pump removal and installation.
• Group 30 – Hydraulic Control Valve/Lift Circuit: Specifications and description; hydraulic-system schematic; troubleshooting; pressure checks and adjustments; control-valve removal and replacement; control-valve overhaul.
• Group 32 – Tilt Cylinders: Specifications and description; checks and adjustments; cylinder removal and replacement; cylinder overhaul.
• Group 34 – Uprights: Specifications and description; troubleshooting; upright inspection; roller-clearance checks and shim adjustments; cylinder removal, shimming, overhaul and replacement; chain inspection and adjustment; fork and carriage service; upright removal and replacement.
• Group 38 – Counterweight and Chassis: Counterweight specifications; counterweight removal and replacement; overhead guard/operator’s cell removal and replacement; floorboard, radiator cover and seat-deck service; operator’s seat removal and replacement.
• Group 40 – Specifications: Nameplates and decals; general specifications; hydraulic fitting tightening procedures.

Taken together, these groups provide a structured path from scheduled servicing through system-level diagnosis and into major component repair. Maintenance charts identify recurring inspection, lubrication and replacement tasks, while the dedicated troubleshooting sections help narrow faults before parts are removed. The later specification pages consolidate truck capacities, weights, performance data, hydraulic settings, engine data, wheel and tire information, brake data, steering values and critical fastener torques for service reference.

Service Procedures and Technical Reference

Illustrated procedures show safe lifting and blocking, engine removal, radiator service, air-cleaner service, transmission work, drive-axle and differential work, hydraulic-valve and cylinder service, upright repair and chassis disassembly. The manual repeatedly pairs service steps with cautions, torque requirements, clearance checks and adjustment values. This matters on a C60D, C70D or C80D because many procedures depend on correct setup, measured wear limits and specified fastener tightening rather than visual judgment alone.

Periodic-service information covers inspection and lubrication routines along with longer-interval work. The engine section adds its own maintenance planning, including engine-oil and filter replacement, fuel-filter service, belt service and tappet-clearance checks. Cooling-system chapters include coolant inspection, pressure testing, thermostat testing, draining, flushing and refilling. Air-induction coverage explains filter service and intake restriction concerns, while the hydraulic groups provide pressure-check and adjustment procedures for the load-handling circuits.

For major repairs, the manual contains the kind of reference information needed during disassembly and reassembly: component orientation, tool references, tightening sequences, clearances, dimensions, service limits and inspection criteria. Electrical diagrams and hydraulic schematics help connect a symptom to the circuit involved, while exploded and sectional illustrations make component relationships easier to follow during workshop work.

Get the Correct Service Information for Your CLARK C60D, C70D or C80D

The Clark C60D C70D C80D Forklift Service Manual SM-751 – PDF is suited to maintenance, diagnosis, adjustment and repair work across the truck’s engine, transmission, brakes, steering, electrical, hydraulic, upright and chassis systems. Using the procedures, specifications and diagrams in the manual helps a technician work to the documented settings and service methods instead of relying on guesswork during component inspection or reassembly.

IMAGES PREVIEW

After payment, the manual is delivered as an instant PDF download. There is no physical book and no shipping delay. You can open the PDF on a compatible computer, tablet or phone, keep it available for workshop reference, and print the pages you need for a particular service job.