Clark EC 90, 120 Forklift Service Manual
314 pages · Publication SM-646
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- Models
- EC 90, 120
- Manual type
- Service Manual
- Pages
- 314
- Publication
- SM-646
- Condition
- Brand new
What's inside
From the manual's own table of contents: 17 sections, 275 entries. See sample pages (PDF, 266 KB)
Arrangement and Use of this Manual
Alphabetical Listing
GROUP SA SAFE MAINTENANCE7 topics
- Section 1. Safety
- Section 2. Lifting, Jacking, and Blocking
- Raising Drive Wheels
- Chaining the Upright in Raised Position
- Raising Rear of Truck
- Raising Entire Truck
- Shipping Tie-Down Instructions
GROUP PS PERIODIC SERVICE18 topics
- Section 1. Maintenance Schedule
- Periodic Service” and “Planned Maintenance
- Determining Maintenance Intervals
- Lubrication Points
- Lubrication Chart Key
- Corrosion Protection
- Recommended Periodic Service Schedule
- Section 2. The Planned Maintenance Program
- Introduction to Planned Maintenance
- External Inspection
- Operational Checks
- Internal Inspection
- Air Cleaning the Truck
- Minor Adjustments Covered by PM
- Axle and Chassis Lubrication
- Critical Fastener Torque Checks
- Wrapping Up the PM
- Section 3. The PM Inspection Form
GROUP 12 BATTERY7 topics
- Section 1. Battery Service
- Battery Handling
- Battery Removal
- Battery Maintenance
- Battery Installation
- Keeping Battery Records
- Battery Tests
GROUP 13 WIRING, SWITCHES, AND INSTRUMENTS13 topics
- Section 1. Electrical Diagrams
- Section 2. General Electrical Service Tips
- Safe Preparations
- Checking Power Cables
- Torquing Fasteners
- Connecting and Mounting Components
- Section 3. Switches and Sensors
- Accelerator Control Switch
- Brake Switches
- Seat Brake Switch
- Direction Control Switches
- Lift and Tilt Pump Switches
- Section 4. Instrument Panel
GROUP 16 ELECTRICAL MOTORS20 topics
- Section 1. Motors Specifications and Description
- Specifications
- Section 2. Motors Inspection and Troubleshooting
- Inspection Procedures
- Brush and Commutator Maintenance
- Section 3. Drive Motor Overhaul
- Drive Motor Removal
- Drive Motor Installation
- Drive Motor Assembly
- Section 4. Lift Pump Motors
- Lift Pump Motors R&R
- Hydraulic Lift Pump Motor Overhaul
- Disassembly
- Frame and Field Assembly
- Testing
- Frame and Field Service Notes
- Assembly
- Section 5. Steer Pump Motor Overhaul
- Motor Removal and Installation
- Steer Pump Motor Overhaul
GROUP 19 MOTOR CONTROLS30 topics
- Section 1. Specifications and Description
- Drive Motor Control Description
- EV200LX General Description
- Circuit Schematic
- EV-200 Features
- Control Panel Components and Connections
- Panel Layout
- Plug Connectors
- Contactors Description
- Section 2. Control System Maintenance and Checks
- Control Panel Maintenance
- Control Panel Troubleshooting
- EV-200LX Components Checks
- EV200LX Recommended Function Checks
- Test Equipment
- Test Procedures
- Card Factory Settings
- Section 3. Control Panel Removal and Replacement
- Control Panel Removal
- Control Panel Installation
- Oscillator Card
- Section 4. Contactors Overhaul
- Removal and Replacement
- Contactor Overhaul
- IA, Main Pump and Regen Brake Contactors
- Power Steering and Field Weakening Contactors
- Forward and Reverse Contactor
- Section 5. EV-200 LX Handset Operation Supplement
- Section 6. EV-200 LX Status Codes
- Blank/01
GROUP 20 DRIVE AXLE28 topics
- Section 1. Drive Axle Specifications and Description
- Specifications
- Description
- Section 2. Drive Axle Troubleshooting
- Troubleshooting Techniques
- Symptoms and Causes
- Section 3. Drive Axle Removal and Installation
- Drive Axle Removal and Installation
- Section 4. Drive Axle Overhaul General Practices
- General Practices
- Disassembling Components
- Cleaning Parts
- Inspecting Parts
- Repairing and Replacing Parts
- Assembling Components
- Section 5. Drive Axle Ends Overhaul
- Drive Axle Removal and Installation
- Drive Axle Ends Disassembly
- Drive Axle Ends Assembly
- Section 6. Drive Axle Differential Adaptor Overhaul
- Differential Adaptor Removal & Installation
- Differential Adaptor Disassembly
- Differential Adaptor Assembly
- Section 7. Drive Axle Differential Overhaul
- Differential Disassembly
- Differential Assembly
- Backlash and Gear Tooth Pattern Adjustment
- CHECK RING AND PINION TOOTH CONTACT
GROUP 22 WHEELS AND TIRES1 topic
- Section 2. Cushion Wheels and Tires
GROUP 23 BRAKE SYSTEM30 topics
- Section I. Brake System Specifications and Descriptions
- Specifications
- Service Requirements
- Service Brake Operation
- Service Brake Disc and Caliper Assembly
- Seat Brake Operation
- Section 2. Service Brake Troubleshooting
- Section 3. Pedal and Linkage Adjustments
- Introduction
- Pedal Travel Adjustment
- Foot Brake Linkage
- Section 3. Service Brake Linkage Adjustment
- Section 4. Brake System Bleeding
- When to Bleed Brakes
- Bleeding Brake System
- Section 5. Brake Master Cylinder Service
- Master Cylinder Removal
- Master Cylinder Installation
- Master Cylinder Overhaul
- Section 6. Service Brake Overhaul
- Operation
- Brake Removal and Installation
- Brake Disassembly
- Brake Inspection
- Brake Assembly
- Brake Lining Inspection
- Brake Lining Replacement
- Section 7. Seat Brake Service
- Seat Brake Test
- Seat Brake Adjustment
GROUP 25 STEERING SYSTEM33 topics
- Section 1. Steering System Specifications and Description
- Specifications
- Steering Hydraulics Description
- Steer Axle Description
- Steer Column Description
- Steering Circuit Schematic
- Section 2. Steering System Troubleshooting
- Section 3. Steering System Relief Pressure Check and Adjustment
- Description and Operation
- Relief Pressure Setting Check and Adjustment
- Section 4. Steering Column Removal and Installation
- Ignition Switch Removal
- Handwheel and Horn Button Assembly Removal
- Directional Control Assembly Removal
- Column Tilt Lock and Steering Gear Assembly Removal
- Steering Column and Component Installation
- Section 5. Steering Gear Overhaul
- Disassembly
- Parts Inspection
- Assembly
- Section 6. Steering Pump Overhaul
- Steering Pump Removal
- Steering Pump Installation
- Steering Pump Disassembly
- Steering Pump Assembly
- Steering Pump Exploded View
- Section 7. Steer Axle Maintenance and Overhaul
- Wheel Bearings
- Steer Axle Removal and Installation
- Steer Axle Overhaul
- Section 8. Steer Cylinder Overhaul
- Steer Cylinder Removal and Replacement
- Steer Cylinder Overhaul
GROUP 29/30 MAIN HYDRAULIC SYSTEM37 topics
- Section 1. Main Hydraulic System Specifications and Description
- Specifications
- Serviceable Items
- Service Intervals
- Description
- Section 2. Fluids and Filters
- Hydraulic Sump Tank Fluid Level
- Hydraulic Fluid and Filters Change
- Section 3. Hydraulic System Troubleshooting
- Noisy Pump
- Pump Not Delivering Hydraulic Fluid
- Failure to Build Pressure
- Pump Not Developing Sufficient Pressure
- Pump Output Low
- Overheated Pump and/or Fluid
- External Leakage
- Shaft Seal Leakage
- No lift, tilt, or auxiliary function
- No motion, slow or jerky action of hydraulic System
- Foaming hydraulic fluid
- Overheated hydraulic fluid
- Load cannot be lifted to maximum height
- Oil leaks at top of lift (secondary) cylinder(s)
- leak at tilt or auxiliary function cylinder
- Load will not hold
- Oil leaks at either end of main hydraulic valve
- Spring-centered spools do not return to neutral
- Untitled
- Load drops when spool is moved from neutral to lift position
- Section 4. Hydraulic System Pressure Checks and Adjustments
- Main Hydraulic System Pressure
- Section 5. Main Hydraulic Pump Overhaul
- Pump Removal
- Overhaul
- Section 6. Hydraulic Control Valve Removal and Overhaul
- Hydraulic Control Valve Removal and Installation
- Overhaul
GROUP 32 TILT CYLINDERS9 topics
- Section 1. Tilt Cylinder Specifications and Description
- Section 2. Tilt Cylinder Checks and Adjustments
- Tilt Cylinder Drift Check
- Tilt Cylinder Racking Check
- Section 3. Tilt Cylinder Mounting and Overhaul
- Tilt Cylinder Removal and Replacement
- Parts Inspection
- Tilt Cylinder Overhaul
- Section 4. Tilt Lock Valve Overhaul
GROUP 34 UPRIGHTS9 topics
- Section 1. Upright Removal and Replacement
- Upright Removal
- Upright Replacement
- Upright to Drive Axle Mounting
- Section 2. Lift Chain Inspection and Service Guidelines
- Periodic Inspections
- Chain Length Adjustments
- Chain Lubrication
- Other Lift Chain Service Tips
GROUP 38 COUNTERWEIGHT AND CHASSIS8 topics
- Section 1. Counterweight Removal and Installation
- Counterweight Removal
- Counterweight Installation
- Section 2. Overhead Guard Removal and Installation
- Overhead Guard Removal
- Overhead Guard Installation
- Section 3. Seat and Sheet Metal Removal and Installation
- Sheet Metal
GROUP 40 SPECIFICATIONS8 topics
- Section 1. Nameplate and Decals
- Nameplate and Decals
- Nameplate and Decal Locations
- Section 2. General Specifications
- Weights and Performance Specifications
- Critical Fastener Torque Specifications
- Group Specifications
- Section 3. Hydraulic Fitting Tightening Procedure
Inside this manual
Real pages from this service manual (314 pages). Open the sample pages (PDF, 266 KB)
- Diagram, page 51: Group 13, Wiring, Switches, and Instruments
- Troubleshooting, page 99: Group 19, Motor Controls
- Specifications, page 295: ClfllW
This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 314 pages
Quantity one is the manual described above.
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Ships in 1 business day.
60-day returns
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Binder not included
Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).