CLARK FORKLIFT OH-390 ITS0D, IT60D, IT70D, IT80D OVERHAUL MANUAL

OH-390 ITS0D, IT60D, IT70D, IT80D

COfl) n11hted Maie,1.11 Intended for CLARK deal"" ool" Do nol sdl oc tl,srnl>utc

ClARK

GROUP 00

GROUP 00 SECTION

7 E N G I N E P E R K I N S

O V E R H AU L D I E S E L

Code: OH-350, MAY 81

Section 7, Page l (.,p�nihlcJ lui<:ri.ll l111Md,-.l l<>r <.:L\R� dc:•lc1 unly not wll « dhtr�,u•�

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CIARK

GROUP

00

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PERKINS ENGINE ASSEMBLY Fig. 22369

4 & 6 CYLINDER

Parts, accessories and manuals for Perkins Engines are available from your Clark dealer.

Section 7, Page 2

Copynghtul M,uw.:,I Intended for CL\RK dc�lcr, only Do nol &ell or di>1rlbu1e

Code: OH-350, MAY 81

INDUSTRIAL TRUCK DIVISION

MARKETING TRAINING DEPT

F O R E W O R D This overhaul manual has been written to aid the mechanic in the disassembly and assembly of the main components of the specific truck that this manual includes. 'Every improvement has been made to help the mechanic to discharge his duties in a safe and practical procedure.

This manual has been written in groups and sections vi.th a table of contents for easy reference.

Each section includes many photographs and drawings to directly show how to do these operations.

The mechanic is told to always use Genuine Clark Parts when replacements are needed. "Look alike" parts from other supplies never work as well as the original parts.

Specifications and notes on safety have been included as needed for each step to be done. The mechanic is told to use safety and accuracy in his work because we cannot control his work and procedures.

Code: OH-339, MAR 81 P.S.L.

If the mechanic does not understand the right procedure in the maintenance of this truck, he is told to see his immediate supervisor instead of risking injury of personnel.

Approved methods of service and correct procedures of repair are important for the safe operation of all trucks as well as the safety of �ersonnel and the mechanic doing the work. This manual gives directions for service and repairs vi.th procedures that are tested.

There are many diJferent procedures, tools, and parts for servicing vehicles, as well as in the ability of the mechanic doing the work. This manual cannot be written for all such variations. Any mechanic who works differently from this manual must first make sure that he works safely and accurately.

C.opyn11htro Makrul Intended for CL'\RK d�alm. onlv Do nol •�II or ti, 1ribu1e

Page 1

INDUSTRIAL TRUCK DIVISION

MARKETING TRAINING DEPT.

T A B L E

0 F

C O N T E N T S GROUP

Alternator Brake Master Cylinder

Carriage Roller Adjustment (Triple Stage)

Differential and Carrier Drive Axle Drive Shaft • Engine

Hydray1 ic Pump

Hydraulic Valve .

Lift Chain Adjustment Lift Chain Maintenance

..........

.......... .............. .... .... .... ..

Lift Cylinder • • • , ,

Lubrication Specifications Parking Brake Starter

..... ............ ...........

Steering Cylinder • Steering Gear .

Tilt Cylinder

Tilt Lock Valve .

Transmission, Forvard & Reverse • • Transmission Speed Change .

Upright Roller Adjustment

Wiri.ng Diagram

Page 2

LOtS

12

1

34

10

12 23

....

2173

2189 and above .

3 3

20 20

14 12

29

7 7

21 00

2

30

1

34 34

7

34

3 1

40 23

4 29

26 25

10 2

31 06

2 7

11

32

4

6

08

4 2

34

11

34

Upright Roller Adjustment (Triple Stage) Wheel Brake Assembly Wheel Brake Cylinder

Section

23 23

IN-16065

30 10

IN-16715

Code: OH-390, APR 81 Cop�n11htcd MJh!nal lntmdcd for CLJ\Rli. dc�lcn onl} Do not •�II or distnbu�

ClARK

GROUP

06

GROUP 06 SECTION

7 0 V E R H A U L F O R W A R D

&

P RO C ED U R E S

R EV E R S E

T A B L E

O F

F O R

T R A N S M I S S I O N

C O N T E N T S

Troubleshooting

Page

2

Tr ansmission Dis as s embly

4

Forwar d and Reverse Shaft Disas s embly

8

Forward and Reverse Clutch Assembly

5

Intermediate Shaft Dis as sembly

10

Cleaning and Inspection

11

Output Shaft Ins t allation

13

Reverse Clutch Shaft Inst allatio�

14 14

Ouput Shaft Disass embly Exploded Views

Int ermediat e Shaft Inst allation

Forwar d Clutch Shaft lns t allat. ... .:>n Clutch Cylinder Installation

Char ging Pumy Installation

Code: 0B-390, APR 81 P . S. L.

11

12, 15, 17, 20

13

16

19

Section 7, Page l COll)Tll!hh.-J l\btcrial

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CIARK

GROUP

06

5.

TROUBLESHOOTING GUIDE: 1.

When a transmiss ion failure occurs the following procedures will help in finding the failure.

2.

Make sure the trans mis sion is at normal operating temperature [81-87° CJ or 1 80-200 ° F.

3.

4.

Check the oil level with the trans­ mission warm and the engine idling at 1000 RPM. The unit should be 1n neutral. The "full" and "add" marks on the dipstick are approximately one quart apart. Fill a.s necess ary with automatic transtllission fluid D exron or D exron II or one equal to Clark part number 879804.

Install pressure gauges to the transmiss ion at the correct locations. Check for proper operating pressures, see chart below.

TRANSMISSION PRESSURE E ngine R PM

kPa Min Max

600 31 0 Main Line 2000 88.5 600 220 Converter 2000 620 Input 600 220 Forward Clutch 2000 655 600 220 Reverse 2000 655 Clutch

485 1 1 03 448 792 448 792 448 792

PSI Min Max 45 140 32 90 32 95 32 95

70 160 115 1 15 65

1 15 65

us

Check all external linkage connec­ tions to the s elector valve and inching control valve for too much wear or binding.

TROUBLE

Righ stall speed.

Section 7, Page 2

PROBABLE CAUSE

REMEDY

Low oil level.

Add oil to proper level.

Low converter pres sure

Check converter pres sure and, if low, check main regulating valve, and cooler bypass valve to see if they are in the "stuck open" position.

Slipping Clutch.

(a) Actuate other clutches to verify slipping of particular clutch being checked. (b) Obs erve main pressure at clutch lines to determine if within limits . (c) Overhaul.

Foaming oil.

(a) Too low or too high oil level. (b) Water in oil. (c) Air leak on intake side of pump. (d) Improper oil.

C,,p> nphkd 1\1.,h:n�I lnunJcJ forCL.\RK de�l.-nooh Do not i,dl or d1tmbu�

Code: OR-390, APR 81 P.S.L.

CLARK

GROUP 06

TROUBLE

Continuously high oil temperature.

Low or high oil level.

Add or drain oil.

Foamed oil.

Check for proper oil and whether or not air leak exists on intake side of pump.

Engine cooling system inope rative.

Improper vehicle operation

Slow or erratic clutch engagement.

Improper shift linkag� arrangement or adjus t­ ment.

Free linkage and adjust.

Worn main pump.

Main pres sure regulator valve stuck. Clean, check springs, free up in valve bore. (a) Check other clutches. (b) Check shaft seal rings. (c) Overhaul.

Ins pect pump and replace if worn.

Low oil level.

Add oil.

Cold oil.

Wann and recheck.

Low converter pressure.

Same as "Low clutch pressure" above.

Leak on intake side of main pump.

Ve hicle drives in one direction and creeps in that direction in neutral but stalls when shifted to opposite direction.

(a) Operate in lower gear range. (b) Operate away from stall more frequently.

Converter pressure regulator valve stuck in near closed position.

Internal oil leaks.

Loss of power.

(a) Check radiator coolant level. (b) Eliminate restricted water or oil flow through cooler.

Low oil flow through converter.

Low main pressure.

Low clutch pressures and s low engagement at idle.

REMEDY

PROBABLE CAUSE

Parking brake applied.

Failed direction clutch in direction vehicle Will move.

Code: OH-39O, APR 81 P . S. L.

Check intake line.

Release parking brake.

Overhaul

Section 7, Page 3 l up�r111htol t.lu1,1i.tl ln1roJcd i;,.. 1."L\Rt;. d.:�lcn l'nl\ IJo not .cU « disinbute

ClARK

GROUP 06 FORWARD AND REVERSE TRANSMISSION DISASSEMBLY: 1.

Remove the forvard and reverse unit from

the truck and drain the transmission

fluid from the unit.

2.

Remove the torque converter .

Fig . 10586 3.

Make a mark on the converter pump and transmission housing for correct alignment .

4.

Remove pump mounting bolts.

Fig. 10587

5.

Remove the converter pump straight off the input shaft.

6.

Remove the stator support mounting bolts (1). ·

Fig. 10589

7.

Remove the input shaft bearing locating ring .

Fig. 10591

Section 7, Page 4

C,,p> nphkd 1\1.,h:n�I lnunJcJ forCL.\RK de�l.-nooh Do not i,dl or d1tmbu�

Code: OH-390, APR 8 1 P . S.L.