Clark CMP 50, 60, 70 Service Manual SM-649

Description

• Model List:
  • CMP 50
  • CMP 60
  • CMP 70

• 1. SM649 CMP50/60/70
• 2. Use of this Manual
• 3. Contents
• 4. GROUP SA SAFE MAINTENANCE
• 4.1. Section 1. Safety
• 4.2. Section 2. Lifting, Jacking, and Blocking
• 4.2.1. Safe Parking
• 4.2.2. Lifting, Blocking, and Jacking Points
• 4.2.3. Raising Drive Wheels Off Floor
• 4.2.4. Raising Truck with a Hoist
• 4.2.5. Blocking the Upright In Raised Position
• 4.2.6. Raising Rear of Truck
• 4.2.7. Raising Entire Truck
• 4.2.8. Shipping TieDown Instructions
• 4.3. Section 3. Towing
• 5. PERIODIC SERVICE
• 5.1. Section 1. Maintenance Schedules
• 5.1.1. Service Chart/Lubrication Points
• 5.1.2. Recommended Periodic Service Schedule
• 5.2. Section 2. The Planned Maintenance Program
• 5.2.1. Introduction to Planned Maintenance
• 5.2.2. The Basic PM Procedures
• 5.2.3. Visual Inspection
• 5.2.4. Functional Tests
• 5.2.5. Air Cleaning the Truck
• 5.2.6. Truck Chassis Inspection and Lubrication
• 5.2.7. Upright and Tilt Cylinder Lubrication
• 5.2.8. Lift Chain Lubrication
• 5.2.9. UndertheHood Inspection
• 5.2.10. Fluid Checks
• 5.2.11. Stall Test
• 5.2.12. Cranking Voltage Test
• 5.2.13. Critical Fastener Torque Checks
• 5.3. Section 3. The PM Form
• 6. GROUP 00 ENGINE
• 6.1. Lubrication Diagrams
• 6.2. Perkins WORKSHOP MANUAL
• 6.2.1. Contents
• 6.2.2. General information
• 6.2.3. Specifications
• 6.2.4. Cylinder head assembly
• 6.2.5. Piston and connecting rod assemblies
• 6.2.6. Crankshaft assembly
• 6.2.7. Timing case and drive assembly
• 6.2.8. Cylinder block assembly
• 6.2.9. Engines fitted with CAV fuel injection pumps
• 6.2.10. Lubrication system
• 6.2.11. Engines fitted with a rotary fuel injection pump
• 6.2.12. Cooling system
• 6.2.13. Flywheel and flywheel housing
• 6.2.14. Electrical equipment
• 6.2.15. Power steering pump
• 6.2.16. List of special tools
• 7. GROUP 01 COOLING SYSTEM
• 7.1. Section 1. Cooling System Specifications and Description
• 7.2. Section 2. Cooling System Troubleshooting
• 8. GROUP 06 TRANSMISSION
• 8.1. DISASSEMBLY / REASSEMBLY
• 8.1.1. DISASSEMBLY AND REASSEMBLY OF(IST) AND 2ND CLUTCH
• 8.1.2. DISASSEMBLY AND REASSEMBLY OF 3RD CLUTCH
• 8.1.3. DISASSEMBLY AND REASSEMBLY OF FORWARD AND REVERSE CLUTCHES
• 8.1.4. REGULATOR VALVE DISASSEMBLY AND REASSEMBLY
• 8.1.5. DISASSEMBLY AND REASSEMBLY OF SPACER PLATE
• 8.1.6. DISASSEMBLY AND REASSEMBLY OF CONVERTER HOUSING
• 8.1.7. OUTPUT FLANGE OIL SEAL SLEEVE DISASSEMBLY AND REASSEMBLY
• 8.1.8. OUTPUT FLANGE AND PARKING BRAKE DISC
• 8.2. REASSEMBLY OF TRANSMISSION
• 8.2.1. ELECTRIC CONTROL VALVE ASSEMBLY
• 8.2.2. DRIVE PLATE INSTALLATION
• 8.2.3. TRANSMISSION TO ENGINE INSTALLATION PROCEDURE
• 8.2.4. SPECIFICATIONS AND SERVICE DATAPOWER SHIFT TRANSMISSION AND TORQUE CONVERTER
• 8.2.5. LUBRICATION
• 8.3. SERVICING MACHINE AFTER TRANSMISSION OVERHAUL
• 8.4. EXTERNAL PLUMBING AND PRESSURE CHECK POINTS
• 8.5. CLEANING AND INSPECTION
• 8.6. PARKING BRAKE LINING AND PISTON REPLACEMENT PROCEDURE
• 8.7. TROUBLESHOOTING GUIDE FOR THE TRANSMISSION
• 8.7.1. Stall Test
• 8.7.2. Transmission Pressure Checks
• 8.7.3. Mechanical Checks
• 8.7.4. Hydraulic Check
• 8.7.5. CONVERTER STALL PROCEDURE
• 8.7.6. TROUBLESHOOTING GUIDE
• 8.8. SPEED ASSEMBLY INSTRUCTION
• 8.9. ASSEMBLY NOTES
• 8.10. TORQUE SPECIFICATION FOR LUBRICATED OR PLATED SCREWS AND NUTS
• 9. GROUP 14 ELECTRICAL
• 9.1. Section 1. Electrical System Specifications and Circuit Diagram
• 9.2. Section 2. Instrument Pod
• 10. GROUP 20 DRIVE AXLE
• 10.1. Section 1. Drive Axle Specifications and Description
• 10.2. Section 2. Drive Axle Overhaul
• 10.2.1. Overhaul Specifications
• 10.2.2. Drive Axle Disassembly
• 10.2.3. Differential Disassembly
• 10.2.4. Drive Axle Cleaning
• 10.2.5. Drive Axle Inspection
• 10.2.6. Differential Reassembly
• 10.2.7. Drive Axe Reassembly
• 11. GROUP 22 WHEELS AND TIRES
• 11.1. Section 1. Wheels and Tires Specifications and Description
• 11.2. Section 2. Pneumatic Wheels and Tires
• 11.2.1. Pneumatic Tire Maintenance Precaution
• 11.2.2. General Tire Maintenance, Inspection, and Repair
• 11.2.3. Wheel Dismounting and Remounting
• 11.2.4. Drive and Steer Wheel Dismounting
• 11.2.5. Drive and Steer Wheel Remounting
• 11.2.6. DualDrive Wheel Dismounting
• 11.2.7. DualDrive Wheel Remounting
• 11.2.8. Wheel Disassembly and Tire Removal
• 11.2.9. Tire Replacement and Wheel Reassembly
• 11.2.10. TiretoWheel Mounting
• 11.2.11. Filling Tires with Air
• 11.2.12. Filling Tires with Nitrogen
• 11.2.13. Checking and Adjusting Tire Pressure
• 12. GROUP 23 BRAKES
• 12.1. Section 1. Brakes Specifications and Description
• 12.2. Section 2. Service and Inching Brakes
• 12.2.1. Pedals Adjustment
• 12.2.2. Brake Bleeding
• 12.2.3. Removal/Installation of Master Cylinders and Pedal Arramgement
• 12.2.4. Brake Valve Overhaul
• 12.2.5. Brake Shoe and Lining Replacement
• 12.2.6. Wheel Cylinder Inspection
• 12.2.7. Brake Drum Inspection
• 12.2.8. Automatic Adjuster
• 12.2.9. Special Brake Tools
• 12.3. Section 3. Parking Brake
• 12.3.1. Parking Brake Adjustment
• 12.3.2. Lever and Cable Installation
• 12.3.3. Parking Brake Lining and Piston Replacement
• 12.3.4. Parking Brake Adjustment
• 13. GROUP 25/26 STEERING SYSTEM
• 13.1. Section 1. Steering System Specifications and Description
• 13.1.1. Specifications
• 13.1.2. Description
• 13.1.3. Schematic
• 13.1.4. Construction
• 13.1.5. Operation
• 13.2. Section 2. Steering System Troubleshooting
• 13.3. Section 3. Steering System Removals and Replacements
• 13.4. Section 4. Steering System Pressure Check and Adjustment
• 13.5. Section 5. Steering Unit Overhaul
• 13.6. Section 6. Priority Valve Overhaul
• 13.7. Section 7. Steer Cylinder Overhaul
• 14. GROUP 29/30 HYDRAULIC SYSTEM
• 14.1. Section 1. Hydraulic System Specifications Schematic Diagram
• 14.2. Section 2. Hydraulic System Troubleshooting
• 14.2.1. Pressure Check and Adjustment
• 14.2.2. Control Valve Troubleshooting
• 14.3. Section 3. Hydraulic Pump Overhaul
• 14.3.1. Main and Auxiliary Pumps Removal and Replacement
• 14.3.2. Main and Auxiliary Pump Overhaul
• 14.4. Section 4. Hydraulic Valve Overhaul
• 14.4.1. Removal and Replacement
• 14.4.2. Description
• 14.4.3. Disassembly
• 14.4.4. Assembly
• 14.4.5. Inspection and Assessment
• 15. GROUP 34 UPRIGHT
• 15.1. Section 1. Upright Specifications and Description
• 15.2. Section 2. Upright Checks and Adjustments
• 15.2.1. Performing Visual Inspection
• 15.2.2. Checking and Adjusting Carriage Side Roller
• 15.2.3. Checking Carriage and Mast Shim
• 15.2.4. Adjusting Standard Mast Shim
• 15.2.5. Adjusting Full Free Lift TwoStage Mast Shim
• 15.2.6. Adjusting Full Free Lift ThreeStage Mast Shim
• 15.2.7. Checking and Adjusting Cylinder Racking
• 15.3. Section 3. Lift Chain Service
• 15.4. Section 4. Removals and Replacements
• 15.4.1. Removing and Installing Mast
• 15.4.2. Carriage Removal and Replacement
• 15.5. Section 5. Lift and Tilt Cylinder Overhaul
• 16. GROUP 38 COUNTERWEIGHT
• 16.1. Section 1. Specifications
• 16.2. Section 2. Inspection
• 16.3. Section 3. Removal and Replacement
• 17. GROUP 40 SPECIFICATIONS
• 17.1. Section 1. Specifications
• 17.1.1. Dimensions and Weight Specifications
• 17.1.2. Performance Specifications
• 17.1.3. Service Specifications by Group
• 17.1.4. Fluids Specifications
• 17.1.5. Critical Torque Specifications
• 17.1.6. Standard Tightening Torque
• 17.1.7. Metric Conversion Chart
• 17.1.8. Hydraulic Fitting Tightening Procedure