CLARK FORKLIFT CGP I CDP 16-50 H Hydrostatic Transmission SERVICE MANUAL -PDF DOWNLOAD

CUARK

Material Handling Europe

CGP I CDP 16-50 H Hydrostatic Transmission

Service Manual SM 5190 GEF GB

Illustrations, descriptions, diagrams and other particular only serve for elucidation and presentation of the text.

They are not binding as regards details of construction, installation or delivery. We do not undertake liability for conformity of the text with national or local regulations. Subject to revision.

Copyright © 2001

by CLARK Material Handling GmbH

All rights reserved.

Reprinting, reproduction of extracts or translation into other languages require our express permission.

No part of this work may be reproduced in any form, or stored, processed, duplicated or distributed using electronic systems, without our prior permission.

,•."

•l

Group 06 (H), Transmission (Hydrostatic)

GROUP 06 (H) Hydrostatic Transmission

Specification and Description ................................................. Section 1 Elektronic-Control ..................................................................... Section 2

Service Manual Variable Displacement Pump ..•••..•............... Section 3 Service Manual Drive Axle CDP/CGP 16-20H (MCR 3) •......... Section 4 Service Manual Drive Axle CDP/CGP 20-35H (MCR 5) .•.....•. Section 5 Service Manual Drive Axle CDP/CGP 40-S0H (MCR 10) •..... Section 6 Diagrams .................................................................................... Section 7 Actuators-Throttle Goveror & Brake Valves ..........•................ Section 8 Service-Informations ..•....••...•••••.....•......•.•....................•........... Section 9

SM 5190, Oct'01

Hydrostatic Transmission

Group 06 (H), Transmission (Hydrostatic)

Abbildungen, Beschreibungen, Schemazeichnungen und andere Angaben dienen nur der Erlauterung und Darstellung des Textes. Sie konnen nicht als Grundlage fur Kon­ struktion, Einbau und Lieferumfang verwendet werden. Wir Obernehmen keine Haftung auf Vollstandigkeit und die Obereinstimmung des lnhaltes mit den jeweils geltenden gesetzlichen Vorschriften. Anderungen vorbehalten.

Copyright © 2001

by CLARK Material Handling GmbH Alie Rechte vorbehalten.

Nachdruck, auszugsweise Wiedergabe und Obersetzung in andere Sprachen dOrfen nur mit unserer ausdrOcklichen Genehmigung erfolgen.

Kein Teil des Werkes dart ohne unsere Genehmigung in irgendeiner Form reproduziert oder unter Verwendung elektronischer Systeme gespeichert, verarbeitet, vervielfaltigt oder verbreitet warden.

Hvdro�t.11tlr. Trs1nc:mlctctlnn

Group 06 (H), Transmission (Hydrostatic)

Section 1 Specifications and Description Maitenance Intervals ...................................................................................................... 1 Description ...................................................................................................................... 2 Installation Variable Displacement Pump CDP/CGP 16-20H ..................................... 4 Installation Variable Displacement Pump CDP/CGP 20-35H ..................................... 5 Installation Variable Displacement Pump CDP/CGP 40-S0H ..................................... 6 Hydraulic Diagram CDP/CGP 16-20H ........................................................................... 7 Hydraulic Diagram CDP/CGP 20-35H ........................................................................... 8 Hydraulic Diagram CDP/CGP 40-S0H ........................................................................... 9

Maintenance Intervals Maintenance and Maintenance Intervals. see Operator Instruction.

SM 5190, Oct.'01

Specifications and Description • 06 (H) -1-1

Group 06 (H), Transmission (Hydrostatic) Description

The diagram below shows the flow of information into and out of the computer that controls the drive system-the SUSMIC 12 microprocessor.

In the hydrostatic drive truck, power is transmitted to the drive wheels by hydraulic-powered motors, rather than by gears and clutches. The entire system is depicted on the next page. The control system is depicted below.

The inputs consist of signals from the various sensors and switches that are affected by positioning of the truck's manual controls.

The signals from the switches consist of either an open or closed circuit. The signal from the engine speed sensor consists of pulses ranging from 0 to 9.9 kHz (cycles per second), increasing as engine speed increases. The signals from the other sensors consists of 0 to 5-volt levels that vary according to the position of the associated control.

The hydrostatic truck's conventional spark-ignited or diesel engine rotates a hydraulic pump, the "hydrostatic drive pump,• that supplies fluid to two hydraulic mo­ tors in the drive axle. Each motor drives a drive wheel.

The hydraulic fluid is drawn from the same sump that supplies the load handling system. [Incidentally, the pump for the load-handling system (covered in Group 29) is mounted on, and mechanically driven by, the hydrostatic drive pump.]

The outputs consists of electrical power to the engine actuator and to the EDC. Zero to 12 volts are sup­ plied to the engine actuator and 0 lo 100 mA are supplied to the EDC.

The hydrostatic drive pump is a variable displacement axial piston pump. Pump output volume and direction of flow are governed by the pump's swashplate. The angle at which the swashplate is tilted controls the length of the piston strokes as the pistons rotate past inlet/outlet ports. Swashplate angle is controlled by an electrical displacement control (EDC). The EDC hydraulically varies the angle of the swashplate in response to the electrical signal level received from the comput

As the truck operates, the computer monitors the positions of the various manual controls in order to sense the desired performance; while at the same time, the computer monitors engine speed and en­ gine actuator position in order to sense the actual performance.

To make the actual performance match the desired performance, the computer varies the engine throttle position via the engine actuator and the drive pump output via the EDC.

The fluid displaced by the drive pump flows through external plumbing to the radial piston drive motors in the drive axle. The volume and direction of the fluid determines the speed and direction of the truck. Each drive motor is connected to an axle shaft that drives an axle end and wheel identical to those used on the standard truck. Parallel circuitry to the drive motors allows a speed differential between the motors when the truck is cornering.

Tilt Switch

Aux 1&2 Switches

.:,,".... ....: ········1........

Parking Brk Switch

Acc. Pedal Sensor

The system can be diagnosed and adjusted with a diagnostic control, usually the SUSMIC-DIA 3, that connects to the SUSMIC 12 computer.

Eng. Actuator Sensor

Brake Pedal Sensor

COMPUTER (SUSMIC 12 MICROPROCESSOR)

,

f'' ••

: Diagnostic : : : Control ,

•··············..

Engine Actuator

Electrical Displacement Control

Throttle

Drive Pump

06 (H) -1-2 • Specifications and Description

Lift Lever

Group 06 (H), Transmission (Hydrostatic)

DRIVE

DRIVE

MOTOR

Drive Axle

MOTOR

Lift Tilt& Aux.

COMPUTER (SUSMIC-12 Micro­ prozcessor)

Hydraulic Pump

z p

T

......,____,,.... Brake L.!....J Valve

Diagnostic Interface Hydraulic Control Axial Valve Displacement Pump

Engine Speed Sensor (PPU)

_j����;r-------.--------­

Electrical _ Displacement

·;...�+ c(��� [;·············

p

e:

+

•

�

·t

Adaptor

:'!> Coupling

Accelerator Pedal Sensor

Engine {Throttle) Actuator and Feedback Sensor Engine (Diesel Shown)

►

= Control Signal

= Hydraulic Line Direction Control Lever

SM 5190, Ocl'01

Specifications and Description • 06 (H) -1 ·3

Group 06 (H), Transmission (Hydrostatic) Installation Variable Displacement Pump CDP/CGP 16-20H

Torque To

20-25 Nm (6x MS)

Torque To

40-45 Nm (7x M10)

Torque To

115-130 Nm

Torque To

40-50 Nm (2x)

Torque To

20-25 Nm (2x MS)

Torque To

40-45 Nm (2x M1O)

Torque To 20-25 Nm

Torque To

40-45 Nm (2x M10)

06 (H) -1-4 • Specifications and Description

Torque To

110-125 Nm (4x M14)

SM 5190. Oct.'01

Group 06 (H), Transmission (Hydrostatic) Installation Variable Displacement Pump

CDP/CGP 20-35H Prior to mounting Pump, Hub must be Installed on Pump Input Shaft and torqued to 60-65 Nm.

,f

.J

I

Torque To 40-45 Nm (8x M10)

�

.4/:

�

'· �� ca,

Torque To 34-38 Nm (2x) Torque To 70-SO Nm (4x M12)

Prior to mounting Pump, Hub must be Installed on Pump Input Shaft and torqued to 50-55 Nm.

SM 5190, Oct.'01

Specifications and Description • 06 (H) -1-5

Group 06 (H), Transmission (Hydrostatic) Installation Variable Displacement Pump CDP/CGP 40-S0H Prior to mounting Pump, Hub must be Installed on Pump Input Shaft and torqued to 50 Nm

View.,X"

TorqueTo 20-25 Nm (6x MS)

/

TorqueTo 20-25 Nm (6x 3GM/M8) TorqueTo 70-75 Nm

DIESEL

TorqueTo 40-50 Nm (3xM10)

TorqueTo 110-125 Nm (4xM14)

06 (H) -1-6 • Specifications and Description