CLARK FORKLIFT OSX 15 SERVICE MANUAL - PDF DOWNLOAD

SERVICE MANUAL OSX 15

Capacity : 1360 kg

Part No. 8089348 Book No. SM 844 Aug. 2010

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

CONTENTS

CONTENTS Group 00. General Information

Group 06. Electrical System

Group 01. Periodic Service

Group 07. Motor Controls

Group 02. Structure and Major Parts

Group 08. Motor - Drive and Pump

Group 03. Drive Axle

Group 09. Hydraulic System

Group 04. Brake

Group 10. Mast Cylinder

Group 05. Drive and Steering System

Group 11. Attachment and Platform

Group 06. Electrical System Group 11. Attachment and Platform

Group 05. Steering System Group 10. Mast Cylinder

Group 07. Motor Controls Group 08. Motor - Pump Group 09. Hydraulic System

Group 08. Motor - Drive Group 03 / 05. Drive Axle and System

Group 04. Brake

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GROUP 00

GROUP 00 GENERAL INFORMATION

General Product Information................... Section 1

Technical Data ............................................Section 2

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Group 00, General Information

Section 1 General Product Information

Truck Presentation The truck is a battery powered order picker truck. The truck is intended solely to be operated indoors carrying pallets or similar load carriers. The truck is equipped with a steering wheel with all the controls for operating within easy access. The truck has a various maximum lifting capacities (review data plate on the truck to note the maximum lifting capacity).

The truck is equipped with a 24V(or 36V) electrical system and the speed is regulated by means of a traction power amplifier (TPA) [transistor controller] to provide gentle control of acceleration and speed while operating. The forks are raised by means of an electric powered hydraulic pump unit. The lift and lower forks thumb knob is on the end of the control handle. Rotating the thumb knob up will lift the forks and rotating the thumb knob down will lower the forks. The truck can be specially equipped to work in cold conditions.

Lift and Lower Steering Wheel

Truck Side Views The terms right-hand and left-hand used indicate the right and left side of the truck as viewed from the operator’s line of sight for proper operation of truck. Use this view when ordering parts to assure proper selection of parts.

Left Side

㶝 㶝

Conrtrol Handle (travel speed / direction) Foreward

Rearward

Right Side

Intended Truck Application The truck is solely designed and manufactured to handle piece picked goods and not full pallets or loads. Truck should be fitted with the appropriate accessories relevant to the application.

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Group 00, General Information Prohibited Truck Application Caution The truck is designed for handling goods indoors. It is not permitted to use the truck for other purposes including the following: •

As a towing tractor for trailers.

•

To tow other trucks.

•

To transport/lift passengers.

•

To drive on gravel or grass.

Truck Data The following table provides information regarding technical data which is of value with daily use of the truck. Lifting capacity, lifting height, and weight of the truck can be found on the truck’s data plate.

Metric dimensions and capacities are show in parenthesis. They have been converted from their original measurements and rounded for convenience.

Truck data

OSX15

Lifting capacity rated load

3000 lbs (1360 kg) at 24 inch (610 mm) load center to 240 inch (6096 mm)

Lift height, inches (mm)

3 stage - 195-366 inch (4953-9296 mm)

Service weight without battery

Approximate 5062 lbs (2296kg) with 210 inch (5334 mm) mast

Service weight including battery

See Sales Truck Specification Sheet for the most up-dated information.

Dimensions

24~28” (610~711mm)

The following diagram shows external dimensions for the truck in its standard design.

1013mm Platform Width

13

19

9

Max. Lift Height

210 inch (5334 mm)

12

Overall Dimensions

78 inch (1981 mm)

13

Width

40 inch (1016 mm)

14

Height, Upright Lowered

95 inch (2413 mm)

16

Height, Overhead Guard

89.4 inch (2270 mm)

17

Step Height

8.2 inch (208 mm)

18

Head Clearance

79.3 inch (2015 mm)

19

Turning Radius

68.7 inch (1746 mm)

36

Wheelbase

57 inch (1448 mm)

37

Ground Clearance

2 inch (51 mm)

9

18 14 16

1210

37

3” (76mm)

36

17

12

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Group 00, General Information Main Components 1. Driver controls: The steering wheel, instrument panel, and switches (key, emergency stop, and light/fan cluster) are on the console cover. The travel speed and direction, hydraulic function, and horn are controlled through the control handle.

2. Steering wheel: Steers the truck in the direction of travel.

3. Dash display: All information to seen about condition of the truck.

4. Key switch: Shuts off electrical power to control system.

5. Emergency power off (EPO) switch: Stops control functions.

6. Lamp switch This functions to turn on various lamp.

7. Brake pedal: The brake is applied in the up position.

8. Pallet clamp: Applies clamping to retain pallets to operator platform.

9. Lower switch: The operator platform and forks will lower when switch is rotated or until lower stops are reached.

10. Raise switch: The operator platform and forks will raise when switch is rotated or until lift stops are reached.

11. Horn: The horn sounds to warn others of your position.

12. Travel speed / direction selection: To select direction rotate in the direction to travel. The further you rotate in that direction the faster you travel.

13. Mast: The mast is clear view model.

14. Hydraulic unit: Pump motor and pump are an integrated unit.

15. Drive unit with brake: Drive motor, gears, drive wheel, and electric brake combine the drive unit.

16. Cover and shields: Easily removed and hinged to provide good access for servicing.

17. Electronics All the electronics are collected in a protected compartment.

18. Battery: 24V(or 36V) battery with different capacities and weights.

19. Load wheel: Load wheel lube location.

20. Tether line, safety belt, and body harness:

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Group 00, General Information

20 14

1 13

2

3

4

5

6

16

12

10

17 9 11

7

8

19

18

15

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Group 00, General Information Inch (SAE) and Metric Fasteners Introduction Threaded fasteners such as bolts, nuts, cap screws, and studs are made to specifications that describe the mechanical strength and hardness of the fastener. A fastener used in a design application is selected in accordance with its specifications. Parts used on this truck are purchased from many countries. Many fasteners are similar but cannot be used as direct replacements.

Service technicians must use replacement fasteners that have the same specifications. Fasteners made to each specification have identification marks for that specification. This specification is commonly called “grade” for SAE standards and “property” for metric standards. This section describes the identification of some common fasteners.

Fastener Torque Values Size and Pitch

Property, Class 8.8

Property, Class 10.9

Property, Class 12.9

N•m

in-lbs

N•m

in-lbs

N•m

in-lbs

M5 x 0.8

5-6

44-53

7-8

62-71

8-10

71-88

M6 x 1

8-10

71-88

12-14

106-124

14-16

124-142

M8 x 1.25

20-25

177-221

30-35

265-309

------------

------------

N•m

ft-lbs

N•m

ft-lbs

N•m

ft-lbs

M8 x 1.25

------------

------------

29-35

22-26

34-40

26-30

M10 x 1.5

40-45

30-33

60-65

44-48

70-75

52-55

M12 x 1.75

70-80

30-33

100-110

74-81

115-130

85-96

M14 x 2

110-125

52-59

155-180

114-133

180-210

133-155

M16 x 2

170-190

125-140

240-270

177-199

280-320

207-236

M20 x 2.5

340-380

251-280

450-500

332-369

550-600

406-443

M24 x 3

580-650

428-479

800-900

590-664

900-1050

664-774

M30 x 3.5

1150-1300

848-959

1600-1800

1180-1328

1850-2100

1364-1549

M36 x 4

2000-2250

1479-1660

2800-3150

2065-2323

3250-3700

2397-2729

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Group 00, General Information

Section 2 Technical Data

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24~28” (610~711mm)

Group 00, General Information

1013mm Platform Width

13

19

9

18 14 16

1210

37

3” (76mm)

36

17

12

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General Information

Group 00, General Information

1 2 3 4 5 6 7 8 9 10

Manufacturer Model Load Capacity Load Center Power Type Operator Type Tire Type Wheels (x=driven)

Manufacturer's Designation

Upright1

Weights3

Performance

Basic Dimensions

11 Fork 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 3 33 3 34

Chassis

35 36 37 38 39 40

Front & Rear Front / Rear Maximum Lift Height, Unload Freelift

in(mm) in(mm)

Std. Fork Size (T x W x L)

in(mm) 2

Overall Dimensions

Step Height Head Clearance Turning Radius Right Angle Stack Aisle Battery Roller Height Stability Speeds Lift Speeds, Loaded Lift Speeds, Unloaded Lower Speeds, Loaded Lower Speeds, Unloaded Service Weight, TSU Axle loading

Tires

Wheelbase Ground Clearance Service Brake Parking Brake Steering

41 Battery Drive Line

lbs(kg) in(mm)

Fork Face to Load CG Electric

42 Motors, Controls

43 Hydraulic Pressure 44 Sound Level

Length to Fork Face (TSU) Width 4 Height, Upright Lowered Height, Upright Extended Height, Overhead Guard Ground to Top of Floor Plate Top of Floor Plate to Bottom of OHG Add Load Length and Clearance 2 Ground to Top of Rollers Accroding to ANSI Travel Speed, Max, With Load Travel Speed, Max, Without Load Triple Stage Upright Triple Stage Upright Triple Stage Upright Triple Stage Upright W/Min Battery Weight With Load, Front With Load, Rear W/O Load, Front W W/O /O Load, Rear Number, Front/Rear

in(mm) in(mm) in(mm) in(mm) in(mm) in(mm) in(mm) in(mm) in(mm) in(mm) mph(kph) mph(kph) fpm(mps) fpm(mps) fpm(mps) fpm(mps) lbs(kg) lbs(kg) lbs(kg) lbs(kg) lb lbs(k (kg)

Size, Front

in(mm)

Size, Rear

in(mm)

At Center of Wheelbase, Loaded Type Type Type Type Max Capacity (6 hr. Rate) Weight, Min Drive Motor, Diameter Hydraulic Motor, Diameter Drive Motor Control Speed Control Hydraulic Motor Control EN 12053

in(mm) in(mm)

kWh lbs(kg) in(mm) in(mm)

dB(A)

CLARK OSX15 3000 (1360) 24 (600) 24 volt Stand Polyurethane 1x / 4 210(5334) 11(279) 1.50x4x42 (40x100x1070) 78.2 (1986) 40 (1016) 95 (2413) 294 (7468) 89.4 (2270) 8.2 (208) 79.3 (2015) 68.9 (1751) 76.7 (1948) 7.4 (188) Yes 7.5 (12.0) 7.5 (12.0) 53 (0.27) 66 (0.34) 84 (0.43) 79 (0.40) 6548 (2970) 1940 (880) 7628 (3460) 3726 (1690) 2822 2822 (1280) (1280) 1/4 12 x 5 (305x127) 6 x 3.625 (152 x 92) 57 (1448) 2 (51) Foot/EM Electro-Magnetic Power Lead-Acid

CLARK OSX15 3000 (1360) 24 (600) 36 volt Stand Polyurethane 1x / 4 210(5334) 11(279) 1.50x4x42 (40x100x1070) 78.2 (1986) 40 (1016) 95 (2413) 294 (7468) 89.4 (2270) 8.2 (208) 79.3 (2015) 68.9 (1751) 76.7 (1948) 7.4 (188) Yes 7.5 (12.0) 7.5 (12.0) 63 (0.32) 92 (0.47) 81 (0.41) 77 (0.39) 6613 (3000) 2028 (920) 7606 (3450) 3792 (1720) 2822 2822 (1280) (1280) 1/4 12 x 5 (305x127) 6 x 3.625 (152 x 92) 57 (1448) 2 (51) Foot/EM Electro-Magnetic Power Lead-Acid

1520 (689) 7.87 (200) 6.69 (170) AC MOSFET AC

1600 (726) 7.87 (200) 6.69 (170) AC MOSFET AC

55.2

56.6

Notes : 1 See upright table for other available uprights.

2 Dimensions are for TSU uprights 3 Specifications are given with preferred triple stage upright 4 Overall width increases with upright height, see chart 5 Actual lift speed prior upright staging. Measured on standard MFH upright after break-in period.

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GROUP 01

GROUP 01 PERIODIC SERVICE

Introduction, Maintenance ....................... Section 1

Service Schedule .........................................Section 2

Lubrication Chart ......................................Section 3

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Group 01, Periodic Service

Section 1 Introduction, Maintenance

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Group 01, Periodic Service Jacking Truck Off The Floor

Truck Frame

To perform maintenance that requires the truck to be lifted from the floor, observe the proper safety precautions as follows: 1. Lower forks completely. Remove any load.

2. Place all controls in neutral.

3. Block wheels to reduce risk of truck movement.

4. Disconnect battery connector from the truck.

2. Jack one side of the truck frame so the drive wheel is off the floor approximately 1 inch (25.4 mm). Block that side of the truck in place.

3. Jack up the other side of the truck frame level with the first side.

4. Block that side of the truck in place.

5. Place the jack under the designated jacking points.

!

1. Place the jack at the designated jacking point to one side of the truck frame.

WARNING

5. With the truck frame securely blocked with the drive tire off the floor, functional tests may be performed to verify truck operation.

Use extreme care whenever the truck is jacked up for any reason. Never block the truck between the mast column and floor. Use a suitable hoist to stabilize the mast. Keep hands and feet clear from beneath the truck while jacking. Use safety stands or solid blocks to support the truck. Do not rely on the safety stands or blocks alone to support the truck.

Example

Operator Platform 1. Using the lift button, raise the operator platform to obtain sufficient clearance.

2. Place a stand or block between the platform and a baseleg and carefully lower the platform onto the safety stand.

3. Turn key switch OFF and depress emergency power off (EPO) switch. Disconnect battery connector from truck.

Tractor Jacking Points

Baseleg 1. Place the jack at the designated jacking point.

2. Jack the baseleg until sufficient clearance to replace the load wheel.

Example Block

Example

Baseleg

Operator Platform Blocking Point

Baseleg Jacking Points

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Group 01, Periodic Service Lubricants Standard The recommended ambient temperature is above 40° F (5° C) for a truck in its standard design under continuous operation. Truck operation should apply to the following guidelines: • •

Parked outside storage area when not in use Charging and maintenance work to be done outside storage

Cold Storage To reduce moisture contamination in the electrical system, a truck equipped with cold storage conditioning packages have electrical compound applied to all electrical connections during assembly. For a cold storage truck with continuous operation, the recommended ambient temperature is to 14° F (-10° C). Truck operation should apply to the following guidelines: • • • • •

Truck completely dry prior to commencing the continuous stay in the cold storage Parked inside the cold storage for operator breaks Charging and maintenance work done outside the cold storage Truck completely dry before returning to continuous cold storage operation

For a cold storage truck with intermittent operation, the recommended ambient temperature is to -4° F (-20° C).

Truck operation should apply to the following guidelines: •

• • •

Surface condensation occurs, “wet” truck should neither remain idle in the cold storage for no longer than 10 minutes nor operate inside the cold storage for extended periods Condensation must not be allowed to freeze on the truck at any time Park outside the cold storage for operator breaks Charging and maintenance work to be done outside the cold storage

Items included in the cold storage package are as follows: •

In an environment where a damp, wet, or corrosive condition exists the following guidelines apply: − All hardware coated with LPS Rust Inhibitor during and/or after assembly − Sealed components (switches, push/pull cables, sensors, etc.) where appropriate

• • • • •

• • •

− Grease fittings provided on axle and other pivot points − Plated pins, shafts and linkage where required − All electrical connections coated with Dow Corning No. 4 compound during assembly − Lift chains coated with Libriplate chain protectant − Components coated with LPS Cold Galvanize where appropriate − Components (adjustable features, bearing races, etc.) coated with Antiseize where appropriate Sealed components used in all non-heated locations Heavy-duty mechanical switches used where appropriate Thermostat controlled heaters used to reduce moisture buildup in electrical component areas Heaters located around the electronic card, the drive and controller, the steering tachometer, and hydraulic control potentiometers Windshield replaced with a screen Hydraulic fluid in lift system changed to 1802154 Standard grease replaced with Mystik JT-6 lubricating grease

Freezer To reduce moisture contamination in the electrical system, a truck equipped with freezer storage conditioning packages have electrical compound applied to all electrical connections during assembly. For a freezer storage truck with continuous operation, freezer temperature must remain above -20° F (- 29° C). Truck operation should apply to the following guidelines: • •

Truck must be parked inside the freezer for operator breaks Truck stays in the freezer during battery charging or change-out (If truck is removed from freezer for maintenance work or battery charging, it must be completely dry before reentering the continuous shift in the freezer.)

Items included in the freezer storage package are as follows: • •

All cold storage items Transmission fluid in the lift system will be changed to Valvoline Heavy Duty Synthetic 80W90

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Group 01, Periodic Service

Section 2 Service Schedule

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Group 01, Periodic Service Planned Maintenance Schedule ITEM

WORK REQUIRED Interval in Hours

8

30

120

240

360

720

1440

Interval in Days/Weeks/Months

1d

1w

1m

2m

3m

6m

12m

1

Chassis

1.1

Check truck data plate and decals for legibility

X

1.2

Check for crack formation and damage

X

1.3

Retighten truck body bolts (to chassis)

X

1.4

Check cover screws

X

2

Motors

2.1

Check for arcing due to poor connections

X

2.2

Check tightness on all connections

X

2.3

Clean motor of dirt and dust

X

2.4

Check torque of motor bolts

X

2.5

Check for abnormal noise in motor bearings

X

2.6

Blow carbon, copper, and plastic particle accumulations from the motor using compressed air

X

2.7

Check brush wear

X

3

Drive Gear

3.1

Check for proper fluid level in the drive unit. If fluid level is low, check for leaks

3.2

Apply grease to drive unit fittings

4

Brake

4.1

Clean dust and debris

4.2

Check brake operation

4.3

Check proper operation of switches by the deadman pedal

X

4.4

Visually inspect friction plate for wear

X

5

Wheels

5.1

Remove all string, wrapping and debris

X

5.2

Check all wheels for wear

X

5.3

Grease load wheel bearings

6

Steering Wheel

6.1

Check fasteners

6.2

Check ease of steering

7

Electrical Control System

7.1

Check key switch

7.2

Check brake micro switch

X

7.3

Check control wiring harness for proper routing

X

7.4

Examine negative cable and wires from battery to the circuit cards.

7.5

Check red emergency stop switch for operation

7.6

Check travel direction/speed control for operation

X X X X

X X X X

X X

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Group 01, Periodic Service

ITEM

WORK REQUIRED Interval in Hours

8

30

120

240

360

720

1440

Interval in Days/Weeks/Months

1d

1w

1m

2m

3m

6m

12m

Check horn button for operation

X

7.8

Check lift/lower control for operation

X

7.9

Check for connections in harness connectors

8

Battery

8.1

Check electrolyte level (0.5-0.625 inch (12-15 mm) above cell plates)

X

8.2

Check all connections: battery, battery and charger plugs

X

8.3

Check all cell and link covers intact

X

8.4

Check battery specific gravity

X

8.5

Check overall condition of battery

X

8.6

Check battery rollers and stops

9

Instrument Panel

9.1

Check battery level and hourmeter for correct operation

10

Controller (Traction, Pump, EPS)

10.1

Cleaning and check mounting to chassis

X

10.2

Check tightness on all connections

X

10.3

Inspect contact tips for burnt or pitted surfaces

7.7

X

X X

X

10.4

Check contactor tips for free movements

X

10.5

Check all cable insulation for damage

X

10.6

Clean and inspector controller

11

Hydraulic System

11.1

Check hoses and connections for leakage

X

11.2

Check hoses for wear and damage

X

11.3

Check oil tank for cracks, leaks and mounting

X

11.4

Check correct oil level

11.5

Change hydraulic oil

11.6

Check for oil leakage

12

Mast

12.1

Check for damage and cracks

X

12.2

Retighten mast mounting bolts

X

12.3

Check clearance of the rollers

X

12.4

Check lateral play of inner section

12.5

Clean and lube lift chains

12.6

Clean and lube mast columns

13

Lifting Device

13.1

Check clearance of platform

13.2

Check platform for damage and cracks

X

X X X

X X X

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Group 01, Periodic Service OSX15 Main Items 12

13 7

9 6

1 4 13

8

5 10

4

3

5 11

2

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Group 01, Periodic Service Planned Maintenance Procedures This section describes how to perform the services listed in the Schedule of Planned Maintenance Operations. As with the “Schedule”, this section is subdivided into service intervals.

Services Performed Daily or Every 8 Operating Hours The daily inspection is to be made by the operator prior to each operating shift. It is the operator's responsibility to report any problems with the truck to the appropriate personnel. The truck should not be operated until it has been inspected and repaired by a trained, qualified, and authorized technician. The operator is ultimately responsible for the safe operation of the truck.

Battery Level (BL) Check the BL for correct operation.The BL will always show the mode with the highest priority that is active. For example, an info display message will override a BL message. The BL measures the level of the battery. The BL indicator has ten LEDs). When the battery is fully charged, all the LEDs will be illuminated. As the battery discharges, the illuminated LEDs will move downward showing the correct discharge level of the battery. When the battery is discharged, the red LEDs on the far below of the BL will flash alternately to warn the operator that the battery needs recharging. The BL has an integrated cut-out function that cuts out the truck’s lift function when a predetermined charge level has been reached. This reduces the risk of overloading the battery and increases the operating economy of the truck.

!

CAUTION

Hourmeter Check the hourmeter for correct operation. The hourmeter displays the time the deadman pedal has been depressed.

Hydraulic System Inspect the entire truck for leaks, especially around the hydraulic pump assembly and the lift cylinders. Any sign of oil on the floor under the truck is an indication that the truck may be leaking hydraulic oil or transmission fluid.

Report any problems to the appropriate personnel. DO NOT operate the truck until it has been inspected and repaired by a trained, qualified, and authorized technician.

Frame/Sheet Metal Inspect the truck for loose, damaged or missing parts. All shields must be in place and functional. Report any problems to the appropriate personnel. DO NOT operate the truck until it has been inspected and repaired by a trained, qualified, and authorized technician.

Wheels/Tires Inspect wheels and tires for wear and damage. Trash that is wrapped around wheels and axles will cause premature tire wear and bearing damage. The floors should be kept clear of trash to reduce damage to the wheels and tires.

Functions/Operations Test truck for the proper operation of all functions including the travel controls, steering, lift and lower functions, brakes, and Emergency Power OFF (EPO) button. Safety devices must be operational and warning decals present and legible. Report any problems to the appropriate personnel. DO NOT operate the truck until it has been inspected and repaired by a trained, qualified, and authorized technician.

Safety Belt, Tether, and Body Harness

If optional devices are connected to the key switch, the result will be a lower battery level reading. The connection of optional devices to the key switch is not recommended. An accessory harness is available from as an option.

Inspect safety belt, tether, and body harness for damage or excessive wear.

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Group 01, Periodic Service Services Performed Monthly or Every 120 Operating Hours

Hydraulic Reservoir

The monthly planned maintenance service should be performed by a trained, qualified, and authorized technician.

Frame Lube

Inspection All of the services and inspections listed for the daily inspection should be performed at this time. The inspection procedure should be more thorough. Minor deficiencies should be corrected.

Transmission Inspect for oil leakage.

Check the fluid level in the hydraulic reservoir.

The pressure type grease fittings (zerk fittings) should be lubricated with grease. The total number of grease fittings depends on the truck options when built. A truck with a cold storage or corrosive environment application package will have more grease fittings than a standard truck. Look for flush-type grease fittings on the load wheel axles. Regular fittings may be found on the transmission mounting bearing and the mast chain sheave shafts.

Pivot Points

Battery Contact your battery dealer for specific instructions on care and maintenance of the battery. An average battery will have a specific gravity of 1.170 at the 80% discharged level. However, there are many different batteries on the market. The battery supplier can accurately determine the fully charged and 80% charged levels. Contact the battery supplier for this information.

There are pivot points and other items that need to be lubricated but do not have grease fittings. Lubricate these nongreasable wear points with a drip oil can using 10 weight machine oil.

Electrical Connections Check that all electrical connections are clean and tight.

Plugin connectors should be unplugged and plugged back in to clean terminals. If the truck is equipped with any of the cold storage, or corrosive environment application packages, the di-electric compound in the plug-in connectors should be renewed.

Contactor Tips (NOT Sealed) Inspect contactor tips for arcing, pitting, or burning. Minor pitting of the tips is not a problem. However, if tips are pitted through the tip to the copper bar, tips should be replaced. DO NOT file tips. Replace tips in complete sets.

Some contactors have concealed tips or are fully sealed so that tips cannot be replaced.

Drive Motor Blow out the drive motor fan and vents. Check for signs of oil on the drive motor fan and air vents. Check for damage to the fan or air vents.

!

WARNING

When using compressed air, wear effective chip-guarding and personal protective equipment. Compressed air used for cleaning MUST be reduced to less than 30 psi (207 kPa).

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Group 01, Periodic Service Services Performed Semi-Annually or Every 720 Operating Hours The annual planned maintenance service will take a longer period of time to complete than does the monthly service.

This would be a good time to arrange other repairs that have been noted on the monthly service.

Inspection All of the services and inspections listed for the daily and monthly inspection should be thoroughly performed at this time. All deficiencies should be corrected.

Transmission The transmission fluid should be drained once a year. The drain port is located on the lower portion of the side cover opposite the drive tire. Remove the bolt to drain the transmission fluid. Flush the transmission case with a cleaning solution. Pour clean solution into the fill port accessed from the battery compartment. With drive tire off the floor, allow solution to run out of drain port while transmission is running. Stop flushing when the solution runs clean.

Allow the solution to drain well before replacing the drain plug bolt. Replace the drain plug bolt. Refill the transmission with the proper clean oil before operating the truck.

Hydraulic System

Lift and Platform Chains Inspect lift and platform chains. A chain gauge should be used to check stretch of the links. To adjust inner columns, loosen jam nut and tighten chains equally until the top of the columns are level in the fully lowered position.

Retighten jam nut and torque. Platform chains should be adjusted in the fully lowered position with the forks level.

Adjust chains until the tip of the forks to the floor at the edge of the platform measures 2.50 inches (64 mm).

Services Performed Annually or Every 1440 Operating Hours Battery At approximately 1500 hours, contact an authorized battery dealer to determine the overall condition of the battery. Determine if the battery needs to be washed down.

This should be done by properly equipped and trained personnel.

Brake Visually inspect friction plate for wear on the electric brake.

Hydraulic Fluid

!

Change hydraulic fluid.

WARNING

Before siphoning oil from reservoir, make certain siphon is clean.

The hydraulic system should be drained, flushed and refilled. To drain reservoir, remove reservoir filter assembly. Siphon oil from reservoir and purge oil out of hydraulic system. Fill reservoir with proper clean oil. Operate the raise and lower function several times to purge air from system. Check oil level. Put rated truck capacity load on the forks and adjust pressure relief valve, if necessary, so that truck will lift a rated load.

Brakes Follow procedures for brake removal before inspecting.

Remove the brake assembly and inspect the friction disc for wear. The friction disc should be replaced once thickness is 0.236 inch (6 mm) or less. The armature and magnetic coil should be adjusted if truck will not meet stopping and holding specifications. The air gap should not exceed 0.015 inch (0.38 mm) and should remain within 0.005 inch (0.127 mm) throughout the circumference.

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01-2-7

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 01, Periodic Service

Section 3 Lubrication Chart

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01-3-1

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 01, Periodic Service

Pos. No. 1 2 3 4 5 6 7 8 9

Interval/Running hours 720 h 1440 h 4320 h L L L C O C L L L L

Service point Wheel bearings Upright Beam Lifting chains Hydraulic system Brake Steering bearings Gear ring Drive Motor shaft, spline Rocker plate L=Lubrication

C=Check

Lubricant A E D B

A G F

O=Oil change

4

2

5 3 6 8 7

5

9 1 Truck Lubrication Points

SM 844

01-3-2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 01, Periodic Service Oil and Grease Specifications Approved Oils and Grease Specification Location

Standard and Corrosion Lubricant

A

Grease

B

Hydraulic oil

C

Drive axle oil

D E F

Motor oil Grease Grease

G

Grease

Continuous Operation Above 40°F [5°C]

Cold Storage Filling Continuous Opera- Application area quantities tion To 14°F [-10°C] Intermittent Operation To -4°F [-20°C]

CLARK spec. MS-6 or MS107-C AZOLLAZS32 (S-OIL)

EQUMS46 III (S-OIL)

Standard: 80w90 / CS Option : 75w90 * Must meet the reguirements of API service GL-5 (Do not use oil that only meets GL-4) In accordance with CLARK #886396 In accordance with CLARK #3762516 Dow corning G-N Assembly paste Kluberflex BEM34-132 or Dow corning Molykote G-N plus paste

Bearings and bushings Hydraulic system

29 L

Gears

2.2 L

Chains Mast rails Rocker plate Drive motor shaft, spline

Grease Location Points

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01-3-3

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

GROUP 02

GROUP 02 STRUCTURE AND MAJOR PARTS

Chassis ........................................................ Section 1

Battery Compartment ................................Section 2

Operator Controls ......................................Section 3

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02-0

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 02, Structure and Major parts

Section 1 Chassis

OzpT[`Y`WP

1

Knob

11

Link_Top Cover

2

Hinge Assy

12

Floor Mat

3

Clevis-Pin

13

Handle

4

Washer-Plain

14

Cover

5

Pin_Split

15

Side Gate MTG Assy

6

Capscrew-Flanged

16

Dash Panel

7

Flanged_Head_Cap_Screw

17

OSX Top Cover

8

Washer-Plain

18

Cover Control Lever

9

Side Cover

19

Multi Pocket

10

Front Cover

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02-1-1

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 02, Structure and Major parts Theory of Operation The chassis is the body section of the truck that contains the battery, motors, drive unit, hydraulic unit and electric control panel. It has several panels and covers that are removable. During operation of the truck, all panels and covers must be secured to the chassis. The front cover opens with easy release of the knob to make all areas of the compartment easily accessible for inspection.

Maintenance See “Planned Maintenance Schedule” on page 01-2-2

Troubleshooting Inspect chassis every six months for crack formation and damage. Bent or damaged body panels should be replaced.

Repair and Rebuild When covers and/or panels become damaged and do not fit or close properly, replace with new as necessary. Extensive damage to chassis or truck in any weldment must be reported to the company. Do not attempt to weld the chassis, mast, or overhead guard without permission from the company .

Front Cover Removal 1. Park truck on a level surface and block.

2. Turn key switch OFF and depress emergency power off (EPO) switch. Disconnect battery connector from truck.

3. Release knob (1) on both sides. Tilt top cover (17) up and slide tabs out of the chassis.

4. Open the front cover (10) from the top.

Installation 1. Position the bottom of the front cover(10) inside the frame and then fasten the knob.

2. Position top cover (17) and push down.

3. Reconnect battery connector to truck. Energize EPO switch and turn key switch ON.

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02-1-2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 02, Structure and Major parts

Operator Platform

OzpT[`ZWXP

SM 844

02-1-3

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 02, Structure and Major parts Theory of Operation

Dash Panel

The operator platform attaches to the mast chains and operates within the mast columns. An operator overhead guard is integral to the operator platform. The pallet clamp applies clamping to retain pallets to the operator platform.

The deadman pedal is located on the floor of the platform.

NOTE!

Call-outs in the following procedures refer to illustration on 02-1-1.

Removal 1. Park truck on a level surface and block wheels, if necessary, to prevent truck from rolling.

!

DANGER

Securely block mast columns to reduce risk of lowering when working on or near mast. If not blocked, unexpected movement could occur resulting in personal injury or death.

Overhead Guard

2. Lower platform.

3. Turn key switch OFF and depress emergency power off (EPO) switch. Disconnect battery connector from truck.

Deadman Pedal

4. Remove screws holding panel to platform.

5. Tip the panel cover from the bottom and remove.

Installation Pallet Clamp

1. Position panel on the platform and secure with screws.

2. Reconnect battery connector to truck. Energize EPO switch and turn key switch ON.

Maintenance

Floor Mat

See “Planned Maintenance Schedule” 01-2-2.

Removal Park truck on a level surface and block wheels, if necessary, to prevent truck from rolling.

Troubleshooting Inspect operator platform every month for crack formation and damage. A bent or damaged platform or overhead guard must be replaced.

Repair and Rebuild When the console cover becomes damaged and does not fit or close properly, replace with new as necessary. The floor mat should be replaced when it becomes damaged and no longer provides proper traction and cushioning. A bent or damaged platform extension (optional) must be replaced.

The overhead guard must not be repaired or welded. If the overhead guard is damaged and requires repair, the platform assembly must be replaced.

!

DANGER

Securely block mast columns to reduce risk of lowering when working on or near mast. If not blocked, unexpected movement could occur resulting in personal injury or death.

3. Lower platform.

4. Turn key switch OFF and depress EPO switch. Disconnect battery connector from truck.

5. Pry floor mat loose and remove from platform.

Installation 1. Position floor mat on the platform.

2. Reconnect battery connector to truck. Energize EPO switch and turn key switch ON.

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02-1-4

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 02, Structure and Major parts

Section 2 Battery Compartment

OzpT\WWX[P

1

Frame Weld Assy

6

SBR Roller Assy

2

Battery Stoper Plate

7

Hexhead_Screw

3

Battery Stoper Plate

8

Hexhead_Screw

4

Battery Stoper

9

Capscrew Flanged

5

Plate Bumper Cover

SM 844

02-2-1

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 02, Structure and Major parts the tongue on the operator compartment end of the battery stop plate.

Theory of Operation The truck is equipped with battery rollers and battery stop plates for ease of battery removal and replacement.

2. Continue lifting until the battery stop plate (2) is clear of the truck, then set aside.

Installation

Maintenance

!

1. Position the battery stop plate (2) with tongued edges on the bottom and facing the operator compartment.

WARNING

Battery electrolyte is a solution of sulfuric acid and water. Battery acid causes burns.

Should any electrolyte come in contact with clothing or skin, flush the area immediately with cold water. Should the solution get on your face or in eyes, flush the area with cold water and receive medical attention immediately.

!

2. The edge toward the operator compartment should be tilted in so that the tongue engages with the slot in the back of the battery compartment.

3. Carefully lower the battery stop plate into position.

Move the plate forward and backward until proper engagement is noted.

Battery Removal

CAUTION

Before working on the battery, review Battery Safety. Batteries may weigh more than 24volt : 1520 pounds (689 kg), 36volt : 1600 pounds (726 kg). Use extreme care during replacement. Use a suitable battery replacement device or hoist for lifting.

Inspect the battery stop plates for bending or cracks, making sure they work properly. Inspect the battery rollers to ensure they can turn freely. Clean battery rollers of all electrolyte with a solution of 1 lb (0.45 kg) of baking soda added to 0.5 gallon (1.9 liters) of hot water. See “Planned Maintenance Schedule” on page 01-2-2.

1. Park truck in an approved battery changing area.

2. Turn key switch OFF and depress Emergency Power OFF (EPO) switch. Disconnect battery connector from truck.

3. Position battery changing device against side of truck at battery compartment according to device manufacturer’s instructions.

4. Remove stop plate on side of removal device.

5. Roll battery using removal device.

Installation 1. Position device with fully charged battery against truck.

2. Roll battery in truck.

Troubleshooting

3. Reinstall stop plate.

Check battery rollers and battery stops every six months.

4. Remove battery changing device.

Repair and Rebuild

5. Reconnect battery connector to truck. Energize EPO switch and turn key switch ON.

The battery rollers and battery stops can not be repaired or rebuilt. Replace battery rollers and battery stops with new as necessary.

NOTE!

Call-outs in the following procedures refer to illustration on page 02-2-1.

Battery Rollers Removal 1. Park truck on a level surface and block.

2. Turn key switch OFF and depress EPO switch. Disconnect battery connector from truck.

Battery Stop Plate

3. Remove batteries from truck.

Removal 1. While lifting the battery stop plate (2) upward, tilt the edge toward the mast slightly forward to disengage

4. While lifting the battery stop plate (2) upward, tilt the edge toward the mast slightly forward to disengage

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02-2-2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 02, Structure and Major parts the tongue on the operator compartment end of the battery stop plate.

5. Continue lifting until the battery stop plate (2) is clear of the truck, then set aside.

6. Remove battery rollers assembly (6).

Installation 1. Install battery rollers assembly (6).

2. Slide battery plate in position.

3. Install batteries in truck 4. Reconnect battery connector to truck. Energize EPO switch and turn key switch ON. Test truck for proper operation before returning to service.

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02-2-3

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 02, Structure and Major parts

Section 3 Operator Controls

Theory of Operation

Maintenance

The operator controls are located either on the console cover or on the control handle. The steering wheel, instrument panel display, and switches (key, emergency stop, and light/ fan cluster) are on the console cover. The travel speed and direction, hydraulic function, and horn are controlled through the control handle. The control handle is the operator’s means of controlling travel, lift/lower, and horn functions. The deadman pedal is located on the floor of the platform. The pallet clamp applies clamping to retain pallets to the operator platform. The tether line, safety belt, and body harness secures the operator in place during truck operation.

For maintenance see “Planned Maintenance Schedule” on page 01-2-2

Repair and Rebuild The control handle, steer wheel, deadman pedal, pallet clamp, or tether may wear due to normal usage. These items can not be repaired or rebuilt and must be replaced with new as necessary.

Multi-Function Control Handle The multi-function control handle is located on the console to the right of the steering wheel of the operator platform.

Travel direction and speed as well as hydraulic functions and the horn are controlled through this handle. Operating instructions are given in the Operator’s Manual.

Removal 1. Turn key switch OFF and depress Emergency Power OFF (EPO) switch. Disconnect battery connector from truck.

2. Remove dash panel (page 02-1-4).

3. Disconnect wiring harness 4. Remove screw and ground screw from control handle assembly. Remove control handle assembly.

Control Handle

Steering Wheel

Installation 1. Install control handle assembly and secure with ground screw and screw.

2. Install dash panel.

3. Calibrate the control handle.

Deadman Pedal

4. Reconnect battery connector to truck. Energize EPO switch and turn key switch ON. Test truck for proper operation before returning to service.

Pallet Clamp

SM 844

02-3-1

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 02, Structure and Major parts Steer Wheel

Steering Wheel Detail

Steering Wheel

Removal 1. Turn key switch OFF and depress EPO switch. Disconnect battery connector from truck.

2. Remove dash panel (page 02-1-4).

3. Remove steer wheel (see page 05-4-2).

Installation 1. Install steer wheel (see page 05-4-2).

2. Install dash panel.

3. Reconnect battery connector to truck. Energize EPO switch and turn key switch ON. Test truck for proper operation before returning to service.

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02-3-2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 02, Structure and Major parts Deadman Pedal

Deadman Pedal 27

Du Bush-Flange, Duf 1825-26

28

Spring-Deamdan Switch

29

Pedal-Deadman Switch

30

Cotter-Pin

31

Support-Cottor Pin

32

Proximity Sensor

SM 844

02-3-3

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 02, Structure and Major parts Pallet Clamp

(SI-50040)

1

Bearing-Shaft

15

Brkt Assy-Clamp

2

Spring-Brake

16

Cable Assy-Clamp

3

Pad-Parking Pedal

17

Cable Assy-Short

4

Nut-Flanged Hex

18

Cover-Lh

5

Pin-Cotter

19

Cover-Rh

6

Capscrew-Flanged

20

Link-Cable

7

Ring-Cotter-Rue

21

Spring

8

Pedal-Pallet Latch

22

Roller Assy

9

Shaft-Latch

23

Nut-Hex

10

Hex-Socket-Cap-Screw 24

Capscrew-Hex

11

Capscrew-Flanged

25

Cover

12

Clevis-Rin

26

Pin-Clevis

13

Jaw Assy-Lh

27

Ring-Retaining C-Type

14

Jaw Assy-Rh

28

Ring-Retaining

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02-3-4

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 02, Structure and Major parts removing the decal. Replacement of warning decals are free from the company.

Decals Remove and replace any decals that are damaged. Replace any missing decals. Remove a damaged decal by using a sharp edge to peel the decal from the surface. Use caution not to scratch or damage the paint on the truck when

Using the required cleaning solution, thoroughly clean the surface of the truck before applying a new decal. Allow the surface to completely dry, be sure that there is no residue.

Touch up the paint in the area of the decal, as required.

5

6

7

11

1 2

8

9 ;3;6898

4

12 10

3

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02-3-5

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

GROUP 03

GROUP 03 DRIVE AXLE

Maintenance and Installation Instructions ..................................................................... Section 1

Repair ..........................................................Section 2

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03-0

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle

Section 1 Maintenance and Installation Instructions

GK20

SM 844

03-1-1

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Safety Instructions •

The use as directed requires the strict observance with the manufacturer’s specifications for installation, dis- and reassembly, initial operation and maintenance.

•

Every person concerned with installation, disassembly and reassembly, initial operation and maintenance of the transmission in the user plant must have read and understood the whole instructions and in particular the safety instructions.

•

Any working method which endangers the safety of the transmission is prohibited.

•

Modifications and changes without the proper permission are affecting the safety of the transmission and are not allowed.

•

Only original spare parts from ZF or spare parts approved by ZF are allowed to be used. It is explicitly pointed out to the fact that spare parts and accessories, which were not supplied by ZF are not checked and approved by us either. We do not accept any liability or admit any warranty for damages caused by the use of spare parts and accessories which are no original parts from ZF.

•

The described work is only allowed to be made by authorized, skilled and instructed staff.

•

The proper repair of these ZF-products requires adequately trained specialists. The repairer is responsible for the training!

•

Keep away aggressive cleaners from your skin, do not drink it or inhale its vapours! Always wear safety gloves and goggles. If by mistake cleaner was swallowed, call medical aid immediately! Strictly observe manufacturer instructions.

•

Do not drain cleaners or transmission oil into the sewerage system or into the soil.

•

Prior to start working on the installed or mounted transmission, the wheels must be blocked.

•

Prior to any work on the installed transmission (e.g. oil change) or its mounted-on parts the voltage source feeding the motor must always be disconnected resp. switched off.

•

The local regulations for safety and prevention of accidents must be observed!

SM 844

03-1-2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Install

EPS Motor

Item NO.

Description

1

Washer-Plain

2

Bolt

3

Pinion-EPS

4

Drive-Unit

SM 844

03-1-3

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle

Screw

Centering ring

Screw Steering limiter

Bearing Screw

Steering pinion

Screw Stop

Breather valve Cap Hex nut

Steering gear

Super gear Taper roller Bearing Shim ring Sealing ring Spacer tube Retaining ring Shim ring Ball bearing

Taper roller Bearing

Input pin

Bevel gear set

Cap Cover

Ball bearing

Housing

Pin

Screw

Shim ring

Ring

Bolt Shaft protection

Sealing ring Gear Shaft

Taper roller Bearing

Plug

Taper roller Bearing

Plug

Pin

SM 844

O-ring

Retaining ring Shim ring

Screw

Cover

03-1-4

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Components and Accessories of a GK Transmission 01 one-piece transmission housing 02 Venthole for electric motor ventilation 03 Optional steering: Gear ring with steering pinion (is shown) or steering chain as alternative 04 Mounting holes (optional) 05 One-piece pivoted bogie bearing (optional) 06 Wheel shaft with centering and locating face for drive wheel 07 Fully integrated drive pinion with motor connection profile 08 Housing cover 09 Oil filler plug and oil level check 10 Oil drain plug

Other customer-specific accessories are possible!

05

03

03 01 02 09

06 10

07

04

04

08

SM 844

03-1-5

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Transmission Identification The transmission type is cast in the transmission housing on the bearing cover side.

Transmission type of the product range GK

The model identification plate is fixed to the transmission housing side.

Technical data of the transmission is indicated on the model identification plate.

Transmission type

Serial Number

GK 20 4699 801 017

200001 14,50

ZF Parts List No.

Total ratio

SM 844

03-1-6

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle

Installation General Instructions Torque limits in Nm for screws to ZF Standard 148 Torque limits, if not especially indicated, can be taken from the following list:

Metric ISO-Standard thread DIN 13, Sheet 13 Size

8.8

10.9

12.9

M4

2.8

4.1

4.8

M5

5.5

8.1

M6

9.5

M7

15

M8

23

M 10

Metric ISO-Fine thread DIN 13, Sheet 13 Size

8.8

10.9

12.9

M 8x1

24

36

43

9.54

M 9x1

36

53

62

14

16.5

M 10x1

52

76

89

23

28

M 10x1.25

49

72

84

34

40

M 12x1.25

87

125

150

46

68

79

M 12x1.5

83

120

145

M 12

79

115

135

M 14x1.5

135

200

235

M 14

125

185

215

M 16x1.5

205

300

360

M 16

195

280

330

M 18x1.5

310

440

520

M 18

280

390

460

M 18x2

290

420

490

M 20

390

560

650

M 20x1.5

430

620

720

M 22

530

750

880

M 22x1.5

580

820

960

M 24

670

960

110

M 24x1.5

760

110

1250

M 27

1000

1400

1650

M 24x2

730

1050

1200

M 30

1350

1900

2250

M 27x1.5

1100

1600

1850

M 33

1850

2600

3000

M 27x2

1050

1500

1800

M 36

2350

3300

3900

M 30x1.5

1550

2200

2550

M 39

3000

4300

5100

M 30x2

1500

2100

2500

M 33x1.5

2050

2900

3400

M 33x2

2000

2800

3300

M 36x1.5

2700

3800

4450

M 36x3

2500

3500

4100

M 39x1.5

3450

4900

5700

M 39x3

3200

4600

5300

Friction value: μ tot. 0.12 for screws and nuts without after-treatment, as well as phosphatized nuts.

Tightened by hand!

SM 844

03-1-7

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Condition as supplied

!

The basic transmission is supplied as follows: •

Ready assembled

•

Without oil filling (customer-specific agreement possible)

•

Painted with prime coating (ZF Standard 902) and coating varnish (RAL 9005), colour: jet black

•

The wheel shaft sealing, the centering- and locating face for the drive wheel on the wheel shaft, the wheel bolt threads, the connecting faces and boreholes for motor and vehicle connection are provided with a short term corrosion protection.

•

Metallic bright sections (like e.g. fits or guides) are also provided with a short term corrosion protection.

•

With internal preservation for short-term storage in a dry ambience.

CAUTION

Do not drain cleaners into the soil. Overflown cleaner is to be disposed of adequately. Do not abrade with emery or scrape off! Avoid that cleaners get in contact with rubber parts, the electrical connections of the accessories or the motor ventilation!

!

DANGER

Keep away cleaning agent from your skin, do not drink it or inhale its vapours! Wear safety gloves and goggles! In case of skin contact rinse immediately with a lot of water! If by mistake the cleaning agent was swallowed, call medical aid immediately! Observe the regulations for the prevention of accidents!

Storage The supplied GK-transmissions are provided with an internal preservation, ensuring a corrosion protection for approx. 1 year at an adequate storage in closed and dry rooms.

If a transmission is to be stored for a longer time, the transmission has to be filled with the specified transmission oil (see Chapter “Initial Operation / Maintenance” “Oil Grade”).

At an input speed of 1000 to 1500 min-¹ the transmission is to be driven for approx. 2 minutes, so that all transmission internal parts are wetted with oil. If this is ensured, the oil can be drained off again.

We recommend repeating this procedure yearly!

Transport The unit is only allowed to be lifted with soft ropes or belts, never with steel ropes or chains. During transportation care must be taken to avoid shocks.

Removal of the corrosion protection Only with a suitable cleaner the corrosion protection is to be removed from the connecting points before installation into the vehicle. Never use benzene, solvents or other combustible substances for cleaning. Only use non-toxic, noncombustible and commercially permissible cleaning agents.

SM 844

03-1-8

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Turn the hole pattern of the pivoted bogie bearing to be accurately aligned with that of the electric motor. Fasten the electric motor by means of six (6) cap screws M8 and locking pieces with the pivoted bogie bearing. Pay attention to the minimum screw-in depth (4).

Attachment of the Electric Motor If the unit is supplied with an already attached electric motor this chapter is not applicable.

The centering- and locating faces for connection of the electric motor must be perfectly clean and undamaged.

Check face run-out of the motor connecting face to the motor shaft. The maximum run-out must not exceed 0.05 mm.

!

!

CAUTION

Please observe the specified mounting dimensions of the corresponding installation drawing!

DANGER

An excessive face runout will have a negative effect on the noise behaviour and results in premature wear of the spur gear stage.

!

CAUTION

For connecting cautiously rotate the wheel shaft of the transmission or the input shaft of the electric motor (depending on the mounting position) until the input shaft engages into the splined hub connection of the drive pinion. When locating the electric motor take care that the splined shaft-hub connection (5) of the drive pinion and the electric motor shaft will not be damaged.

Assembly instructions for the splined shafthub connection An assembly paste has to be used as assembling aid and later long-term lubricant for the splined shafthub connection.

Attachment of the electric motor to the transmission

!

Apply a thin and even coat of the special lubrication grease BEM 34-132 onto the splined shaft-hub connection.

Assemble the electric motor (1) into the centering seat of the pivot bogie bearing (2) and join it cautiously with the splined hub connection of the drive pinion (3).

DANGER

Damages cause louder running noises and premature failure of the splined shaft-hub connection!

Example for the electric motor attachment without centering ring connection directly to the pivoted bogie bearing.

01

04

02

03 05

SM 844

03-1-9

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Pivoted Connection-Steering Mounting of the gear ring with pivoted bogie bearing GK 20 1. The centering and supporting face for the gear ring has to be clean.

2. Pay attention that no foreign substances or cleaning agents get through the threaded holes (01) of the mounting construction (hole pattern of the housing) inside the transmission.

03

04

3. Place the gear ring (02) and rotate it, so that the boltholes in the gear ring are aligned with the threaded holes of the mounting construction.

02

4. By means of a plastic tip hammer install the gear ring.

5. Put on the pivoted bogie bearing (03) with the correct side and rotate it so that the boltholes in the pivoted bogie bearing are aligned with the hole pattern of the gear ring and the housing.

01

6. Fasten the pivoted bogie bearing and the gear ring on the mounting construction by means hexagon screws M8x40 (04).

01

Attention In order to avoid inadmissible leakage problems on the screws, it is mandatory to observe the following procedure for thread sealing: •

Always seal the screws (01) located in the oil sump of the transmission! For this purpose these are to be wetted with LOCTITE 243 around the thread contact face and only then to be attached.

•

In order to avoid inadmissible variations among the screw clamping forces, always pretension the screws carefully crosswise to the specified value. Tightening torque: 34 Nm

•

After a possible disassembly the LOCTITE residues in the threaded holes must be removed. It is necessary to use new screws.

SM 844

03-1-10

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Lubrication and maintenance of the pivoted connection First lubrication of the teeth is to be made immediately after mounting. Spray grease is to be sprayed or to be applied evenly onto the teeth. For this purpose and any later relubrication only use acid-free, nonresinous, waterproof and non-ageing greases!

!

DANGER

Without lubrication and relubrication respectively there will be a direct metallic contact of the teeth resulting in damages.

Relubrication intervals The relubrication intervals depend essentially of: •

the existing operating conditions

•

the environmental influences like e.g. dirt, water, etc.

•

the mounting type of the pivoted connection

!

CAUTION

Prior to every relubrication procedure it is necessary to clean the teeth, in particular the tooth root.

Exact relubrication intervals can only be determined by tests under application conditions. If no comparable results are available, Table 01 serves as orientation.

Operating condition dry and clean rooms

Relubrication interval after 250 h

heavier dirt accumulation, after 100 to 150 h outdoor operation extreme dirt accumulation

continuously

<Approximate values for the relubrication interval> The indicated values are based on the following conditions: •

Operating temperature <70°C

•

Circumferential speed <0,5m/s

•

Low to medium load

If longer relubrication intervals are determined by tests, the relubrication interval can be determined by the ageing resistance of the lubricant, if necessary.

SM 844

03-1-11

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Transmission Attachment to the Mounting Construction in the Vehicle For economy reasons the cross sections of the pivoted bogie bearings are kept very small in comparison with the diameter.

This requires a rigid and torsion-resistant mounting construction for these bearings. Additionally the supporting face for the pivoted bogie bearings and mounting of the same must also provide the maximum evenness or flatness.

The supporting face in the vehicle requires a mechanical machining. Inadmissible distortions or deformations during fastening of the screws occur due to uneven locating on the frame plate or unevenness in the locating area of the pivoted bogie bearing.

!

DANGER

The pivoted bogie bearing must support evenly on the whole surface of the mounting construction. If this requirement is not fulfilled the service life of the pivoted bogie bearing reduces. Additionally, the reliability in service is put at risk.

!

CAUTION

Shape alternatives of the locating face require a written approval by ZF, which however will only be given after a preceding installation investigation.

M 12

0.15

Screw-in depth min 15 mm

!

CAUTION

Please observe the specified vehicle mounting dimensions indicated in the corresponding installation drawing of the unit!

SM 844

03-1-12

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Initial Operation / Maintenance

!

Oil Change Drain the transmission oil at GK 20

DANGER

If the units are not delivered with filled oil, fill in the transmission oil before the initial operation!

!

Do not drain transmission oil into the soil or the sewerage system. Pay attention to the type and quantity of debris.

Oil grade for transmission types GK 20 Approved are only oils which fulfill the below specifications: •

Classification to API-GL5 − Standard : SAE 80W90 − Option : SAE 75W90

•

Do not use oil that only meets GL-4

!

DANGER

High oil temperatures are to be expected after continuous operation of the transmission.

Wear temperature-resistant gloves!

Oil capacity

•

Position the vehicle on even ground and lock the wheels for safety purposes.

•

Carefully clean the area around the oil filler and oil drain plug.

•

Place a suitable big oil collecting vessel under the oil drain plug.

•

Loosen the oil filler plug (01) with a 6mm Allen wrench. Remove the oil filler plug and the sealing ring (02).

•

Loosen the oil drain plug (03) with a 6mm Allen wrench. Remove the oil drain plug and the sealing ring (02).

•

Have the transmission oil drained into the vessel completely.

Total transmission oil quantity GK 20: 2.2 liters The oil quantities are approximate values and serve as guide only.

Maintenance intervals Transmission After approx. 25 operating hours: • Visual inspection for possible oil leakage on the transmission; oil level check

After 1500 operating hours or at yearly intervals: (whatever occurs first) • Visual inspection for damages, leakages and possible oil loss on the transmission – oil level check

!

CAUTION

CAUTION

No further transmission oil changes are required. Repaired transmissions are to be treated like new transmissions.

Modifications of these specifications require the written approval by ZF.

02

01 02

03

SM 844

03-1-13

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle

!

CAUTION

For transmissions an oil drain time of approx.

5 min. must not be exceeded.

•

GK – product range Max. wheel load

Fill in the transmission oil at GK 20 •

Technical Data of the GK – Product Range GK 20 kg

2000

Max. wheel size Ø

mm

310

Clean magnet on the oil drain plug (03) and always reattach it with a new sealing ring (02). (Please refer to the drawing on page 03-1-13) Tightening torque: 22 Nm

Max. wheel size

mm

125

Max. wheel torque

Nm

980

Max. speed

min-1

4500

Fill in the transmission oil. For oil quantities and viscosity classes see Chapter „Initial Operation / Maintenance“ Paragraph „Oil Grade“ & „Oil Capacity“

Ratio

•

For filling use a suction and pressure injector ( 05).

This allows an easy and rapid filling of the transmission with oil.

•

The correct oil level and the correct oil quantity is achieved when the oil level is at the lower edge of the oil filler plug, at least when oil penetrates at the oil filler plug.

•

Attach the oil filler plug (01) with a new sealing ring (02).

•

Tightening torque: 22 Nm

10.2 – 25.4

Envelope

mm

168

Temperature range

°C

- 30 to + 40

Weight, without oil, E-motor, drive wheel

kg

46

Subject to technical modifications.

05

!

CAUTION

After 25 operating hours check the oil level once again. Refill oil, if necessary!

SM 844

03-1-14

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Maintenance Scheme Maintenance intervals varying, depending what occurs first

only once after after operating hours at intervals

regularly after

0h

25h

200h

300h

600h

1500h

Mounting

7 days

1 month

3months

6months

12months

Maintenance work Attention: after 50 km it is absolutely necessary to retighten the wheel nuts of the installed drive wheel with the specified tightening torque of 140 Nm!

●

Retighten the fixing bolts of the pivoted connection with the specified tightening torque 34 Nm!

●

Oilchange Greasing of the teeth on the pivoted connection

● ●

Visual inspections Visual inspection for oil leakage

●

●

●

General condition of the pivoted connection (for extreme conditions, see Chapter “Lubrication and maintenance intervals of the pivoted connection”

●

General condition of the transmission (e.g. damages; cracks in the housing, noises, etc.)

●

General condition of the drive wheel (e.g. deformation, damage, etc.)

●

General condition of the motor (e.g. grease in the motor, tempering colours, fan inspection, etc.)

●

Special application conditions stored transmissions

Conservation to be renewed every 6 months

Transmissions with less operating hours acc. to maintenance scheme Transmissions with extreme operating Intervals to be reduced by half conditions

SM 844

03-1-15

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle

Section 2 Repair

General Data for Disassembly and Reassembly Instructions •

• • • •

• • • • • •

Pay attention to cleanliness and expert like manner for all work to be carried out. Transmissions removed from the vehicle have therefore to be cleaned prior to opening. Both utmost care and cleanliness are essential conditions for a correct disassembly and reassembly of the transmission as well as for the installation of each spare part. A fault during installation can result in an early wear and chips or other foreign particles in the transmission can cause fatal damages.

Prior to assembly all parts must be cleaned and inspected for wear and other defects.

If it is found that removed parts are damaged or worn, do not reinstall but replace them by new ones.

If not separately indicated, the housing and cover faces forming an oiltight connection are to be provided with the corresponding sealing compound during assembly.

Special devices and special tools are necessary besides the standard tools. Their use is unavoidable for a technically adequate dis- and reassembly! The application of devices, special tools and other fixtures are to be adapted to circumstances of the respective users.

Commercial tools and fixtures belonging to the basic equipment are assumed to be available.

If not otherwise indicated all pressing operations are made by means of the hand lever press.

All screws and threads in this transmission have metric dimensions. Only spanners and socket spanners with metric sizes are allowed to be used.

For reassembly all of the indicated setting values, test data and tightening torques must be observed.

Observe the described sequence of the working steps.

All pictures serve the illustration and are not obliging for this execution.

SM 844

03-2-1

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Replacement of Wheel Bolts Necessary Tools Standard Tools

Tool 1

Tool 2

Tool 3

Tool 4

Tool 5

Center punch

Hammer

Drill ø 3.0

Drill ø 7.1

Tap Wrench

Tool 6

Tool 7

Tool 8

Tool 9

Tool 10

Screw extractor

Tap

Thread plug gauge

Torque spanner

Fixture 62313-03

Special Tools

M11-M14

SM 844

03-2-2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Replacement of Broken Wheel Bolts •

Initial situation

•

Punch mark with hammer and center punch (TOOL 2 and 1).

•

Bore with drill (TOOL 3).

•

Bore with drill (TOOL 4).

•

Place the screw extractor (TOOL 6).

SM 844

03-2-3

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle •

Place trap wrench (TOOL 5) onto screw extractor (TOOL 6) together with a suitable locking tool (shown is a crow bar).

•

Unscrew the wheel bolt.

•

Chase thread with the tap (TOOL 7).

•

Check thread with thread plug gauge (TOOL 8) – ”GO side“

• •

Check thread with thread plug gauge (TOOL 8) – “NO-GO side“ If the NO-GO side fits, the wheel shaft is to be replaced completely.

(See Page 03-2-21. Removal of Wheel Shaft and Crown Gear)

SM 844

03-2-4

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle •

Put fixture 62313-03 (TOOL 10) with new wheel bolt into the thread and lock it with a suitable tool. (shown is a crow bar).

<Figure 1> •

Tighten wheel bolt with torque spanner (TOOL 9).

Torque: 80 Nm.

<Figure 2>

Replacement of Wheel Bolts • • •

Lock the transmission like <Figure1> by means of pliers unscrew the wheel bolt to be replaced CCW and get it disposed of. install the new wheel bolt as explained in <Figure1> and<Figure 2>.

SM 844

03-2-5

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Replacement of Shaft Seal – Wheel Shaft (Field Version) Disassembly •

Put the fixture “63428” onto a suitable and robust support and place the transmission as shown in the Figure on the right.

•

Loosen and remove the 8 cap screws (1) on the transmission cover.

Then pull off the cover cautiously.

GK 20: M10x30-8.8

IMPORTANT Parts will be needed again for reassembly!

•

The taper roller bearing (2) which is now visible in the transmission interior on the wheel shaft has to be removed with the puller.

IMPORTANT Parts will be needed again for reassembly!

•

Remove the circlip wheel shaft – crown gear (3) by means of the flat-head pliers.

IMPORTANT Parts will be needed again for reassembly!

SM 844

03-2-6

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle •

Connect hydraulic hose (4) of the hydraulic cylinder 62222 (5), mentioned as cylinder 1 in the following, with the wheel shaft and tighten it (6).

•

Connect the dis- and assembly fixture (7) with the press-out cylinder 63428 for the wheel shaft, mentioned as cylinder 2 in the following, and tightened it with the transmission (8) completely.

!

WARNING

For work at high oil pressures there is the danger of eye and skin injuries, if oil would come out under high pressure. Always wear goggles and safety gloves during this work!

•

Actuate cylinder 1 (9) until approx. 30MPa/4300PSI is reached.

Under this pressure the bevel gear is expanded sufficiently. This pressure is to be kept constant by pumping subsequently until the wheel shaft has been loosened completely.

•

Actuate cylinder 2 until the wheel shaft has been loosened from the bevel gear completely.

SM 844

03-2-7

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle •

Take the wheel shaft out of the transmission.

•

Unscrew the hydraulic hose of cylinder 1 from the wheel shaft.

Wipe off the excessive oil.

IMPORTANT Wheel shaft will be needed again for reassembly!

•

Unscrew the dis- and assembly fixture form the transmission.

ATTENTION Pay attention not to damage the crown gear at the following removal. Damages might cause louder noises later.

The crown gear is needed again for reassembly later.

•

Take the crown gear out of the transmission cautiously.

SM 844

03-2-8

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle •

Removal of further components: on GK 20: Taper roller bearings and shims Parts will be needed again for reassembly!

ATTENTION Do not damage the transmission housing!

•

By means of the impact-resistant screwdriver beat out the shaft seal.

Thus the disassembly is ended.

SM 844

03-2-9

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Reassembly

!

CAUTION

Wear safety gloves for working with adhesives and observe the LOCTITE instructions.

•

Apply Loctite 574 onto the outside of new shaft seal evenly.

•

Mount the shaft seal with striking mandrel and hammer cautiously.

GK 20 : Striking mandrel 63291

•

Apply grease SHELL ALVANIA R3 onto the shaft seal.

SM 844

03-2-10

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle •

Clean the parts removed at disassembly: on GK 20: Taper roller bearings and shims

•

Reinstall acc. to the same sequence: on GK 20: Taper roller bearings and shims

ATTENTION Install the crown gear cautiously. It is absolutely necessary to avoid tooth flank damages. An incorrect installation will cause louder running noises later!

•

Clean and degrease the crown gear.

•

Assemble the crown gear into the transmission cautiously.

•

Center the shims and spacer ring with the crown gear by hand.

•

Apply a thin layer of glycerin onto the crown gear.

SM 844

03-2-11

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle ATTENTION Do not damage the shims!

•

Clean and degrease the wheel shaft.

•

Mount the wheel shaft from the bottom through the transmission housing, the shims, the spacer ring and the crown gear.

•

Bolt the dis- and assembly fixture with the press-out cylinder for the wheel shaft with the transmission.

•

Insert the transmission into the press-in fixture 63429 and check for tight fit.

ATTENTION Too fast pressing-in might damage the transmission. Press-in the wheel shaft slowly and evenly!

•

Press in the wheel shaft actuating the press until stop.

SM 844

03-2-12

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle •

Remove the dis- and assembly fixture.

•

Mount the circlip on the wheel shaft and crown gear with the flathead pliers.

•

Mount the bearing inner ring by means of a hammer and mounting fixture 63294 onto the wheel shaft.

SM 844

03-2-13

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle •

Clean contact surfaces on the transmission housing and the transmission cover from Loctite residues carefully. Wet the O-ring slightly with silicone grease 704 and insert it into the housing cover.

•

Apply a thin and even layer of Loctite 574 onto the contact surfaces of the transmission housing and transmission cover.

ATTENTION Use an adjustable torque spanner to tighten the screws. Tighten the screws several times!

Tightening torques: GK 20: M10x30-8.8 46 Nm •

Fasten the transmission cover with 8 cap screws.

Thus the reassembly is ended.

ATTENTION For reinstallation of the transmission into the vehicle observe the installation instructions in the operating instructions of the transmission and the instructions of the vehicle manufacturer.

ATTENTION Transmission and vehicle respectively may be used or operated at the earliest 24 hours after the reassembly again!

SM 844

03-2-14

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Complete Disassembly General Instructions Disassembly • • • •

Remove the transmission from the vehicle as described in ”ZF-Ergomat GK 20 Maintenance and Installation Instructions“ for the transmission types GK 20. Remove the drive.

Prior to dismantling the transmission is to be cleaned carefully.

Parts which are only available as assemblies will not be dismantled further.

It is recommendable to install a locating fixture as shown in picture. It serves to rotate the unit and offers easy working for disassembly and reassembly.

Locating fixture

62507 for GK 20

SM 844

03-2-15

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Necessary Special Tools for Disassembly and Reassembly Reference number Description

Is necessary for:

225296

Extracting fixture

Removal of drive pinion

62519

Holding fixture

Loosening of taper press fit

62507-1

Counter holder

Determination of shim thickness

62523

Assembly fixture

Installation of drive pinion

62478

Striking mandrel

Roller bearings Drive pinion

62507

Locating fixture

Transmission locating jack

62529

Striking mandrel-Insert

Bearing outer ring Pinion shaft bottom

62625

Striking mandrel

Roller bearing Housing

63428

Press-in/out fixture

Wheel shaft and crown gear

62521

Striking mandrel

Shaft seal Drive pinion

62522

Striking mandrel

Breather Cover

63290

Press-in sleeve

Grooved ball bearing Drive pinion

63293

Strik.mandrel without handle

Thread protective shield

63291

Strik.mandrel without handle

Shaft seal Wheel shaft

62542

Strik.mandrel without handle

Bearing outer ring Crown gear

63294

Strik.mandrel without handle

Bearing inner ring Wheel shaft

62748

Striking mandrel

Bearing outer ring Cover

63296

Handle

Striking mandrels

62819

Measuring stop

Torsional backlash

62228

Gear lock

Helical gear lock

62222

Pressure oil device

Loosen press fit

223705,22

Press-in sleeve

Bearing inner ring Pinion shaft

62747

Striking mandrel

Bearing outer ring Pinion shaft top

62846

Striking mandrel

Helical gear on pinion shaft

62825

Measuring fixture

Housing dimension Wheel shaft

62827

Measuring fixture

Housing dimension Crown gear

222863.2

Extracting fixture

Pulling-off taper roller bearing outer ring

222863.2

Extracting fixture

Pulling-off taper roller bearing outer ring

62532

Measuring fixture

Bearing friction torque Wheel Shaft

SM 844

03-2-16

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Removal of Drive Pinion ATTENTION Pay attention not to damage the surface (1) where the radial sealing ring is located!

• •

•

With a screwdriver press the radial sealing ring (2) upwards from the bore seat of the housing and remove it.

Dispose of the radial sealing ring according to Page 03-2-62 "Disposal".

Unsnap and remove the retaining ring (3) from the housing bore by means of flat-head pliers.

Extracting fixture 225296 is necessary to remove the drive pinion (4) from the bore.

•

Insert the extracting fixture into the bore of the drive pinion.

•

Fasten the hexagon screw of the bearing puller hand-tight so that a sufficient preload of the clamping jaws is given.

•

By tightening the hexagon screw expand the clamping jaws of the bearing puller (5) in the bore of the drive pinion.

SM 844

03-2-17

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle •

Handle the extracting fixture "S" as shown on the right. Move the handle on the bar upwards strongly several times until the drive pinion is loosened from the bearing seat completely.

ATTENTION Do not damage the gearing of the drive pinion at the next work step! Damages might cause louder running noises and consequential damages •

By means of the extracting fixture pull the drive pinion (6) out of the housing bore and remove it.

•

Loosen the hexagon bolt (7) and remove the extracting fixture from the drive pinion.

ATTENTION Do not damage the gearing of the drive pinion! Damages might cause louder running noises and consequential damages!

•

Pull of the grooved ball bearing (Item 8) by means of a puller or a parting tool over the bearing seat of the drive pinion and dispose it of according to Page 03-2-62 "Disposal".

SM 844

03-2-18

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Removal of Gear Ring and Pivoted Bogie Bearing •

Loosen the 12 hexagon screws (1) on the pivoted bogie bearing (2), remove and dispose them of acc. to Page 03-2-62 "Disposal".

•

With a dead-blow soft-face hammer slightly beat against the gear ring (Item 3) from the bottom to loosen it from the connecting construction. Take off and remove the pivoted bogie bearing and the gear ring.

SM 844

03-2-19

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Disassembly of Transmission Housing with Transmission Components Removal of Sealing Cap ATTENTION The surface (1) where the sealing cap is located must not be damaged. The sealing cap itself is destroyed and cannot be reused.

•

Insert a screwdriver (2) into the sealing cap (3) beating cautiously and press it off or by using the lever effect upwards and scrap it.

•

The breather valve is not to be scrapped.

Removal of Side Cover •

Loosen and remove the 10 cap screws (4) on the side cover.

ATTENTION Do not damage the housing surface at the next working step! Burrs and other damages on the sealing surface which are caused during the removal have to be eliminated. Touch up damaged sealing surface on the housing with an oil stone!

•

Separate the side cover (5) from the sealing compound with a suitable screwdriver. Place the tool between housing and cover and press it off slightly from the housing.

•

Loosen the side cover from the housing by tapping onto the outer contour and dispose it of acc. to Page 03-2-62 "Disposal".

SM 844

03-2-20

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Removal of Wheel Shaft and Crown Gear •

Loosen and remove the 8 cap screws (1) in the housing cover.

ATTENTION Do not damage the housing and cover surface! Burrs and other damages on the sealing surface which are caused during the removal have to be eliminated. Touch up damaged sealing surface on the housing with an oil stone!

Loosen the housing cover (2) by tapping against the outer edges and remove it. Use the two recesses in the housing.

•

With a three-armed puller (4) pull the taper roller bearing inner ring (3) over the bearing seat of the wheel shaft and remove it.

•

Unsnap and remove the retaining ring (5) by means of flat-head pliers.

SM 844

03-2-21

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Loosening of Taper Press Fit ATTENTION For work at high oil pressures to loosen the taper press fit there is the danger of eye and skin injuries, if oil would come out under high pressure. Always wear goggles and safety gloves! Observe and follow the instructions of the pressure oil device manufacturer.

A pressure oil device with a maximum pressure of up to 300 MPa is necessary for widening of the taper press fit. There are two possibilities to press out the shaft wheel from the crown gear which are described in the following: (S)

Pressure oil device 62222

Pressing-off by means of press •

(S)

Locate the housing (Item 1) in the press-out fixture "S" on the press as shown in the picture.

Press-out fixture 63428

•

The holding fixture "S" which is used as stop for the gliding off wheel shaft is to be connected to the cover surface with the appropriate cap screws (2).

•

Fasten the 4 supporting bolts (3) hand-tight until contact with the crown gear.

(S)

GK 20: Holding fixture 62519.

SM 844

03-2-22

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle •

Connect the flexible high-pressure pipe (4) from the pressure oil device into the connecting bore provided in the wheel shaft (5).

•

Fixedly tighten the connecting nipple with an openjaw spanner.

ATTENTION Pay attention for pressing-off that there is sufficient clearance in pressing-off direction avoiding that the wheel shaft is bottoming. Do not jam the wheel shaft at the pressing-off procedure.

•

Mount the stamp (6) from the holding fixture into the press.

•

Adjust a pressing-off force from approx. 80 ... max. 120 KN on the press.

•

At the same time also use fixture 62222 to produce the necessary pressure until the wheel shaft is pressed out from the crown gear.

•

Remove and handle the wheel shaft in such a way that the flexible high-pressure pipe can be unscrewed from the connecting bore of the wheel shaft (9), removed and put aside.

SM 844

03-2-23

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle •

Loosen the cap screws (Item 10), take off and remove the holding fixture "S" from the housing.

Pressing-off by means of 2nd hand pump Alternatively the wheel shaft can be pressed off with a second press-out cylinder, e.g. in the mobile area. It is to be proceeded as follows: • (S)

Connect the dis- and assembly fixture with the press-out cylinder for the wheel shaft and bolt it with the transmission completely.

Press-out cylinder 63428

•

Actuate the pressure oil device (7) until approx. 30MPa/4300PSI is reached. Under this pressure the bevel gear is expanded sufficiently. This pressure is to be kept constant by pumping subsequently until the wheel shaft has been loosened completely.

•

Actuate the second oil pressure device (8) until the pressure oil cylinder has loosened the wheel shaft from the bevel gear completely.

SM 844

03-2-24

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle •

Take the wheel shaft out of the transmission.

•

Unscrew the hydraulic hose from cylinder 1 of the wheel shaft.

Wipe off excessive oil.

•

Unscrew the dis- and assembly fixture from the transmission.

ATTENTION When the gearing is damaged, running noises and consequential damages might occur, so that the bevel gear set has to be replaced.

•

Take the crown gear (11) cautiously out of the housing as shown.

SM 844

03-2-25

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle •

Then remove the following parts from the housing (12): − on GK 20: Shims and taper roller bearing

Removal of Bevel Pinion Shaft •

Put the gear lock "S" into the housing bearing bore of the drive pinion and block the helical gear with it.

(S) Gear lock 62228

•

Unlock the hexagon nut (1). Loosen, take off and remove the hexagon nut.

•

Take out and remove the gear lock.

ATTENTION Pay attention not to damage the bevel pinion shaft when it is expelled in the following procedure.

•

By means of a dead-blow soft face hammer expel the bevel pinion shaft (2) from the internal gearing and the bearings.

SM 844

03-2-26

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle •

Pull out, remove and keep the helical gear (3) from the cover opening of the housing.

•

Take out and remove the taper roller bearing inner ring (4) from the bearing bore: − on GK 20: upwards

Only on GK 20: Take off and remove the spacer bush (5) from the bevel pinion shaft.

On GK 20: Pull off and remove the taper roller bearing inner ring (6) from the bevel pinion shaft.

ATTENTION If disassembly of the bearing inner ring is not possible with a special tool or puller, the bearing cage must be destroyed and the inner ring must be removed by heating.

ATTENTION When the gearing of the bevel pinion shaft is damaged, running noises and consequential damages might occur, so that the bevel gear set has to be replaced.

SM 844

03-2-27

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Removal of Thread Protective Shield and Radial Sealing Ring ATTENTION Do not damage the housing and supporting face!

•

By means of a hammer remove the thread protective shield (Item 1) from the glued joint on the housing.

ATTENTION Do not damage the surface where the radial sealing ring is seated! At this working step the radial sealing ring is destroyed completely.

•

With a screwdriver and a hammer expel and remove the radial sealing ring (Item 2) cautiously from the housing seat.

Disassembly of Bearings Disassembly bearings drive pinion •

•

With an extracting fixture (S) pull out the grooved ball bearing (1) from the bore of the housing seat and dispose it of acc. to Page 032-62 "Disposal".

The service of the extracting fixture (S) is analogous like in the page 03-2-17 to 18 shown.

ATTENTION Upon removal of the bearing outer rings put them to the respective bearing inner ring.

SM 844

03-2-28

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Disassembly bearings bevel pinion shaft •

Expel the outer rings of the taper roller bearings (2) on both sides from the housing seat cautiously.

•

Shims which were damaged have to be replaced by new shims of the same size.

Disassembly bearings wheel shaft

(S)

•

Expel the outer ring of the taper roller bearing (3) by means of a copper mandrel and a hammer from the housing cautiously.

•

Pull out and remove the outer ring of the 2nd taper bevel bearing (Item 4) with the bearing extracting fixture "S" from the bore of the housing cover.

•

The service of the extracting fixture (S) is analogous like in the page 03-2-18 shown.

•

Shims which were damaged have to be replaced by new shims of the same size.

GK 20: Extracting fixture 222863.2

Thus the disassembly is ended.

SM 844

03-2-29

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Complete Reassembly General Instructions for Reassembly •

Clean components by means of cleaning agent if necessary and remove the LOCTITE residues.

•

Check all components for wear, damage and cracks, if necessary components have to be replaced.

•

All connection faces and plan face clean and steadly smoothing.

Consumables Suitable cold cleaners, e.g. LOCTITE. Only use suitable agents, which are non toxic, non-combustible and permissible on the market. Never use benzene, solvents or other combustible agents for cleaning purposes.

Description

To be used for

LOCTITE No. 243

Screw lock up to Size M10 and bigger

LOCTITE No. 270

Screw lock for studs

LOCTITE No. 574

to glue the shaft seals into the housing & sealing of housing and cover

LOCTITE No. 5910

Surface sealing for side cover on the housing

Grease “Shell Alvania R3”

to grease or wet the sealing lip of the shaft seal

Silicone grease 704 or transmission oil to grease or wet the O-rings acc. to API GL-5 or MIL-L-2105C/D

Used Descriptions and Symbols You will find again all descriptions used in the following sections and their calculations.

Description

Symbol

Bearing width Taper roller bearing

Dimension „B“

Housing dimension

Dimension „G”

Housing bearing bore 1

L1

Housing bearing bore 2

L2

Housing bearing bore 3

L3

Zero position at measuring fixture I (Part I) with dial gauge

Dimension “1”

Difference dimension Bevel pinion shaft calculation of L3

Dimension “2”

Zero position at measuring fixture II (Part I) with dial gauge

Dimension “3”

Difference dimension Crown gear calculation of L3

Dimension “4”

Installation dimension Bevel pinion shaft

Dimension “E”

Bearing difference dimension

Dimension “D”

Constant on GK 20

K1

Free constant

a

Shim dimension

Dimension “P”

Shim thickness

Dimension “X”

SM 844

03-2-30

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Use of Removed Shims as Basis for Reassembly The bevel gear set, consisting of bevel pinion shaft and crown gear, has fixed installation dimensions. However the transmission housing and the taper roller bearings have to be measured.

• • •

If the removed shims are used as basis it is not necessary to measure the transmission housing.

If all of the removed components are to be reused, the original shim thickness has also to be used again.

If the taper roller bearings with the bevel gear set are replaced, only the taper roller bearings have to be measured.

Determination of Bearing Width and Difference of a Taper Roller Bearing Determination of Bearing Width General •

Zeroize depth gauge (1) by means of gauge blocks (2).

•

Put the new bearing on both gauge blocks and roll it as shown.

SM 844

03-2-31

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle •

Determine Dimension “B”.

Example: Dimension “B” = 22.09 mm

Determination of Bearing Difference for the Installation of Removed Shims The difference dimension „D“ of the new bearings to the bearings to be replaced is compensated with the shim dimension.

Example: New bearing Dimension “B”

22.09 mm

Original bearing

-21.99 mm

Difference “D”

0.10 mm

The height of the existing shim set must by reduced by 0.1 mm.

SM 844

03-2-32

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Determination of Basic Installation Dimensions Determination of the Necessary Shim Thickness for the Exact Installation Dimension Setting of the Bevel Pinion Shaft The correct position of the bevel pinion shaft is required for an optimum service life of the transmission.

Thickness of the shim (Item 1) and the correct setting of the bevel pinion shaft respectively will be determined acc. to the following method:

L2

X

1. Put measuring fixture I Part 1 into the housing bearing bore L1 until contact is obtained.

B

L1

E

G

2. Put measuring fixture I Part 2 into the housing bearing bore L2 until contact is obtained and fasten it hand-tight with measuring fixture I Part 1.

1

L3

3. Put measuring fixture part 1 to zero.

Part I

(S) GK 20

Measuring fixture I

62825 or 62231

At zero position of the dial gauge the following can be taken as basis: GK 20

Dimension “1” = 111.50 mm

Determine Dimension “2” in housing bearing bore L3 and add it to the respective Dimension “1”.

Example: Dimension “1”

111.50 mm

Dimension “2”

0.05 mm

Housing dimension “G”

111.55 mm

SM 844

03-2-33

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle By means of the equation X=G-E-B The required thickness of the shim (1) can be calculated. “E“ means the installation dimension of the bevel pinion shaft Dimension “E”: GK 20

89.00 mm

Calculation example for GK 20: Dimension “G”

- 111.55 mm

Dimension “B”

- 22.09 mm

Dimension “E”

- 89.00 mm X=G-E-B X = 111.55 - 89.00 - 22.09 = 0.46 mm

Add shims acc. to thickness X = 0.46 mm.

Determination of Necessary Shim Thickness for Optimum Setting of Torsional Backlash of the Crown Gear Correct setting of the crown gear is necessary to obtain an optimum torsional backlash of the bevel gearing.

Bearing width “B” for the taper roller bearing on the crown gear can be measured according to Page 03-2-31 “Determination of Bearing Width and Difference of a Taper Roller Bearing”.

Thickness of the shim and the correct setting of the crown gear respectively will be determined acc. to the following method: 1. Put the measuring fixture into the housing bearing bore L3 until contact is obtained

(S) GK 20

Measuring fixture

62827

2. Put measuring fixture dial gauge to zero position.

At zero position of the dial gauge the following can be taken as basis: GK 20

Dimension “3” = 68.50 mm

Determine Dimension “4” in housing bearing bore L3 and add it to the respective Dimension “3”.

Example: Dimension “3” Dimension “4”

68.50 mm 0.03 mm

Housing dimension “G”

68.53 mm

SM 844

03-2-34

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Schematic sketch GK 20 By means of the equation: X = G – E – B – K1 the required thickness of the shim (Item 3) can be calculated, i.e. with

E B

Dimension “E” GK 20 = 46.00 mm

L1

Example GK 20: Dimension “G” 68.53 mm Dimension “B” 22.09 mm Dimension “E” 46.00 mm Dimension “K1” 0.11 mm X = G – E – B – K1 X = 68.53 – 46.00 – 22.09 – 0.11 = 0.37 mm

3 X

M

G

SM 844

Center Bevel gear set

L3

03-2-35

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Installation of Bearing for Bevel Pinion Shaft and Exact Setting of the Bearing Preload Preassembly of Bevel Pinion Shaft with Bearing ATTENTION Pay attention to the gearing when the bearing of the bevel pinion shaft is installed. In case of damage, noise problems can be caused later.

•

Use a hand-lever press for pressing the taper roller bearing inner ring (Item 1) with the press-in sleeve “S” cautiously on the bevel pinion shaft (Item 2) until contact is obtained.

(S) GK 20

Press-in sleeve 223705,22

Installation of Bearing Outer Ring into the Housing •

•

Prepare the shim thickness determined according to Page 03-2-33 “Determination of the Necessary Shim Thickness for the Exact Installation Dimension Setting of the Bevel Pinion Shaft” by means of the differently thick shims.

Put the shim(s) (1) and the bearing outer ring (2) into the bearing seat.

SM 844

03-2-36

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle •

By means of striking mandrel "S" install the shim(s) and the bearing outer ring into the bearing seat of the housing until contact is obtained.

(S) GK 20

Striking mandrel 62529

ATTENTION A repeated measurement of the bearing height is only allowed to result in a deviation of max. ±0.05 mm.

Otherwise the process of the shim calculation has to be repeated.

Calculation of Distance Dimension between Collar Bevel Pinion Shaft and Housing •

Install the preassembled bevel pinion shaft (1) from the bottom into the housing.

•

By means of the counter holder "S" preload the bearing outer ring in the housing hand-tight.

(S) GK 20

•

Counter holder 62507-1

Put the spacer bush (2) onto the bevel pinion shaft.

SM 844

03-2-37

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle For GK 20

GK 20

Determine distance dimension "D" from the spacer bush (2) to contact of the bearing outer ring in the housing.

(Item 3 is the required shim thickness)

3 D 2

Determination of Bearing Slack of the Taper Roller Bearing •

Arrow gap = Bearing slack H

Measure the bearing slack "H" with a measuring fixture and gauge blocks/measuring ledge in the following steps: •

Zeroizing of depth gauge (1) by means of gauge blocks (2).

SM 844

03-2-38

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle •

Rolling-in of bearing.

•

Measuring of bearing slack H.

•

Example: Dimension “H” = 0.10 mm

Calculation of Shims Required for Upper Bevel Pinion Shaft Bearing By means of the equation X=D–H the required thickness of the shim (Item 3 Figure 108 or 109) can be calculated, i.e. with Dimension “D”

on GK 20: Distance from spacer bush

Dimension “H”

Bearing slack of taper roller bearing

Dimension “a”

Constant = 0.04 mm

Example: Distance dimension:

Dimension D measured on the housing

- 0.7 mm

Bearing slack:

Dimension H measured on the bearing

- 0.10 mm

X=D–H– a X = 0.7 – 0.10 – 0.04= 0.56 mm Add shims corresponding to thickness X = 0.56 mm.

SM 844

03-2-39

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Installation of Upper Taper Roller Bearing of the Bevel Pinion Shaft Prepare the shim thickness determined according to Page 03-2-39 “Calculation of Shims Required for Upper Bevel Pinion Shaft Bearing” by means of the differently thick shims and continue the installation as follows: GK 20: •

Put shim(s) (1) and bearing outer ring (2) into the bearing seat.

•

By means of striking mandrel "S" install the shim(s) and the bearing outer ring into the bearing seat of the housing until contact is obtained.

(S) GK 20: Striking mandrel 62747

ATTENTION A repeated measurement of the bearing height is only allowed to result in a deviation of max. ±0.05 mm.

Otherwise the process of the shim calculation has to be repeated.

•

Put the bearing inner ring (Item 3) into the outer ring of the taper roller bearing.

SM 844

03-2-40

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Installation of Grooved Ball Bearing for Drive Pinion (GK 20) ATTENTION Prior to installation of the helical gear the lower grooved ball bearing has to be installed into the housing bearing bore.

•

Install the grooved ball bearing (Item 1) with the striking mandrel "S" into the bearing seat of the housing until contact is obtained.

(S) Striking mandrel 62625

Installation of Helical Gear with Bevel Pinion Shaft

!

CAUTION

Wear safety gloves for working with adhesives and observe the LOCTITE instructions.

•

Apply a thin and even layer of LOCTITE 270 onto the internal gearing of the helical gear (1).

ATTENTION When inserting the helical gear pay attention that the helical gear is not damaged. In case of damage noise problems can occur later.

•

Insert the helical gear (2) by the lateral opening of the housing, align it centrally and put it onto the taper roller bearing.

SM 844

03-2-41

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle •

Install the bevel pinion shaft (3, on GK 20 with spacer bush) from the bottom into the housing and assemble is through the profiled seat of the helical gear bore.

•

Preload the bevel pinion shaft (3) with the counter holder "S" hand-tight against the bearing outer rings in the housing.

(S)

GK 20:

•

By means of striking mandrel “S” install the helical gear until contact is obtained. Hand-tighten the adjusting screw on the counter holder repeatedly, so that all components like taper roller bearing, spacer bush (on GK 20) and shims are located exactly!

•

When all components are located tightly the counter holder can be removed again.

(S)

GK 20:

•

(S)

Counter holder 62507-1

Striking mandrel 62846

Insert gear lock "S" into the housing bearing bore of the drive pinion and block the helical gear.

Gear lock 62228

SM 844

03-2-42

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle •

Place the hexagon nut M16x1.5 (GK 20) onto the bevel pinion shaft and tighten it with a torque spanner (4).

Tightening torque:

GK 20:

100 Nm

ATTENTION Do not yet peen the hexagon nut with the bevel pinion shaft! The hexagon nut must only be peened after setting and checking of the bearing preload! Use the hexagon nut only once.

• •

Turn the bevel pinion shaft and the helical gear respectively by hand several times, that the taper rollers can align in the bearing rings.

Check the bearing preload by means of a drag torque spanner with dial gauge.

The bearing preload is adjusted correctly, when a bearing friction torque of 0.5 ... 1.0 Nm is reached on the bevel pinion shaft.

If this value deviates the procedure must be repeated.

•

Drive the collar of the hexagon nut (5) by means of a chisel (6, edge of the chisel must be a radius of approx. 2.0 mm) into the recesses of the bevel pinion shaft. Lock the hexagon nut by peening!

SM 844

03-2-43

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Installation of Crown Gear and Wheel Shaft into the Housing Installation of Thread Protective Shield and Radial Sealing Ring •

(S)

Wet the thread protective shield (Item1) on the bore seat evenly with LOCTITE 270 and install it until contact by means of the striking mandrel "S".

Striking mandrel 63293

•

Apply a thin and even layer of LOCTITE 574 onto the outer diameter of the radial sealing ring.

•

By means of the striking mandrel "S" drive the radial sealing ring (Item 2) into the housing seat until contact is obtained at the mandrel.

(S)

GK 20:

Striking mandrel 63291

ATTENTION Pay attention that the radial sealing ring is not jammed during installation. Jamming will cause leakage.

ATTENTION Do not damage the sealing lip of the radial sealing ring.

•

Wet the sealing lip of the radial sealing ring with grease (e.g. Shell Alvania R3) slightly.

SM 844

03-2-44

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Installation of Taper Roller Bearing into the Housing •

(S)

By means of striking mandrel “S” drive the bearing outer ring into the bearing seat of the housing until contact is obtained.

GK 20

• •

•

Striking mandrel 62542

Insert the bearing inner ring (1) into the outer ring of the taper roller bearing.

Prepare the shim thickness (Thickness X) with the differently thick shims as determined in Page 03-2-39 “Calculation of Shims Required for Upper Bevel Pinion Shaft Bearing”.

Insert shim(s) (2).

Determination of Control Dimension for Seat •

Place the wheel shaft (3) onto a plane and solid support. Mount the crown gear (4) onto the taper seat of the wheel shaft by hand cautiously and press it on slightly.

•

Determine distance "A" from plane face P of the wheel shaft to face S of the crown gear as shown in page 03-2-46 <Figure 3>.

Dimension “A”

e.g. 30.85 mm

ATTENTION Carry out this measuring procedure to 1/100 mm exactly.

ATTENTION Pay attention not to damage the gearing of the crown gear, when the crown gear is mounted onto the wheel shaft. In case of damage, noise problems can occur later.

SM 844

03-2-45

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle

P A S

<Figure 3> ATTENTION Pay attention not to damage the gearing, when the crown gear is assembled.

•

Assemble the crown gear (Item 4) into the housing carefully and insert it into the gearing of the bevel pinion shaft at the same time.

Pay attention that the crown gear is aligned centrally to the shim and the bush.

SM 844

03-2-46

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Pressing-on of Wheel Shaft ATTENTION Taper press fit must be grease- and oilfree. Pay attention to an impeccable surface of the press fit. In case of damage use a new wheel shaft.

All components must be aligned and centered for the press-on procedure.

For this installation procedure a press with a controllable press-on force is required.

Press-on force: 250 kN up to max. 300 kN. •

Assemble the wheel shaft (1) cautiously and install it until contact is obtained.

•

Screw on the press-on fixture (S).

(S)

Press-on fixture 63428

ATTENTION For pressing on the wheel shaft, only apply the press-on force to the wheel shaft.

•

Press the wheel shaft onto the crown gear.

During this procedure the shim(s), the taper roller bearing inner ring are pressed on until contact is obtained.

SM 844

03-2-47

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Determination of Seat ATTENTION The seat must be 10 to 15 mm.

•

Measure Dimension A from plane face/wheel shaft to face/crown gear once again (see Page 03-2-45 “Determination of Control Dimension for Seat”).

Dimension “A”

e.g. 44.34 mm

Example: Dimension “A”

after pressing-on

44.43 mm

Dimension “A”

after pressing-on

30.85 mm

resulting difference = Seat

13.49mm

ATTENTION If the seat determined is not between 10 and 15 mm a new wheel shaft and a new crown gear have to be installed.

•

Install the retaining ring (2).

SM 844

03-2-48

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Installation of Bearing for Wheel Shaft Determination of Required Shim Thickness for Exact Bearing Preload of the Wheel Shaft

C

Thickness of the shim (4) to be added can be determined with the following method:

Meas. ledge

1

L

4 Block gauge

Block gauge

2

Measuring ledge Housing cover Distance from mounting face / housing cover equal to zero position on measuring instrument Measure distance from contact shim / housing cover. e.g. Zero position on measuring instrument = 0 e.g. 0.85 mm

1 2 3 4 5

Measuring ledge Bevel pinion shaft Wheel shaft Crown gear Housing

Dim. “A” Distance from mounting face / housing equal to zero position on measuring instrument Dim. “F” Measure distance from contact bearing inner ring / wheel shaft.

Dim. “A” e.g. zero position on measuring instrument = 0 Dim. “F” e.g. 23.01 mm

A

F

1 2 Dim. “L” Dim. “C” Dim. “L” Dim. “C”

1

Meas. ledge

3 2 5 4

SM 844

03-2-49

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Calculation of Shim Required Thickness of shim can be calculated with the dimensions determined.

Example for GK 20: Cover dimension:

Dim. C measured on housing cover

- 0.85 mm

Housing dimension:

Dim. F measured on housing

- 23.01 mm

Bearing dimension:

Dim. B measured on bearing under preloading force

- 21.85 mm

X1 = F - (C + B) X1 = 23.01 - (0.85 + 21.85) = 0.31 mm Constant:

a = 0.20 at X1 0.31 a = 0.25 at X1 0.30 X = X1 + a X = 0.31 + 0.20 mm = 0.51

Add shims according to thickness X.

Installation of Bearing into Housing Cover and Wheel Shaft

(S)

•

Prepare the shim thickness determined upper Page 03-2-50 “Calculation of Shim Required” by means of the differently thick shims.

•

Put shim(s) (1) and bearing outer ring (2) into the bearing seat.

•

By means of striking mandrel “S” drive shim(s) and bearing outer ring (1) into the bearing seat of the housing cover until contact is obtained.

GK 20:

Striking mandrel 62748

SM 844

03-2-50

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle •

(N)

Place counter holder "N" into the assembly fixture and preload it hand-tight against the wheel shaft (cf. page 03-2-42).

GK 20:

•

Counter holder 62507-1

Mount the taper roller bearing inner ring (2) by means of striking mandrel "S" onto the bearing seat of the wheel shaft (3) until contact is obtained.

(S) Striking mandrel 63294

Installation of Housing Cover ATTENTION Use a new O-Ring for the installation. Wet the O-Ring with transmission oil or grease slightly. Clean plane face of the housing cover carefully and do not damage it.

•

Put the O-Ring (4) into the groove of the housing cover.

•

Plane face for housing cover on the housing is to be cleaned carefully and must be grease-free.

•

Apply a thin and even layer of LOCTITE 574 onto the plane face.

SM 844

03-2-51

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle •

Place the housing cover cautiously and install it slightly tapping with a dead-blow soft face hammer until contact is obtained.

•

By means of cap screws M10x25 (Item 5) bolt the cover to the housing. Tighten the cap screws crosswise evenly!

Tightening torque of the cap screws: 46 Nm.

Checking of Bearing Friction Torque on Wheel Shaft Rolling •

(S)

For measuring of the bearing friction torque place tool “S” on the wheel shaft congruent with the wheel bolts and by means of the torque spanner turn the wheel shaft several times.

GK 20:

Measuring fixture 62532

Bearing preload is adjusted correctly when a bearing friction torque of 7.0 ... 14 Nm for GK 20 is obtained at the wheel shaft.

If this value is not reached the working steps from page 03-2-50. have to be repeated. The cover has to be removed again.

If the measured value is greater than the above mentioned value, the shim thickness of value “X” in “Page 03-2-50. Calculation of Shim Required” has to be reduced.

If the measured value is smaller than the above mentioned, the shim thickness of value “X” in “Page 03-2-50. Calculation of Shim Required” has to be increased.

SM 844

03-2-52

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Measuring of Torsional Backlash on Wheel Shaft •

For measuring of the torsional backlash lock the bevel pinion shaft against distortion, e.g. with a wooden wedge (1).

•

Measure the torsional backlash with measuring stop “S”.

(S) Measuring stop

62819

Admissible torsional backlash: GK 20

0.10 - 0.15 mm

The torsional backlash can be adjusted by adding or removing of the shim(s) (see Page 03-2-34. “Determination of the Necessary Shim Thickness for Optimum Setting of the Torsional Backlash of Crown Gear“).

The wheel shaft has to be removed again.

Installation of Side Cover •

Prior to the installation of the side cover clean the sealing surface on the housing and remove the oil residues.

The sealing surface must not be damaged

!

CAUTION

Wear safety gloves for working with adhesives and observe the LOCTITE instructions.

ATTENTION The following step must be carried out within 10 minutes since the LOCTITE hardens.

SM 844

03-2-53

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle •

For sealing of the through holes as well as of the area around the screw the following sealing application is required: LOCTITE 243: Product application into the threaded blind holes M6 as sealing function by excess product.

•

Sealing of the cover: LOCTITE 5910: Product application as uniform adhesive application onto the sealing surface at the housing as sealing function.

•

Put on the side cover (sheet cover) and fasten it hand-tight with 10 cap screws M6x10 (2) onto the housing.

ATTENTION Do not yet tighten the cap screws with the corresponding tightening torque.

•

Tighten the 10 cap screws evenly only in the tightening sequence shown in Picture.

Sequence of tightening: Number 1 beginning ...... Number 10 end Tightening torque of the cap screws: 9.5 Nm

9

5

1

3

7

8

4

2

6

10

SM 844

03-2-54

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Preassembly and Installation of Drive Pinion Installation of Ball Bearing •

(S)

For mounting of the bearing onto the drive pinion use assembly fixture "S", as shown.

GK 20:

Assembly fixture 62523

•

Put the drive pinion (Item 1) onto the guide mandrel (2) of the assembly fixture and install it until contact is obtained.

•

Put on the ball bearing (Item 4) and the pressing sleeve (3). By means of a hand lever press, press on the ball bearing with the pressing sleeve onto the drive pinion (1) until contact is obtained.

(3)

Press

3

2

Pressing sleeve 63290

S

If there is no hand press available, the bearing can be installed as follows:

4

!

CAUTION

Danger of burnings! Wear safety gloves.

1 •

Heat the ball bearing to max. 90°C and install it onto the drive pinion until contact is obtained.

•

After cooling down install the bearing subsequently.

SM 844

03-2-55

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Mounting of Sealing Cap For sealing of the bore in the drive pinion a sealing cap (5) must be mounted. This requires the following sealing application: •

LOCTITE 5910: Product application as adhesive application onto the supporting face and around the bore in the drive pinion as sealing function by excessive product.

•

Insert the sealing cap.

•

Press in the sealing cap with a press until contact is obtained.

Installation of Drive Pinion ATTENTION Pay attention when inserting the drive pinion not to damage the gearing of drive pinion and helical gear.

Damages might cause louder running noises and consequential damages!

•

Install the preassembled drive pinion (1) into the housing bearing bore cautiously. For joining turn the wheel shaft of the transmission cautiously until the drive pinion engages into the gearing of the helical gear.

SM 844

03-2-56

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle •

By means of the striking mandrel "S" install the drive pinion into the bearing seat until contact is obtained.

(S) Striking mandrel 62478

•

Snap the retaining ring (2) by means of flat-head pliers into the groove of the housing bore and install it until contact is obtained.

•

Wet the sealing lip of the radial sealing ring with grease (e.g. Shell Alvania R3) slightly.

•

Apply a thin and even layer of LOCTITE 574 onto the outer diameter of the radial sealing ring.

•

By means of striking mandrel "S" drive the radial sealing ring with the closed surface upwards into the housing seat until contact at the mandrel is obtained.

(S) Striking mandrel 62521

SM 844

03-2-57

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Installation of Sealing Cap •

Press the breather valve (1) slightly by hand into the central bore of the sealing cap (2) (Reference depth approx. 5mm).

•

Insert the sealing cap with breather valve (Item 3) into the boring seat of the housing bore in the bevel pinion shaft.

•

By means of the striking mandrel "S" install the sealing cap subsequently until contact is obtained.

(S) GK 20: Striking mandrel 62522

Attachment of Pivoted Connection Geared Steering •

Place the gear ring (2) and turn it so that the bolt holes match the threaded holes of the connecting construction.

•

Install the gear ring with a dead-blow soft face hammer until contact is obtained.

•

Put on the pivoted bogie bearing (Item 3) with the peripheral recess upwards and turn it that the bolt holes in the pivoted bogie bearing match with the gear ring and housing hole pattern.

SM 844

03-2-58

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle ATTENTION Pay attention for installing of the drive pinion that the gearing of drive pinion and helical gear are not damaged. Damages might cause louder running noises and consequential damages!

•

Wet screws M8x40-10.9 (GK 20) (4) with LOCTITE 243.

By means of the screws fasten the pivoted bogie bearing and the gear ring onto the connecting constructions.

•

Tighten the screws evenly in the tightening sequence shown in Figure 169.

Sequence of tightening: Number 1 beginning....................... Number 12 end Tightening torque of cap screws: 34 Nm

7

1

6

10

11 3

4 12

5 9

2

SM 844

8

03-2-59

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle General Instructions after Reassembly •

For reinstallation of the transmission into the vehicle observe the installation instructions in the operator's manual of the transmission and the instructions of the vehicle manufacturer.

•

Fill in oil according to the operating instructions.

•

Transmission and vehicle respectively may be used or operated at the earliest 24 hours after the reassembly again!

SM 844

03-2-60

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Failures, Possible Causes and Elimination Noises Kind of Noise

Loud, beating noise

Loud, steady noise Dull, grinding noise

Possible Cause

Elimination Check tooth flanks of the drive pinion and the Gearing of helical gear stage damaged, indenhelical gear for damage. In case of damage tations always replace both components Fault on grooved ball bearing Input Remove and replace drive pinion bearing Contaminations Remove and replace drive pinion bearing Motor/transmission connection not ok Check motor installation Motor bearing defective Check motor bearing Check bearing preload and backlash and readWrong bearing preload or incorrect backlash just it, if necessary

Leakages Location Breather

Possible Cause Elimination Excessive oil level Check oil level Screws not tightened with the specified tight- Tighten screws with the specified tightening ening torque torque Housing cover O-Ring sealing defective Replace O-Ring Screws not tightened with the specified tight- Tighten screws with the specified tightening ening torque torque Oil filler or oil drain plug Dirt between sealing ring and housing Clean Sealing ring worn Install new sealing ring Radial sealing ring damaged or worn Install new radial sealing ring Input shaft / wheel shaft Replace input shaft and wheel shaft respecDamaged race on input- and/or wheel shaft tively Tighten screws according to correct sequence Screws not tightened according to sequence of of tightening and with the tightening torque tightening and the tightening torque specified Side cover No uniform adhesive application of LOCTITE Apply LOCTITE 5910 evenly and continu5910 ously Observe LOCTITE specification and replace Joining time not observed the sealing No uniform adhesive application of LOCTITE Apply LOCTITE 5910 evenly and continuously Sealing disc on drive 5910 pinion Observe LOCTITE specification and replace Joining time not observed the sealing

Other Fault Possibilities Location

Possible Cause Elimination Cover disc has loosened and dirt got into the Only sluggish rotation of Replace pivoted bogie bearing the pivoted bogie bear- bearing ing is possible or bearing Cage segments are damaged Replace pivoted bogie bearing clearance is sensible Plastic deformation of the balls or the ball race Replace pivoted bogie bearing

SM 844

03-2-61

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 03, Drive Axle Disposal Dispose of the replaced components, materials and substances adequately, environmentally friendly and in accordance with the legal regulations for disposal for the respective material: Component

Consisting of

Transmission oil

Disposal acc. to the regulations: Waste oil

Side cover

Sheet

Radial sealing ring

Sheet

Shims

Sheet

Wheel bolts

Steel

Grooved ball bearing

Steel

Screws

Steel

O-Ring

PE

Shaft seal

PE

Sealing cap

PE

Scrap metal

PE plastic materials

SM 844

03-2-62

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

GROUP 04

GROUP 04 BRAKE

General Information ...................................... Section 1 Safety Instructions ..........................................Section 2 Technical Data.................................................Section 3 Mechanical Installation ..................................Section 4 Electrical Installation......................................Section 5 Commissioning and Operation ......................Section 6 Maintenance/Repair........................................Section 7 Troubleshooting and Fault Elimination........Section 8

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04-0

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 04, Brake

Section 1 General Information

Product key Pr oduct k ey

INTORQ

14

442

12

−

100

Legend for INTORQ 14.442.12 product key A

Product group

Brakes

B

Product type

Two-step brake

C

Size

12

D

Design/version

100

Not coded: supply voltage, hub bore, options

SM 844

04-1-1

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 04, Brake Abbreviations used Abbreviation

Unit

Designation

P

[kW]

Power

Mrated

[Nm]

Rated brake torque

ML

[Nm]

Load torque

Mreq

[Nm]

Required brake torque

Ma

[Nm]

Deceleration torque

Δn0

[rpm]

Relative initial speed of brake

JL

[kgm2]

Moment of inertia of all driven parts referred to the shaft to be braked

t1

[ms]

Engagement time, T1 = T11 + T12

t2

[ms]

Disengagement time (time from the beginning of the torque drop to reaching 0.1 MK)

t11

[ms]

Slipping time (time during which there is a relative motion between input and output with brake engaged)

t11

[ms]

Delay during engagement (time from switching off the supply voltage to the beginning of the torque rise)

t12

[ms]

Torque rise time

Q12

[J]

Calculated friction work per operation

Qperm

[J]

Max. permissible friction work per operation

K

Safety factor

Sh

[h ]

Operating frequency, i.e. the number of periodical brakings

sair

[mm]

Rated air gap

-1

SM 844

04-1-2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 04, Brake Scope of supply

Drive systems

•

The drive systems are combined individually according to a modular design. The scope of delivery is indicated in the accompanying papers.

Labelling

•

After receipt of the delivery, check immediately whether it corresponds to the accompanying papers. INTORQ does not grant any warranty for deficiencies claimed subsequently. Claim

Manufacturer: INTORQ GmbH & Co KG, Wülmser Weg 5, D-31855 Aerzen

− visible transport damage immediately to the forwarder. − visible deficiencies / incompleteness immediately to INTORQ GmbH & Co.KG.

Disposal The spring-applied brake consists of different types of material.

•

Recycle metals and plastics.

•

Ensure professional disposal of assembled PCBs according to applicable environmental regulations.

Drive systems and components are unambiguously designated by the indications on the nameplate.

•

The spring-applied INTORQ brake is also delivered in single modules and individually combined to its modular design. The data - package labels, nameplate, and type code in particular - apply to the complete stator.

•

If single modules are delivered, the labelling is missing.

Legal regulations Liability •

The information, data and notes in these Operating Instructions met the state of the art at the time of printing. Claims referring to drive systems which have already been supplied cannot be derived from the information, illustrations and descriptions.

•

We do not accept any liability for damage and operating interference caused by: − − − − −

inappropriate use unauthorised modifications to the drive system improper working on and with the drive system operating faults disregarding these Operating Instructions

Warranty •

Terms of warranty: see terms of sale and delivery of INTORQ GmbH & Co. KG.

•

Warranty claims must be made to INTORQ immediately after detecting defects or faults.

•

The warranty is void in all cases where liability claims cannot be made.

SM 844

04-1-3

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 04, Brake

Section 2 Safety Instructions

SM 844

04-2-1

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 04, Brake however necessary to check the functionality of all mechanical components under the corresponding operating conditions.

General safety information •

•

•

•

INTORQ components ... − ... must only be applied as directed. − ... must not be commissioned if they are noticeably damaged. − ... must not be technically modified. − ... must not be commissioned if they are incompletely mounted. − ... must not be operated without the required covers. − ... can hold live as well as moving or rotary parts during operation according to their degree of protection. Surfaces may be hot.

For INTORQ components ... − ... the documentation must always be kept at the installation site. − ... only permitted accessories are allowed to be used. − ... only original spare parts of the manufacturer are allowed to be used.

All specifications of the corresponding enclosed documentation must be observed.

This is vital for a safe and trouble-free operation as well as for achieving the specified product features.

Only qualified, skilled personnel are permitted to work on and with INTORQ components.

According to IEC 60364 or CENELEC HD 384, qualified, skilled personnel are persons ... − ... who are familiar with the installation, mounting, commissioning, and operation of the product. − ... who have the qualifications necessary for their occupation. − ... who know and apply all regulations for the prevention of accidents, directives, and laws relevant on site.

•

Risk of burns! − Surfaces may be hot during operation! Provide for protection against accidental contact.

•

Risk of injury due to a rotating shaft! − Wait until the motor is at standstill before you start working on the motor.

•

The friction lining and the friction surfaces must by no means have contact to oil or grease since even small amounts reduce the brake torque considerably.

•

The brake is designed for operation under the environmental conditions that apply to IP54. Because of the numerous possibilities of using the brake, it is

Application as directed •

INTORQ components ... − ... are intended for use in machinery and systems. − ... must only be used for the purposes ordered and confirmed. − ... must only be operated under the ambient conditions prescribed in these Operating Instructions. − ... must not be operated beyond their corresponding power limits.

Any other use shall be deemed inappropriate!

Possible applications of the INTORQ spring-applied brake •

Humidity: no restrictions

•

Ambient temperature: − -20°C to +40°C (standard)

•

At high humidity and low temperature: − Take measures to protect armature plate and rotor from freezing.

•

Protect electrical connections against contact.

SM 844

04-2-2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 04, Brake

Section 3 Technical Data

Product description

General information The spring-applied brake 14.442.12.100 is a single-disk brake with two friction surfaces. The braking torque is generated by several compression springs (3.1 and 3.2) by means of friction locking. This spring-applied brake features two braking steps, the stator of braking step 1 (1) and the stator of braking step 2 (2). Like this the user can generate two braking torques if the brake is connected accordingly:

Versions

A Braking torque - by braking step 1 B Braking torque - by braking step 1 plus braking step 2 (total braking torque) The spring-applied brake is designed for the conversion of mechanical work and kinetic energy into heat. For operating speed, see page 04-3-3 Rated data. Due to the static brake torque, the brake can hold loads without speed difference. Emergency braking is possible at high speed, see page 04-3-3 Rated data. The more friction work, the higher the wear.

(Fig. 1) Structure of a spring-applied brake 14.442

Item

Name

1

Stator

Braking step 1

Compression spring

Braking step 1

2 3.1

Braking step 2

3.2 4.1

Braking step 2 Armature plate

Braking step 1

Setting ring gauge

Braking step 1

4.2 5.1

Braking step 2

5.2 5.3

Braking step 2 Cheese head screw

Braking step 2

6

Rotor

7

Hub

8

Sleeve bolts

9

Fixing screw set: DIN 912 cheese head screws

Braking During the braking process in the partial load operational range, the rotor (6) that can be displaced axially on the hub (7) is pressed against the friction surface by the springs (3.1) in the stator of braking step 1 (1) via the armature plate (4.1). The spring pressures generated by the compression springs in connection with the asbestos-free friction linings create a low-wear braking torque. If an increased braking torque is required in the full load operational range, the braking process is intensified by the stator of braking step 2 (2). The armature plate (4.2) is pressed against the armature plate (4.1) of braking step 1 by the compression spring (3.2), and the contact pressing force of the armature plate (4.1) to the friction surfaces of the rotor (6) is increased.

The braking torque is transmitted between the hub (7) and the rotor (6) via gear teeth.

SM 844

04-3-1

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 04, Brake Brake release In the braked state, in the partial-load operational and in the full-load operational range the air gap "s" is between the stator of braking step 1 (1) and the armature plate of braking step 1 (4.1) . For release the coils of the stators of braking steps 1 and 2 are excited with the intended DC voltage. The magnetic force that is generated pulls the armature plates (4.1 / 4.2) against the spring pressure of the stators of braking steps 1 and 2. Thus the rotor (6) is released of the spring pressure and can rotate freely.

Due to the size and design of the stator of braking step 2, it is not able to activate the internal armature plate (4.2) without support of the stator of braking step 1 when it is supplied with current and, like this, attain a braking process in the partial-load operational range from the full-load operational range. The brake always has to be released by means of both braking steps.

Brake torque reduction Both steps contain compression springs (see items 3.1 and 3.2 in fig. 1) for generating the braking torques. Both steps can be altered independently of each other via the setting ring gauges (items 5.1 and 5.2 fig. 1) within certain limits.

SM 844

04-3-2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 04, Brake Rated data Dimensions Size

Rated air gap Max. adjust“s” ment, permis+0.1 mm sible wear -0.05 mm

12

[mm]

[mm]

0.3

2.0

Rotor thickness

Pitch circle

min. [mm] max. [mm] d [mm] Thread 8.0

10.0

132

3 x M6

Tightening torque

Setting ring gauge max. perm. projection 1)

[Nm]

[mm]

9.5

8.5

Tab. 1) Dimensions of the spring-applied brake 14.442.12.100 1) See page 04-6-1

Operating frequency / friction work 100000

Switching energy Q [J]

12 10000

1000

100

10 1

10

100

1000

10000

Operating frequency Sh[h−1]

(Fig. 2) Switching energy as a function of the operating frequency Stf

Stf

Sfperm 1

Q QE

Qperm

QE 1

e

Sf

The permissible operating frequency "Shperm" depends on the friction work "Q" (see Fig. 2). An operating frequency of "Sh" results in the permissible friction work "Qperm".

With high speed and friction work, the wear increases strongly, because very high temperatures occur at the friction faces for a short time.

SM 844

04-3-3

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 04, Brake Emission Electromagnetic compatibility Note!

The user must ensure compliance with EMC Directive 2004/108/EC using appropriate controls and switching devices.

.If an INTORQ rectifier is used for the DC switching of an INTORQ spring-applied brake and if the operating frequency exceeds five switching operations per minute, the use of a mains filter is required. If the INTORQ springapplied brake uses a rectifier of another manufacturer for the switching, it may become necessary to connect a spark suppressor in parallel with the AC voltage. Spark suppressor according to coil voltage on request.

Heat Since the brake converts kinetic energy as well as mechanical and electrical energy into heat, the surface temperature varies considerably, depending on the operating conditions and possible heat dissipation. Under unfavourable conditions, the surface temperature can reach 130℃.

Noises The switching noises during engagement and disengagement depend on the air gap "sair" and the brake size.

Depending on the natural oscillation after installation, operating conditions and state of the friction faces, the brake may squeak during braking.

Others The abrasion of the friction parts produces dust.

In case of high load, the friction face will become so hot that odours may occur.

SM 844

04-3-4

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 04, Brake

Section 4 Mechanical Installation

Important notes Stop!

Toothed hub and screws must not be lubricated with grease or oil!

Necessary tools Type

14.442.12

Torque wrench Insert for hexagon socket screws

Wrench size of Hook wrench DIN Socket spanner for open-jawed span1810 design A outer flange ner [mm] mounting

Q

Measuring range [Nm]

Width [mm]

Sleeve bolts

Diameter [mm]

Width [mm]

1 to 12

5 x 1/4" square

12

80 - 90

10 x 1/2" square

* For flange mounting insertion with journal guidance

Feeler gauge

Caliper gauge

SM 844

Multimeter

04-4-1

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 04, Brake Mounting

Installation

Important notes

Installation of the hub onto the shaft

Minimum requirements of the end shield: •

Material S235 JR , C15 or EN-GJL-250 − If different materials are used, INTORQ.

contact

•

Levelness < 0.06 mm

•

Axial runout 0.10 mm,

•

Roughness Rz 10 to Rz 16

•

The threaded holes must have the minimum thread depth (page 04-3-3).

•

The end shield must be free of grease and oil.

•

Minimum requirements of the motor shaft: − The diameter of the shaft shoulder must not be bigger than the tooth root diameter of the hub.

Preparation

(Fig. 3) Mounting the hub on the shaft 4

Hub

15

4.1

Circlip

15.1 Keyway

End shield

1. Insert keyway (15.1) into the shaft.

1. Unpack spring-applied brake.

2. Press hub (4) onto the shaft.

2. Check for completeness.

3. Secure the hub against axial displacement, e.g. with a circlip (4.1).

3. Check nameplate data, especially rated voltage.

4. Fit threaded holes in end shield. − Observe minimum depth!

Stop!

Stop!

•

Observe the required minimum thread depth in the motor flange to be able to readjust the brake: − Thread depth > penetration depth of the fixing screw for brand-new brake + maximum adjustment path. (page 04-3-3, Tab. 1)

•

If the required thread depth is not observed the fixing screws may run into the thread root when adjusting the brake. As a result, the required prestressing force will no longer be built up and the brake is no longer fixed securely!

In reverse operation, it is recommended to additionally glue the hub to the shaft, (e.g. using Delo-ML 5328)!

Brake assembly

(Fig. 4) Mounting without counter friction face 7

Hub

7.1

Circlip

SM 844

15

End shield

04-4-2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 04, Brake Assembly of the rotor 1

Stator 1

9

Sleeve bolts

2

Stator 2

11

Connector block

6

Complete rotor

15

End shield

8

Cheese head screw

6. Screw the complete stator (1) onto the end shield (15) using the supplied screw set (8). − Use torque key.

7. Remove and throw away the connector blocks (11).

Check air gap (Fig. 5) Mounting of the rotor 6

Complete rotor

7

Hub

15

End shield

4. Push the rotor (6) onto the hub (7) and check whether it can be moved by hand.

Assembly of the stator 5. Push the stator onto the shaft.

XU

(Fig. 7) Checking "s" 8. Check the air gap "s" near the screws (8) using a feeler gauge and compare the values to the values in the table (page 04-3-3).

If "s" is not within the tolerance, readjust the air gap (page 04-7-3).

YU

(Fig. 6) Mounting of the complete stator

SM 844

04-4-3

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 04, Brake

Section 5 Electrical Installation

Danger!

• •

Electrical connection must only be carried out by skilled personnel!

Connections must only be made when the equipment is de-energised! Danger through unintended starts or electric shocks.

Stop!

• •

It must be ensured that the supply voltage corresponds to the nameplate data.

Voltages must be adapted to the local environment!

Note!

•

The control of the brake is customised. If required, it should be agreed with INTORQ.

SM 844

04-5-1

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 04, Brake

Section 6 Commissioning and Operation

!

Commissioning

DANGER

The live connections and the rotating rotor must not be touched.

The drive must not be running when checking the brake.

1. Switch on drive system.

2. Carry out a braking test, if necessary, reduce brake torque.

Setting the braking torque

Function checks before commissioning

Stop!

Operational check

!

The braking torques of the external and internal braking step can be altered after consultation with INTORQ If required, the brake has to be redesigned.

Braking step 1 DANGER

The brake must be free of residual torque.

The motor must not rotate.

!

DANGER

Live connections must not be touched.

1. Remove two bridges from the motor terminals. Do not switch off the DC brake supply. When connecting the rectifier to the neutral point of the motor, the PE conductor must also be connected to this point.

2. Connect the mains supply.

3. Measure the DC voltage at the brake. − Compare the DC voltage measured with the voltage specified on the nameplate. A ± 10 % deviation is permissible.

4. Check air gap "s". It must be zero and the rotor must rotate freely.

5. Switch off the power supply.

6. Bolt bridges to the motor terminals. Remove additional PEN conductor.

7. The preparations for commissioning are completed.

1

SM 844

Stator

5.1

Setting ring gauge

04-6-1

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 04, Brake 1. Turn the setting ring gauge (5.1) counter-clockwise with a pin wrench. − Observe latchings. Positions between the notches are impermissible. − Observe maximally permissible projection "h1max" of the setting ring gauge (5.1) to the stator (1) (values for "h1max" see page 04-3-3).

!

During operation

!

DANGER

The running rotor must not be touched.

!

DANGER

Live connections must not be touched.

DANGER

The reduction of the braking torque does not increase the maximally permissible air gap "s".

•

Check the brake regularly during operation. Take special care of: − unusual noises and temperatures − loose fixing elements − the condition of the electrical cables.

•

The armature plate must be attracted and the rotor must move without residual torque.

•

Measure the DC voltage at the brake. − Compare the DC voltage measured with the voltage specified on the nameplate. A ±10 % deviation is permissible.

•

In the event of failures, refer to the troubleshooting table in Section 8. If the fault cannot be eliminated, please contact the aftersales service.

Possibility of emergency release In the event of a breakdown (e.g. power failure) the brake can be released mechanically via two cheese head screws M5x35. By means of the cheese head screws the armature plate (4.1) is pulled against the stator (2). Thus the braking effect is cancelled.

Stop!

2

Stator

5.2

Setting ring gauge

4.1

Armature plate

5.3

Cheese head screw

During normal operation the cheese head screws must not remain within the brake!

1. Loosen cheese head screw (5.3).

2. Turn setting ring gauge (5.2) counter-clockwise.

3. Tighten cheese head screw (5.3) again to prevent the setting ring gauge from being turned out of position unintentionally during operation.

SM 844

04-6-2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 04, Brake

Section 7 Maintenance/Repair

Wear of spring-applied brakes INTORQ spring-applied brakes are wear-resistant and designed for long maintenance intervals. The friction lining and the mechanical brake components are subject to function-related wear. For safe and trouble-free operation, the brake must be checked and readjusted at regular intervals, and, if necessary, be replaced.

The following table describes different causes of wear and their effects on the components of the spring-applied brake. For calculating the service life of rotor and brake and determining the maintenance intervals to be observed, the relevant factors of influence must be quantified. The most important factors are the friction work, initial speed of braking and the operating frequency. If several of the causes of wear indicated for the friction lining occur in an application at the same time, the influencing factors must be added for calculating the wear. The INTORQ Select dimensioning program can be used to calculate the maintenance intervals.

Component

Cause

Effect

Influencing factors

Braking during operation Emergency stops Overlapping wear during start and stop of drive Friction lining

Friction work

Active braking via the drive motor Wear of friction lining with support of brake (quick stop) Starting wear in case of motor mounting position with vertical shaft, even when the brake is not applied

Armature plate and Rubbing of brake lining counter friction face Splining of brake rotor

Number of start/stop cycles Run-in of armature plate and Friction work counter friction face

Relative movements and shocks Wear of splining (primarily on Number of start/stop between brake rotor and brake shaft the rotor side) cycles

Load alternation and jerks in the backNumber of start/stop Breaking of armature plate, Armature plate support lash between armature plate, sleeve cycles, braking sleeve bolts and guide bolt bolts and guide bolt torque Springs

Axial load cycle and shear stress of Number of switchReduced spring force or fatigue springs through radial backlash on ing operations of failure reversal of armature plate brake

SM 844

04-7-1

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 04, Brake Stop!

Inspections To ensure safe and trouble-free operation, spring-applied brakes must be checked and maintained at regular intervals. Servicing can be made easier if good accessability of the brakes is provided in the plant. This must be considered when installing the drives in the plant.

Primarily, the necessary maintenance intervals for industrial brakes result from the load during operation. When calculating the maintenance interval, all causes for wear must be taken into account (see page 04-7-1). For brakes with low loads such as holding brakes with emergency stop, we recommend a regular inspection at a fixed time interval. To reduce the cost, the inspection can be carried out along with other regular maintenance work in the plant if necessary.

Stable properties of the organic friction lining are only achieved in the case of continuous use. The readiness for operation of the brake has to be ensured with a braking energy that is equivalent to one emergency stop per week. Unplanned emergency stops occurring at a sufficient frequency have the same effect.

If the brakes are not maintained, failures, production losses or damage to the system may occur. Therefore, a maintenance concept adapted to the particular operating conditions and brake loads must be defined for every application. For the INTORQ spring-applied brakes, the maintenance intervals and maintenance operations listed in the below table must be provided. The maintenance operations must be carried out as described in the detailed descriptions.

Maintenance intervals Service brakes

• according to service life calculation • otherwise every six months • after 4000 operating hours at the latest

Holding brakes with emergency stop

• at least every 2 years • after 1 million cycles at the latest • plan shorter intervals for frequent emergency stops

Checking the component parts

With mounted brake

After removing the brake

• • • •

Check release function and control Measure the air gap (adjust if necessary) See page 04-4-3 Measure rotor thickness (replace rotor if necessary) See page 04-7-3 Thermal damage of armature plate or counter friction face (darkblue tarnishing)

• Check clearance of the rotor toothing (replace rotors with worn out See page 04-7-3 teeth) • Play of torque plate on sleeve bolts, dowel pins and armature plate • Check springs for damage • Check armature plate and counter friction face or end shield − Levelness < 0.06 mm − Max. run-in depth = rated air gap of brake size

SM 844

04-7-2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 04, Brake Maintenance

Readjustment of air gap

Note!

Brakes with defective armature plates, cheese head screws, springs or counter friction faces must always be replaced completely.

Generally observe the following for inspections and maintenance works: •

•

Remove impurities through oil and grease using brake cleaning agents, if necessary, replace brake after identifying the cause of the contamination.

Dirt deposits in the air gap between stator and armature plate impair the function of the brake and must be removed.

After replacing the rotor, the original braking torque will not be reached until the run-in operation of the friction surfaces has been completed. After replacing the rotor, run-in armature plates and counter friction faces have an increased initial rate of wear.

Checking the rotor thickness

!

(Fig. 8) Air gap adjustment

Stator 1

2

Stator 2

9

Sleeve bolt

4.1

Armature plate

15

End shield

DANGER

The motor must not run during this test.

1. Remove the motor cover and seal ring, if mounted.

2. Measure the rotor thickness using a caliper gauge.

3. Compare measured rotor thickness with minimally permissible rotor thickness (for values see page 04-33).

4. Replace the complete rotor if necessary. See page 047-3 for description.

8

Cheese head screw

1

!

DANGER

The brake must be free of residual torque.

1. Unbolt screws (Fig. 8).

2. Screw the threaded sleeves into the stator by using a spanner. 1/6 revolution reduces the air gap by approx.

0.15 mm.

3. Tighten the screws, (for torques see page 04-3-3).

4. Check the air gap "s" near the screws using a feeler gauge, ("s" see page 04-3-3).

5. If the difference between the measured air gap and "s" is too large, repeat the readjustment.

Check air gap

!

DANGER

Rotor replacement

The motor must not run during this test.

1. Measure the air gap "s" between armature plate and stator using a feeler gauge (see page 04-3-3).

2. Compare the measured air gap to the maximum permissible air gap "s_max." (see table in page 04-3-3).

3. If necessary, adjust the air gap to "s". See page 04-73 for details.

!

DANGER

The brake must be free of residual torque.

1. Switch off voltage!

2. Disconnect the supply cable.

3. Loosen the screws evenly and remove them completely.

SM 844

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Group 04, Brake 4. Remove the complete stator from the end shield.

Observe the supply cable.

Spare-parts list • •

5. Pull the complete rotor off the hub.

6. Check hub teeth.

7. Replace the hub as well if worn.

Only parts with item numbers are available.

The item numbers are only valid for the standard design.

8. Check the friction surface at the end shield. In case of strong scoring at the flange, replace the flange. If scoring occurs at the end shield, re-finish end shield.

9. Measure rotor thickness (new rotor) and sleeve bolt head with a caliper gauge.

10. Calculate the gap between the stator and the armature plate as follows: Gap = rotor thickness + s - head height ("s" see table in page 04-3-3) 11. Unscrew the sleeve bolts evenly until the calculated gap between stator and armature plate is reached.

12. Install and adjust new rotor and stator (see page 04-43).

13. Reconnect the supply cable.

(Fig. 9) Spring-applied brake 14.442.12-100

Item Name

Variant

1

Stator of braking Voltage / braking steps 1 + 2 torque

6

Complete rotor

8

Fixing screw setDIN 912 cheese head screw

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Group 04, Brake

Section 8 Troubleshooting and Fault Elimination

If any malfunctions should occur during operation of the drive system, please check the possible causes using the following table. If the fault cannot be eliminated by one of the listed measures, please contact the aftersales service.

Fault

Cause

Remedy

Coil interruption

• Check coil resistance using a multimeter: − If resistance is too high, replace the complete stator.

• Check coil resistance using a multimeter: − Compare result with rated resistance. For values see page 04-3-3. If resistance is too low, replace the complete stator.

Coil has interturn fault or short cir- • Check coil for short circuit to ground using a multiBrake cannot be released, cuit to ground meter: air gap is not zero − Replace the complete stator if short circuit to ground is detected.

• Check brake voltage (see "defective rectifier, voltage too low").

Wiring incorrect or defective

• Check and correct wiring.

• Check cable continuity using a multimeter: − Replace defective cable.

Air gap too large

Adjust air gap (see page 04-7-3)

Rotor cannot rotate freely

Air gap s too small

Check air gap “s” and readjust it, if necessary (see page 04-7-3).

Rotor not thick enough

Rotor has not been replaced in time Replace rotor (see page 04-7-3).

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GROUP 05

GROUP 05 DRIVE AND STEERING SYSTEM

Drive Wheel .................................................... Section 1

Load Wheels ....................................................Section 2

Steering Unit ....................................................Section 3

Steering Arm / Wheel / Lever ........................Section 4

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Group 05, Drive and Steering System

Section 1 Drive Wheel

Repair and Rebuild Replace worn tire with new as necessary.

Drive Tire

Drive Dr ve Wheel Nuts Nu (SI-49294)

Nut

Removal

Theory of Operation The drive wheel is mounted on the transmission final drive axle. The drive wheel is part of the drive motor assembly.

Maintenance

1. Turn steering wheel all the way to the left to access drive wheel mounting bolts.

2. Turn key switch OFF and depress Emergency Power OFF (EPO) switch. Disconnect battery connector from truck.

!

See “Planned Maintenance Schedule” on page 01-2-2.

Troubleshooting Inspect wheel and tire for wear and damage. Trash that is wrapped around wheel and axle will cause premature tire wear and bearing damage. The floors should be kept clear of trash to reduce risk of damage to wheel and tire.

WARNING

Use extreme care whenever the truck is jacked up. Never block the truck between the column and the floor. Keep hands and feet clear from truck while jacking the truck.

After the truck is jacked, place solid blocks beneath it to support it. DO NOT rely on the jack alone to support the truck.

3. Jack and block truck under truck frame (see page 011-2).

4. Remove chassis covers (see page 02-1-1).

5. Remove drive wheel mounting nuts.

6. Remove drive wheel.

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Group 05, Drive and Steering System Installation 1. Install drive wheel on drive wheel shaft.

2. Install drive wheel mounting bolts and torque to 114~133 ft-lbs (155~180 N•m).

3. Install chassis covers (see page 02-1-1).

4. Remove block and lower truck with jack.

5. Reconnect battery connector to truck. Energize EPO switch and turn key switch ON. Test truck for proper operation before returning to service.

Tire Pressing Procedure Outside de of Hub and Tire re A Assembly Ne New Tire Worn Tire Circu rcular Ram Ra Press Tab able

1. Check the inside surface of metal insert on the new tire. Remove any scaling or rust with sandpaper.

Clean the inside of metal insert and lubricate with a soap solution.

2. Place a circular ram on press table. The length of ram must be longer than the width of the old tire to allow complete removal of old tire. The outside diameter of ram must be small enough to fit loosely in the insert of tire, but large enough to rest squarely on the flat surface on the outer edge of hub.

tioned upward. The outside edge of hub has a chamfer to help guide the new tire onto the wheel. The chamfered edge must always be the leading edge when a tire is pressed onto hub.

5. Center hub assembly on the top of the ram and make sure they mate squarely.

6. Position new tire with its chamfered insert facing hub.

Align new tire and hub so they are concentric.

!

CAUTION

Any misalignment of tire and hub while tire is being pressed onto hub can cause damage to hub. For this reason, chamfers have been provided on the outside edge of the hub and on the end of the inside diameter of the tire’s metal insert. The chamfers help to center the hub and tire during the pressing operation and decrease the possibility of misalignment.

To reduce damage, the hub must be installed on circular ram with its chamfered side up.

NOTE!

If new tire does not press on with a minimum of 5 tons (4535 kg) force, replace hub.

7. Begin pressing new tire onto hub and old tire off hub.

Run press slowly for the first few inches of travel, because this is the critical stage of the operation. If tire begins to cock to one side, stop press and realign tire. A sharp jar with a softheaded mallet will usually realign tire on hub.

8. Release the press. Remove wheel, tire assembly, and old tire from press table. Inspect wheel and tire assembly.

9. Install wheel assembly following the procedure for the specific type of wheel.

3. If the outside edge of the hub is not flush with the edge of the metal insert in old tire, measure how far hub is recessed inside the tire. The new tire must be placed in the same position the old tire was installed on the hub. A spacer (slightly smaller in diameter than the inside diameter of the tire insert and the same thickness as the depth of the recess) can be used to obtain proper amount of recession.

4. 4. Position hub assembly with the old tire on the top of circular ram so the outside of the wheel is posi-

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Group 05, Drive and Steering System

Section 2 Load Wheels

OzpT[`Y`\P

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Group 05, Drive and Steering System Theory of Operation The load wheels are mounted on the baselegs of the truck to enable the truck to travel smoothly. The side guide rollers can be mounted on the truck as an option to assist the operator in locating items on a rack or shelf.

7. Drive the axle back out through the wheels. Remove rocker (4). Remove washers (5) and shims on each side of the wheel. The axle is welded into the rocker plate (3). Remove the load wheel (1) from the toe box.

8. Inspect bearings (2).

Installation

Maintenance Inspect the wheels and tires daily for wear and debris wrapped around wheels. Check load wheel bearings for binding or excessive play. See “Planned Maintenance Schedule” on page 01-2-2.

1. Pack bearings (2) with grease and install in the load wheel.

2. Install load wheel assembly in toe box.

NOTE!

Place a block behind the axle to hold it in place while assembling the rocker plate and snap rings.

3. Install axle, washers (5), shims and rocker plate (3).

Troubleshooting Every two months inspect load wheel bearings for chunking, bond failure and excessive or uneven wear. Make sure tires are functioning smoothly. Make sure sufficient grease is applied to load wheels.

4. Install snap rings (7) on axle.

5. Remove blocking. Lower truck to the floor.

6. Reconnect battery connector to the truck. Energize EPO switch and turn key switch ON. Test truck for proper operation before returning to service.

Repair and Rebuild Load wheels or guide wheels can not be repaired or rebuilt.

Replace worn wheel or wheel assembly with new as necessary.

Tandem Articulated Load Wheel NOTE!

Call-outs in the following procedures refer to illustration on page 05-2-1.

Removal 1. Park the truck on a flat surface.

!

DANGER

Securely block mast columns to reduce risk of lowering when working on or near mast. If not blocked, unexpected movement could occur resulting in personal injury or death.

2. Lower platform.

3. Turn key switch OFF and depress EPO switch. Disconnect battery connector from truck.

4. Check to make sure the battery retainer plates are in place.

5. Hoist truck so load wheels are approximately 2 inches (51 mm) off the floor and securely block.

6. Remove snap ring (7) from the axles.

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Group 05, Drive and Steering System

Section 3 Steering Unit

OzpT[`X_[P

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Group 05, Drive and Steering System Theory of Operation The steer motor drives a gear ring enabling the drive unit to be rotated through 180 degrees (90 degrees in either direction). The steer motor operates the electric transducer to the steer power card. Steering angle is limited to 180° + 90°.

Maintenance See “Planned Maintenance Schedule” on page 01-2-2.

Repair and Rebuild The steering motor can not be repaired or rebuilt. Replace steering motor with new as necessary.

NOTE!

Call-outs in the following procedures refer to illustration on page 05-3-1.

Removal 1. Park the truck on a flat surface.

2. Turn key switch OFF and depress Emergency Power OFF (EPO) switch. Disconnect battery connector from truck.

3. Remove chassis covers (see page 02-1-1).

4. Disconnect electrical connections from steer/ tractor manager.

5. Remove steer switches.

6. Remove mounting screws (5). Pull steer motor (4).

Installation 1. Install new steer motor (4) assembly on pivot ring and secure with screws (5).

2. Install new steer motor assembly on pivot ring. Apply Loctite 242® to bolts. Secure bolts to assembly.

3. Install steer switches.

4. Reconnect electrical connections to steer/tractor manager.

5. Install chassis covers (see page 02-1-1).

6. Reconnect battery connector to truck. Energize EPO switch and turn key switch ON. Test truck for proper operation before returning to service.

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Group 05, Drive and Steering System

Section 4 Steering Arm / Wheel / Lever

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Group 05, Drive and Steering System Theory of Operation The steer wheel is mounted to the console. The wheel steers the truck in a direction of travel.

Maintenance See “Planned Maintenance Schedule” on page 01-2-2.

Repair and Rebuild Steering Wheel NOTE!

Call-outs in the following procedures refer to illustration on page 05-4-1.

Removal 1. Park truck on level surface.

2. Turn key switch OFF and depress Emergency Power OFF (EPO) switch. Disconnect battery connector from truck.

3. Remove dash panel cover (see page 02-1-4).

4. Loosen capscrew(14) on the bracket (13).

5. Remove screw(15), washer(16,17) and step(11).

6. Remove shaft (12).

7. Remove bearing (9), snap ring (8) from bracket.

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GROUP 06

GROUP 06 ELECTRICAL SYSTEM

General ............................................................ Section 1 Battery ..............................................................Section 2 Component Function ......................................Section 3 Diagram and w/harness ..................................Section 4 Dash Display ....................................................Section 5 Fuse Box ...........................................................Section 6 Electrical Components....................................Section 7

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Group 06, Electrical System

Section 1 General

Summary for electrical components Electrical system is composed with 4 sections as below.

1. Main power line ; Conduct driving, hydraulic operation, and steering controlled by 2 AC controllers.

2. Control signal line ; The signals from all of the switches and sensors communicate with control boards.

3. Display ; Display communicate all of signals with controller and switches by CAN-BUS, It display the diagnosis and status of truck at real-time, and could be displayed information by pressing the membrane switch on it.

4. Accessories ; The truck is equipped with lamps, horn, and backup alarm.

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Group 06, Electrical System

Section 2 Battery

Battery Specification Voltage (V)

Battery Capacity (AH)

Weight (kg)

Connector

24V

1240 AH

975

SB350-RED(REMA)

36V

775 AH

1600

SB350-GRAY(REMA)

Battery Compartment (W x L x H) (mm) 975 x 362 x 800

H w

L

Feature Using one touch vent plug, easy to find an electrolyte lack and has easier serviceability.

[ Full ]

(Plug up)

[ Empty ]

(Plug down)

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Group 06, Electrical System Theory of Operation

Charging

A 24 volt or 36 volt battery is not supplied with the truck.

Check the truck’s data plate for the size of battery required for the truck. Contact your local battery supplier for the purchase of a proper voltage battery.

OSHA regulations require that battery charging installations be located in areas designated for that specific purpose. Such areas must provide for flushing and neutralizing spilled electrolyte, fire protection, protecting charging equipment from damage by trucks and adequate ventilation of fumes from gassing batteries.

Maintenance Information in this section does not supercede or replace information supplied by the battery and battery charger supplier. Read, understand, and follow the procedures in the manual supplied with the battery and battery charger.

Notify your supervisor if there are any concerns or questions regarding the battery or procedures.

To charge a battery, direct current is passed through the battery cells in the direction opposite that of discharge.

Charging time is 5% to 20% longer than discharge time.

Read, understand, and follow procedures, recommendations and specifications in the battery and battery charger supplier’s manuals.

Inspection and Care NOTE!

Read, understand, and follow procedures, recommendations, and specifications in the battery and battery charger supplier’s manuals.

Batteries in industrial trucks pick up various kinds of dirt and dust depending on their surroundings and the types of material handled. If cells are overfilled and electrolyte collects on the covers, the following occurs: 1. The top of the battery becomes wet and stays wet, since the acid in the electrolyte does not evaporate.

2. This moist surface, in combination with certain kinds of dirt, becomes electrically conductive and permits stray currents to flow externally over the top of the battery. This degrades battery performance and truck operation.

3. The acid also causes corrosion of cell posts, nuts, connectors and the steel battery case.

When inspecting batteries, check the following: 1. Wet covers can indicate overfilling, leaky seals at posts, or excessive gassing during charge. If covers are wet, determine the cause and correct the problem.

2. Make sure batteries cannot move more than 0.5 inch (13 mm) in any horizontal direction. Shim or block the batteries to restrain them.

Exterior Cleaning Refer to recommended battery supplier’s guidelines for details.

!

CAUTION

NEVER plug the battery charger into the truck. This will severely damage the truck’s electrical system. Plug the charger into the connector from the battery.

Storage Before storing battery, make sure the electrolyte is at the proper level in all the cells, the filler plugs are tight, and the battery is fully charged. Store battery in a clean, cool, dry location away from radiators and other sources of heat.

Check electrolyte level and specific gravity every 30 days during storage. Whenever specific gravity is less than 1.230, charge the battery.

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Group 06, Electrical System History Record

Repair and Rebuild

A battery record system is essential because battery failure can cause production slowdowns and increased battery operating costs. A properly supervised record system can detect and call attention to such operating irregularities as:

Contact your local battery supplier for replacements or rebuilds.

•

Overcharging

•

Undercharging

•

Over-discharging

•

Excessive water consumption

•

Excessive dirt and corrosion

•

Worn-out batteries

•

Excessive current consumption of trucks

!

WARNING

Battery electrolyte is a solution of sulfuric acid and water. Battery acid causes burns. Should any electrolyte come in contact with clothing or skin, flush the area immediately with cold water. Should the solution get on your face or in the eyes, flush the area with cold water and receive medical attention immediately.

Records should be kept for each battery. Your battery supplier should be able to provide maintenance record sheets.

Each report should contain: •

Battery number, type, serial number, and service data

•

Specific gravity and voltage readings for each cell

•

Temperature of the air and electrolyte

•

Electrolyte

•

Amperes

•

Condition of connectors, covers, sealing compound and tray

•

General cleanliness

•

Number of total cycles

•

Average specific gravity drop

•

Watering frequency

!

CAUTION

Before working on the battery, review Battery Safety. Batteries may weigh more than 24 volt : 1520 pounds (689 kg), 36 volt : 1600 pounds (726 kg). Use extreme care during replacement.

Use a suitable replacement device or hoist for lifting.

NOTE!

The distance from the floor to the top of the battery rollers is 7 inches (175 mm).

Removal 1. Turn key switch OFF and depress Emergency Power OFF (EPO) switch. Disconnect battery connector from truck.

2. Position battery removal device in accordance with supplier’s recommendations.

3. Remove battery stop plates (see page 02-2-2).

4. Remove battery from truck onto suitable battery table or battery lifting device.

Troubleshooting Many electrical problems are caused by a faulty or dirty battery. Make sure the battery is clean. Check the electrolyte level and battery level. Look for simple causes of problems. A qualified technician should perform testing and troubleshooting on batteries.

Installation 1. With a fully charged and tested battery on the battery handling device, position the handling device at the truck according to the supplier’s recommendations.

2. Move the battery into the compartment and install battery stop plates (see page 02-2-2). Be sure the battery has no more than 0.50 inch (13 mm) of “free play” movement in the battery compartment.

3. Move handling device from the area.

4. Reconnect battery connector to truck. Energize EPO switch and turn key switch ON. Test truck for proper operation before returning to service.

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Group 06, Electrical System 5. Check inside connectors at internal contacts for damage, dirt, or corrosion. DO NOT use a metal object to clean connectors.

Battery Connector Theory of Operation

6. Connector housings must not be cracked or broken.

The truck battery connector is located on the right side of the truck. The battery and charger have similar battery connectors. It is necessary to connect the battery to the truck before powering ON.

Truck Batte Battery ector Connec

Maintenance Visually inspect cables and connectors. Negative and positive cables should be visually inspected for breaks and wear. Check connectors for damage and to ensure proper connections of cables.

Inspection

Troubleshooting

1. Turn key switch OFF and depress Emergency Power OFF (EPO) switch. Disconnect battery connector from truck.

Make sure of the cable wires are in good condition and connector has proper connections to cables.

2. Check battery connectors for damaged cables.

Repair and Rebuild

3. Check to see if cables are pulling out of the connectors.

Do not attempt to repair or rebuild the battery connectors or power cables. Replace any damaged pieces with new.

4. Check cables at battery terminals. Connections should be tight, with no corrosion.

A

B

B B-B A

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Group 06, Electrical System Removal, Repair, and Installation The cables to the battery connectors have a lip on the forward end. This lip snaps over a spring-loaded retainer which is part of the connector. To remove a cable from the connector, push retainer down while pushing cable towards the rear and out of the connector.

!

WARNING

Battery charger unintentionally connected to battery connector at truck frame could lead to premature failure. Installation of a spacer block onto charger half of battery connector could reduce the risk of a battery charger to a truck connection.

1. Disconnect power supply to battery charger.

2. Reconnect supply to battery charger.

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Group 06, Electrical System

Section 3 Component Function

Motor EPS Motor Traction Motor Pump Motor

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Group 06, Electrical System Traction motor

Pump motor

Non contactedPickup sensor type.

Thermal sensor (inside of Body )

Terminal board (U,V,W)

Non contactedPickup sensor type.

Thermal sensor (inside of Body )

Terminal board (U,V,W)

Spec : 4.7Kw/3265rpm/24V/160A

Spec : 14Kw/2325rpm/24V/450A

Insulation : “F” IP Grade : IP43 Enclosed Motor

Insulation : “F” IP Grade : IP43 Enclosed Motor

− No brushes to change or commutator to turn.....ever − Enclosed Motor (IP43), Keeps out dust and contaminates − Short distance on plugging mode. − All motors are equipped with a thermistor which constantly monitors temperature. Should the temperature approach the thermal limit, the control cuts back current. − When motor is stall condition(during 15 seconds), it reduce the power to motor to protect overheating and damage. − Equipped with non contacted pickup speed sensor.

Strength durability and serviceability. (Before used contacted bearing sensor)

− No brushes to change or commutator to turn.....ever − Enclosed Motor (IP43), Keeps out dust and contaminates − Short distance on plugging mode. − All motors are equipped with a thermistor which constantly monitors temperature. Should the temperature approach the thermal limit, the control cuts back current. − When motor is stall condition(during 15 seconds), it reduce the power to motor to protect overheating and damage. − Equipped with non contacted pickup speed sensor.

Strength durability and serviceability. (Before used contacted bearing sensor)

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Group 06, Electrical System EPS motor

Non contactedPickup sensor type.

Terminal board (U,V,W)

Thermal sensor (inside of Body ) Spec : 400W/2750rpm/24V/21A Insulation : “H” IP Grade : IP43 Enclosed Motor − No brushes to change or commutator to turn.....ever − Enclosed Motor (IP43), Keeps out dust and contaminates − Short distance on plugging mode. − All motors are equipped with a thermistor which constantly monitors temperature. Should the temperature approach the thermal limit, the control cuts back current. − When motor is stall condition(during 15 seconds), it reduce the power to motor to protect overheating and damage. − Equipped with non contacted pickup speed sensor.

Strength durability and serviceability. (Before used contacted bearing sensor)

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Group 06, Electrical System Controller Traction Controller

Pump Controller

EPS Controller

1. 3Phase inverter has much controllable area than DC system.

2. Steering sensor enable driving left and right motor independently to secure small turning radius.

3. Height switch enable reduce the lift and travel speed as follow the height of cabin.

9. Auto centering option − When key switch off-on, the steer axle always return to 0-position.

10. Wire guidance option − When wire guidance function “ON” truck is moving straightly regardless the position of steer handle.

4. Watchdog functioning before starting truck.

5. Maximize the truck depending on working condition and operator. (Travel speed, pump speed, fine operating zone, acceleration/deceleration rate) 6. Can-Bus communication.

7. Dead-man switch equipped as standard, protect operator who took platform off from travel and lift work.

8. Cooled controller on the surface of counterweight and operating fan for ventilating heated air inside of control room. − Fan operates only the case of heated controller to 40 degrees, It is for reducing the fan operating noise. − Selectable fan operating mode depending on working condition. (Turning on whenever gear in.) − Selectable travel alarm operating mode depending on working condition. (Forward and Backward or Backward only )

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Group 06, Electrical System Safty Switches 1. Emergency Switch − This switch cut off all of the power to the truck, and conducted just by pressing red button. Located easy reach of operator.

2. Deadman Switch − Engaged inductive sensor for long life cycle

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Group 06, Electrical System Directional lever − More durable sensor using Hall effect sensor − Protected from pollution, sensor is molded with epoxy : IP65 (Grade)

− Dual signal is installed to protect malfunction on electrical signal. − Accelerator signal is activated only pressing mechanically.

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Group 06, Electrical System

Section 4 Diagram and w/harness

1)

Wiring-Diagram (24V)

2)

Wiring-Diagram (36V)

3)

W/harness - Main (24V)

4)

W/harness - Main (36V)

5)

W/harness - Operator platform (24V)

6)

W/harness - Operator platform (36V)

7)

W/harness - Accessory (24V)

8)

W/harness - EXT Accessory

9)

W/harness - Accessory (36V)

10) INSTL - Elec comp 11) INSTL - Accessory 12) INSTL - Mast Switch 13) INSTL - Cables

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Group 06, Electrical System

OpuTY_[YYP

1) Wiring-Diagram (24V) - 1/4

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Group 06, Electrical System

OpuTY_[YYP

1) Wiring-Diagram (24V) - 2/4

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Group 06, Electrical System

OpuTY_[YYP

1) Wiring-Diagram (24V) - 3/4

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OpuTY_[YYP

1) Wiring-Diagram (24V) - 4/4

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Group 06, Electrical System

OpuTY_[YZP

2) Wiring-Diagram (36V) - 1/4

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Group 06, Electrical System

OpuTY_[YZP

2) Wiring-Diagram (36V) - 2/4

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Group 06, Electrical System

OpuTY_[YZP

2) Wiring-Diagram (36V) - 3/4

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OpuTY_[YZP

2) Wiring-Diagram (36V) - 4/4

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Group 06, Electrical System

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3) W/harness - Main (24V) - 1/2

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Group 06, Electrical System

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3) W/harness - Main (24V) - 2/2

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Group 06, Electrical System

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4) W/harness - Main (36V) - 1/2

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Group 06, Electrical System

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4) W/harness - Main (36V) - 2/2

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Group 06, Electrical System

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5) W/harness - Operator platform (24V) - 1/2

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Group 06, Electrical System

O_W^[_[XP

5) W/harness - Operator platform (24V) - 2/2

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Group 06, Electrical System

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6) W/harness - Operator platform (36V) - 1/2

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Group 06, Electrical System

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6) W/harness - Operator platform (36V) - 2/2

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Group 06, Electrical System

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7) W/harness - Accessory (24V)

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Group 06, Electrical System

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8) W/harness - EXT Accessory

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Group 06, Electrical System

O_W^[\\^P

9) W/harness - Accessory (36V)

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06-4-20

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Group 06, Electrical System

OzpT[`XZ^P

10) INSTL - Elec comp (1/2)

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06-4-21

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Group 06, Electrical System

OzpT[`XZ^P

10) INSTL - Elec comp (2/2)

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06-4-22

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Group 06, Electrical System

OzpT[`X[WP

11) INSTL - Accessory

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06-4-23

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Group 06, Electrical System

OzpT[`Y^`P

12) INSTL - Mast Switch

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06-4-24

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Group 06, Electrical System

OzpT[`XZ`P

13) INSTL - Cables (1/2)

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06-4-25

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Group 06, Electrical System

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13) INSTL - Cables (2/2)

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06-4-26

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Group 06, Electrical System

Section 5 Dash Display

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06-5-1

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Group 06, Electrical System Display introduction

Display initialization (When keyed on) Key on

Display appearance

1. Initializing as picture 2. Basic data is displayed in the screen after initializing for 1 second. (At real time for clock) 3. Seat belt LED and buzzer :Operate for 3 seconds with 1hz 4. Icons upper mode switch operate for 1 second with 1hz.

Name of section 1. Fuel remaining amount indication 2. Movable time and speed indication 3. Model name, message and breakdown contents indication 4. Currently date / timely indication 5. SLOW SPEED set indications 6. Vehicle travelling direction indication 7. Functional switches and warning light − MODE switch − ENTER switches − speed limit switch − travelling mode switch − parking warning light − warning light

Basic display 1. Displayed after initializing 2. Display the data receiving from other controller and switches through CAN-BUS 3. Clock is operated by internal system of display at a real time

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Group 06, Electrical System Explanation of display function Battery charging level 1. Function : Display the battery level at the present time.

2. One unit means 10% of battery charging status.

3. If a red unit is displayed, hydraulic function is disabled and truck should go the charging pot using remained power and be charged.

Error message 1. Function : Model name, Travel direction, Alert and error message displayed 2. Status − On normal status : Model name, Travel direction

Hourmeter and speed meter 1. Function : Display the working hour by now, and speed at real time 2. Operating sequence − If the speed is lower than 0.5km/h, it display the hourmeter

− If the speed is above 0.5km/h, it display the speed.

− Speed unit could be displayed to Km/h and MPH by mode selecting .

− When error is occured: Error number and message displayed as below.

− Message display : It could be checked as operating function switch on right side of display. − Function switch could be operated similar with Handset and used for serviceable function. For more detailed description, please refer to the page 06-5-7.

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Group 06, Electrical System Clock (Date/Time)

Functional switch and alert icon

1. Function : Dsiplay date and time at real time.

Function − It is used for display system datas. − Able to change variable value.

Explanation of function

2. Data for date and hour could be stored in display memory for 1 month without external power by internal battery (Whenever keyed on, internal battery is charged promptly)

− Mode buttons are composed with 6 at the righ side of display. − Each button is used as switch and setting set. − Refer to page 06-5-7 “Function setting and operation” for the detail

3. TIME setting : Refer to the page 06-5-13. time setting.

Button

Function 1. When press this button at normal condition, it will go the Menu mode.

2. At the Menu mode, this switch is used for going to lower menu.

3. It also used for store key, when changing password and major factor.

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Group 06, Electrical System

1. At the Menu mode, this switch is used for going to higher menu.

1. At the Menu mode, this switch is used for going to left menu.

2. At the normal operation mode, it is used for seletion of slow speed (turtle mode)

− When press this button, it go to the turtle mode. And to release this turtle mode, press one more time

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Group 06, Electrical System

1. At the Menu mode, this switch is used for going to right menu.

2. At the normal operation mode, it is used for seletion of power mode − P OWER Mode is devided with 3 step. − Whenever press ‘P’ button, it will be changed to Economy → Normal → Power Mode 1) Economy : Slow speed up mode, it will minimize the acceleration of the truck and could be save the battery power.

2) Normal : Normal operation mode, operator could control the truck smoothly.

3) Power : operator could control the truck with powerful acceleration 1. At the normal mode, it is used for increasing the data.

1. At the normal mode, it is used for decreasing the data.

Icons

1. Parking brake : Display parking brake set status.

2. Seat belt icon : Alarm seat belt set when KEY ON. 3. Maintenance icon : When there is fault on the truck, this icon is turn on and error code and description will be displayed on monitor.

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Group 06, Electrical System Function setting and Operation Method of Mode Switch Mode Switch

Mode Switch Explaining Switch

Function Pressing this button in normal operating condition, it will move to Menu mode.

Pressing it in Menu mode, it will move to lower menu.

1. Pressing this button, it will move to upper menu.

2. It will also take role of "Enter" button when confirming the changed password or main parameters.

Pressing this button, it will move to left menu.

Pressing this button, it will move to right menu.

Increase the data as set value in the current Menu mode.

Decrease the data as set value in the current Menu mode.

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06-5-7

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 06, Electrical System Menu mode Chart Menu No. 1

Parameter STATUS-TRACTION

Overview

Minimum

MaximAdjReference um usted

The digital and the analog input/output conditions of the driving controller are displayed.

1.1

BATTERY VOLTAGE

The present battery voltage is displayed.

0.00V

115.00V ACTUAL

1.2

HOUR METER

The driving hour of the vehicle so far is displayed.

0Hr

59999Hr ACTUAL

1.3

ACCELERATOR

The accelerator voltage is displayed.

0.00V

5.00V

ACTUAL

1.4

LIFT & LOWER

The sensor operating voltage of the LIFT/LOWER lever is dis0.00V played.

5.00V

ACTUAL

1.5

STEER ANGLE

The steering angle is displayed.

128

ACTUAL

1.6

DEADMAN SWITCH

The open/closed conditions of the DEADMAN switch are disOPEN played.

CLOSE

ACTUAL

1.7

MAST SWITCH-1ST

The open/closed conditions of the 1st MAST switch are disOPEN played.

CLOSE

ACTUAL

1.8

MAST SWITCH-2ND

The open/closed conditions of the 2nd MAST switch are disOPEN played.

CLOSE

ACTUAL

1.9

MAST SWITCH-3RD

The open/closed conditions of the 3rd MAST switch are disOPEN played.

CLOSE

ACTUAL

1.10

MAST SWITCH-4TH

The open/closed conditions of the 4th MAST switch are disOPEN played.

CLOSE

ACTUAL

1.11

SIDE GATE SWITCH-LH

The open/closed conditions of the left side gate switch are disOPEN played.

CLOSE

ACTUAL

1.12

SIDE GATE SWITCH-RH

The open/closed conditions of the right side gate switch are OPEN displayed.

CLOSE

ACTUAL

1.13

ENCODER

The encoder frequency of the driving motor is displayed.

1.14

TEMPERATURE

The present temperature of the driving controller is displayed. -40°C

1.15

MOTOR TEMPERATURE The present temperature of the driving motor is displayed.

1.16

CURRENT RMS

The current consumption of the driving controller is displayed. 0A

2

STATUS-PUMP

The digital and the analog input/output conditions of the hydraulic controller are displayed.

2.1

ENCODER

The encoder frequency of the hydraulic motor is displayed.

2.2

TEMPERATURE

The present temperature of the hydraulic controller is dis-40°C played.

2.3

MOTOR TEMPERATURE The present temperature of the hydraulic motor is displayed.

2.4

CURRENT RMS

The current consumption of the hydraulic controller is dis0A played.

3

STATUS-EPS

The digital and the analog input/output conditions of the steering controller are displayed.

3.1

0° SWITCH

OPEN

CLOSE

3.2

90° SWITCH

OPEN

CLOSE

3.3

TEMPERATURE

3.4

MOTOR TEMPERATURE The present temperature of the EPS motor is displayed.

-40°C

250°C

3.5

CURRENT RMS

0A

2000A

The present temperature of the EPS controller is displayed.

The current consumption of the EPS controller is displayed.

SM 844

-128

-200Hz 200Hz -40°C

127°C

ACTUAL ACTUAL

300°C

ACTUAL

1000A

ACTUAL

-200Hz 200Hz

ACTUAL

-40°C

127°C

ACTUAL

300°C

ACTUAL

1000A

ACTUAL

-128°C 127°C

06-5-8

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 06, Electrical System

Menu No. 4

Parameter

Overview

Minimum

MaximAdjReference um usted

DISPLAY SETTING

The settings and the details of other items are displayed.

4.1

SLOW SPEED

The maximum speed of the vehicle is set. (in the turtle mode only)

3Km/h 14Km/h 1MPH 9MPH

10Km/h 6MPH

+/-

4.2

SPEED UNIT

The speed unit of the vehicle is set.( km/h or MPH)

Km/h

MPH

Km/h

+/-

4.3

SOFTWARE VERSION

The present software version of the TFT display is displayed.

V1.00

~

X

2000

2099

5

TIME SETUP

The year, the date, the day and the hour are set.

5.1

YEAR

The year is set.

5.2

MONTH

The month is set.

1

12

+/-

5.3

DATE

The date is set.

1

31

+/-

5.4

WEEK

The day is set.

MON

SUN

+/-

5.5

HOUR

The hour is set.

0

23

+/-

5.6

MINUTE

The minute is set.

0

59

+/-

5.7

AM/PM

AM/PM is set.

AM

PM

+/-

SM 844

+/-

06-5-9

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 06, Electrical System Menu Mode (Tree structure) − Data Refer to Setup Sheet

Menu mode operation menual Truck status checking Check the truck status at real time.

1. Battery voltage

2. Hourmeter

3. Accelerator voltage

4. Lift / Lower lever sensor

5. Steer angle

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06-5-10

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 06, Electrical System Switch status ON/OFF checking Check the switch ON/OFF status on the truck at real time

1. DEADMAN SWITCH OPEN / CLOSE

2. 1ST MAST SWITCH OPEN / CLOSE

3. 2ND MAST SWITCH OPEN / CLOSE

4. 3RD MAST SWITCH OPEN / CLOSE

5. TH MAST SWITCH OPEN / CLOSE

6. LEFT SIDE GATE SWITCH OPEN / CLOSE

7. RIGHT SIDE GATE SWITCH OPEN / CLOSE

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06-5-11

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 06, Electrical System Annex function set It is allowed to change the details of the vehicle, which are available of setting and changing, to comply with the requirements of the users.

Setting the speed unit The unit of the speed of the vehicle displayed on the speed sensor is set.

It is allowed to set the unit in km/h or MPH.

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06-5-12

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 06, Electrical System Year, date, day and hour This function sets the date and the hour displayed in the vehicle.

It is allowed to change the year, the month, the date, the day and the hour.

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06-5-13

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 06, Electrical System Failure diagnosis Automatic diagnosis function The automatic diagnosis function detects, displays and alarm failure of the vehicle.

CAN communication diagnosis Malfunction of the driving controller, or problem on the CAN bus line is displayed.

Inspect the CAN bus, and check if the power line fuse has blown.

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06-5-14

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 06, Electrical System

Section 6 Fuse Box

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06-6-1

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 06, Electrical System Function Damage to the electric component by excessive current is prevented.

FUSE SPEC (36V) NO

CAPACITY

LOAD NAME

F1

10A

DC-DC CONVERTER

F2

15A

READING LAMP

F3

10A

WORK LAMP

F4

5A

FAN

F5

5A

DC-DC(DISPLAY)

F6

5A

DISPLAY

-

5A

SPARE

-

10A

SPARE

FUSE SPEC (24V) NO F1

CAPACITY 10A

LOAD NAME READING LAMP

F2

15A

WORK LAMP

F3

10A

FAN

F4

5A

DISPLAY

-

5A

SPARE

-

10A

SPARE

ATO (Autofuse) Blade Fuse - 297 Series

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06-6-2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 06, Electrical System LINE FUSE SPEC (24V/36V) NO

CAPACITY

LOAD NAME

F1

20A

KEY SWITCH

F2

10A

EPS CONTROLLER

F3

10A

TRACTION CONTRLLER

F3

F2

F1

ATO (Autofuse) Blade Fuse - 257 Series

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06-6-3

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 06, Electrical System

Section 7 Electrical Components

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06-7-1

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Group 06, Electrical System Strobe light Function The strobe light is used for alarming operation of equipment around the equipment.

Battery

No

Description

1

LENS

2

BULB

3

BASE

Specification Item Rated Voltage

Spec.

DC 12V~24V ± 10%

Consumption Max 200mA Electric Current Frequency

60times/min ± 3

Testing Supply the power as shown on the figure, and check if the strobe light normally operates. (When supplying the power, the positive pole and the negative pole of the battery shall correctly be connected. Connecting the poles in the wrong way, the component is damaged.)

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Group 06, Electrical System Work lamp

Lamp-Interior

Function

Function

The work lamp provides view in the front and the rear when working at night or indoor.

The interior lamp lights up the driver compartment for convenient operation when working at night or indoor.

[ 12V ]

[ 24V ]

Specification

Specification

Item

Spec.

Item

Spec.

Rated Voltage

DC 12V

DC 24V

Rated Voltage

DC 12.8V

DC 28V

Bulb Spec.

GE862, 37.5W

H3, 70W

Bulb Spec.

1156, 27W

1683, 28W

Testing

Testing

Supply 12/24V power to check if the work lamp operates normally.

Check the interior lamp for proper operation 12/24V as shown above.

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Group 06, Electrical System Fan Function The fan circulates the air into the driver compartment during indoor work for convenient operation.

Specification Item Rated Voltage

Spec.

DC 12V

DC 24V

Consumption 8.5W Electric Current

9.5W

Rotation Speed

3400 rpm

3400 rpm

Testing Check the fan for proper operation 12/24V as shown above.

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06-7-4

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Group 06, Electrical System Start Switch Function This functions to start the forklift and supplies electrical power to some electrical parts.

No

Description

1

Master Key

Specification Item

Spec.

Rated voltage

DC 48V

ON current

30A

Lamp and Fan Switch Function The lamp and fan switch turns on and off the lamp and the fan.

Specification Item

Spec.

Rated voltage

DC 12V

DC 48V

Contact current

20A

15A

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Group 06, Electrical System Relay Function The relay supplies the power to the lamp and the fan.

Resist.

Circuit

Specification Item

Spec.

Rated voltage

DC 12V

DC 24V

Contact current

NO : 20A NC : 15A

NO : 20A NC : 15A

Testing Position multi-meter to resistance mode and measure resistance between both terminals as above.

Normal : 85±5Ω(12V) / 340±5Ω(24V)

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Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 06, Electrical System SSR Relay Function The relay supplies the power to the cooling fan of the controller.

Specification Item

Spec.

Rated voltage

DC 7 ~ 60V

Load current

0.02 ~ 7A

Operating voltage

NO : Max 7Vdc, OFF : Min 1Vdc

Maintenance switch Function The switch controls the hydraulic operation when maintaining the vehicle outside.

Specification Item

Spec.

Rated voltage

DC 28V

Load current

3A

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06-7-7

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 06, Electrical System DC-DC Converter (DISPLAY) Function The converter supplies the power to the display.

Block Diagram

Specification Item

Spec.

Rated voltage

DC 25V ~ 26V

Load current

1A, 12Vdc

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06-7-8

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 06, Electrical System DC-DC Converter

Backup Alarm

Function

Function

The converter supplies the power to some of the electric systems.

The alarm provides audible warning when driving backward.

Specification

Specification

Item

Spec.

Item

Spec.

Rated voltage

DC 36/ 48V

Rated voltage

DC 12/ 48V

Load current

300W, 12Vdc

Load current

600mA ± 10%

Sound pressure

77 ~ 97dB

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06-7-9

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 06, Electrical System Horn Function The horn is one of the alarming devices, and makes the sound with the sound pressure of defined setup when the horn switch is turned on.

[ Connection ]

Specification Item

Spec.

Rated voltage

DC 12/48V

Load current

0.25A at 28Vdc

Sound pressure

105 dB

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06-7-10

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 06, Electrical System Lamp Switch - The switch is water tight, and vibration resistant. IP68 (Grade) - The switch is mounted on the dashboard for easy access by the driver.

- Switch Spec.

Carling Technologies company, V-series 4VA@24VDC (Max.) Mechanical endurance : 150,000 cycles minimum V-Series Contura Sealed Rocker Switches

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06-7-11

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

GROUP 07

GROUP 07 MOTOR CONTROLS

Controller Mounting ................................. Section 1

Description ..................................................Section 2

Factory Control Settings............................Section 3

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07-0

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Group 07, Motor Controls

Section 1 Controller Mounting

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07-1-1

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Group 07, Motor Controls

OzpT[`Y]ZP

Controller Mounting

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07-1-2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 07, Motor Controls

Section 2 Description The CLARK OSX15 uses a Dual AC controller to control both drive motors and a single AC controller to control the single motor/pump combination which supplies flow to all hydraulic functions and steering.

Traction Control and Motors The dual AC traction control consists of two motor controls mounted to a single heat-sink plate and enclosed by a single cover. The right portion of the control is reference to as the "slave" control and operates the left drive motor.

The left portion of the control is referred to as the "master" control and operates the right drive motor. The control receives inputs from the speed control (accelerator) pedal, steer tire position sensor (steer pot), direction switches, foot brake switch, motor encoders, motor thermistors and other miscellaneous switches. The control is able to proportional reduce the speed of the pivot tire when the truck is in a turn, based on the steer angle input from the steer sensor. Once the steer angle exceeds a certain value, the pivot wheel will start to reverse. The speed of the vehicle is controlled by the accelerator control pedal. For a given pedal position the control will maintain a set speed, as determined by control parameter settings.

These settings are adjustable to meet your customer's needs. One feature of AC controller is "release braking".

This feature will apply a regenerative braking force every time the driver lifts up off the accelerator pedal. The final travel speed will be determined by the new pedal position.

The control receives motor speed feedback from the motor encoders which allow for precise speed regulation.

Every motor also has a built-in thermistor which constantly monitors the winding temperature and reports this information to the control. Should it sense that the motor is approaching the temperature limit, the control will cutback motor current until the temperature decreases. Since it is cutting back current and not voltage, the top end speed will not be effected, unless on a grade. Each control also has built-in thermal protection that will reduce output current should the control approach the thermal limit.

the desired flow rate. Tilt and aux switches mounted on the hydraulic valve provide unique inputs to the control. The speed of each function can be programmed independently so that only the required flow rate is produced, minimizing power losses. If the control receives an input from the lift potentiometer, tilt or aux switches, then it will ramp up the motor speed to match the desired speed. Once the request is removed the motor speed will return to the fixed level.

As with the traction control and motors, the lift control and motor have thermistors for thermal protection and the motor has a built-in encoder for speed feedback.

EPS Control and Motor The EPS-ac0 perform auto-centering function on the truck.

Feedback sensors are mandantory to close the loop when an automatic function is required. The EPS-ac0 runs an inexpensive, rust and maintenance free three phases AC induction motor. The EPS control and motor have thermistat for thermal protection and the motor has built-in encoder for speed feedback.

Lift Control and Motor A single motor is used for hydraulic function. The motor is controlled by a dedicated controller. The lift lever is equipped with a linear potentiometer that measures the distance the lever is stroked and provides this input to the control. The control uses this information to increase motor speed in proportion to the distance stroked, providing only

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07-2-1

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 07, Motor Controls

Section 3 Factory Control Settings

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07-3-1

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 07, Motor Controls 1. Traction Control

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07-3-2

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Group 07, Motor Controls

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07-3-3

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Group 07, Motor Controls 2. Pump Control

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07-3-4

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Group 07, Motor Controls 3. EPS Control

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07-3-5

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Group 07, Motor Controls

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07-3-6

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GROUP 08

GROUP 08 MOTOR - DRIVE AND PUMP

Drive Motor Intallation ................................. Section 1

Drive Motor Maintenance Instruction ..........Section 2

Pump Motor Mounting...................................Section 3

Pump Motor Maintenance Instruction .........Section 4

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08-0

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 08, Motor - Drive and Pump

Section 1 Drive Motor Intallation

OzpT[`Y][P

SM 844

08-1-1

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 08, Motor - Drive and Pump

Section 2 Drive Motor Maintenance Instruction

Before starting the maintenance please disconnect the power supply.

Screws should be tightened according to the screw quality (please see your torque chart with torque wrench).

1. BALL BEARING Both ball bearings are maintenance free. Should it be necessary to remove the bearings in case of repair, they should be replaced. In any case the sealing parts (shaft sealing ring etc.) have to be replaced!

If a bearing which is to be replaced has only one sealing lip, this should be greased with quality bearing grease (Staburags NBU 8EP).

After approximately 10,000 operating hours the bearings have to be replaced.

2. ASSEMBLY / DISASSEMBLY The motor is assembled and disassembled according to the relevant sectional drawing and spare part list.

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08-2-1

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 08, Motor - Drive and Pump Sectional Drawing and Spare Part List

Pos. 51 220 221 222 223 227 241 250 271 272 300 400 500 515 520 530 700 705 710 720 730 950 951 952 955 956 957 9999

Mat.-No. 50075394 50058734 50043895 50014730 50014673 50015164 50066336 50066936 50073529 50075704 50075381 50075389 50036341 50062217 50052216 50014631 50075399 50014497 50014829 50013713 11006750 50051536 50051386 50054153 50051385 50051386 50054153 50077269

Description STATOR AC 200 TERMINAL M10 3-POLIG HEXAGON SCREW HEXAGON NUT DIN934 M10-A1P DISK DIN125-10,5-A1P SCHNORR-DISK 10-A1P CYLINDER SCREW TERMINAL BASE SENSOR COMPLETE CYLINDER SCREW DIN912 M6x16-8.8-A1P-OT30 DRIVE END RING 200 COMMUTATOR END PLATE 200-AS BALL BEARING 6205 2ZC3 HL CYLINDER SCREW DIN912 M8x150-8.8-A1P TEMP.SENSOR KTY 84-130 PPS 0,5m CIRCLIP DIN472-52X2,0 ROTOR 200-AS FITTING KEY CIRCLIP DIN471-25X1,2 SPACER SENSOR-TARGET 200-64 Ø128,0/Ø36,5 CONNECTOR AMP 282104-1 2-POLE FLAT-TABS AMP 282404-1 PLUG SEAL AMP 281934-4 CONNECTOR AMP 282106-1 4-POLE FLAT-TABS AMP 282404-1 PLUG SEAL AMP 281934-4 S.D.- AC-MOTOR

SM 844

QTY 1 1 3 6 3 3 2 1 1 1 1 1 1 4 1 1 1 1 2 1 1 1 2 2 1 4 4 1

08-2-2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 08, Motor - Drive and Pump

Section 3 Pump Motor Mounting

OzpT[`Y_[P

SM 844

08-3-1

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 08, Motor - Drive and Pump

Section 4 Pump Motor Maintenance Instruction

Before starting the maintenance please disconnect the power supply.

Screws should be tightened according to the screw quality (please see your torque chart with torque wrench).

1. BALL BEARING Both ball bearings are maintenance free. Should it be necessary to remove the bearings in case of repair, they should be replaced. In any case the sealing parts (shaft sealing ring etc.) have to be replaced!

If a bearing which is to be replaced has only one sealing lip, this should be greased with quality bearing grease (Staburags NBU 8EP).

After approximately 10,000 operating hours the bearings have to be replaced.

2. ASSEMBLY / DISASSEMBLY The motor is assembled and disassembled according to the relevant sectional drawing and spare part list.

SM 844

08-4-1

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 08, Motor - Drive and Pump Sectional Drawing and Spare Part List

Pos. 51 220 221 222 223 227 241 250 271 272 300 320 330 400 500 505 515 520 520 700 730 950 951 952 955 956 957 9999

Mat.-No. 50075022 50058734 50043895 50014730 50014673 50015164 50066336 50064934 50073529 50075704 50075106 50036343 50013927 50075057 50036340 50074592 11016244 50052216 50057538 50074999 11005462 50051536 50051386 50054153 50051385 50051386 50054153 50077277

Description STATOR AC 170 TERMINAL M10 3-POLIG HEXAGON SCREW HEXAGON NUT DIN934 M10-A1P DISK DIN125-10,5-A1P SCHNORR-DISK 10-A1P CYLINDER SCREW TERMINAL BASE SENSOR COMPLETE CYLINDER SCREW DIN912 M6x16-8.8-A1P-OT30 DRIVE END COVER BALL BEARING 6206 2ZC3 HL SHAFT SEALING RING 28X52X7 BA NON DRIVE END PLATE BALL BEARING 6204 2ZC3 HL WAVY-WASHER 6204-EMOX-41 SCREW M8 x 270 ISO4762-8.8 Zn5B 6g TEMP.SENSOR KTY 84-130 PPS 0,5m TEMP.SENSOR KPL KTY 84-130 0,5m PPS AMP ROTOR 170-AS SENSOR-TARGET 170-64 Ø102,0/Ø36,5 CONNECTOR AMP 282104-1 2-POLE FLAT-TABS AMP 282404-1 PLUG SEAL AMP 281934-4 CONNECTOR AMP 282106-1 4-POLE FLAT-TABS AMP 282404-1 PLUG SEAL AMP 281934-4 SD- ASYNCHRONOUS MOTOR

SM 844

QTY 1.000 1.000 3.000 6.000 3.000 3.000 2.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 4.000 1.000 1.000 1.000 1.000 1.000 2.000 2.000 1.000 4.000 4.000 1.000

ST ST ST ST ST ST ST ST ST ST ST ST ST ST ST ST ST ST ST ST ST ST ST ST ST ST ST ST

08-4-2

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GROUP 09

GROUP 09 HYDRAULIC SYSTEM

Hydraulic Diagram ........................................ Section 1

Hydraulic System ............................................Section 2

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Group 09, Hydraulic System

Section 1 Hydraulic Diagram

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09-1-1

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Group 09, Hydraulic System Hydraulic Oil HYD. OIL 2776239 (6094 - 10010)

PART NO ESSO REFERANCE

OSX15

8027099 (6594 - 20030)

NUTO H32

GS

RANDO HD32

SK

ZIC SUPERVIS AW32

S-OIL

AZOLLA ZS 32R

RANDO HD CZ EQUIVIS ZS 46 III

MFH 4953~7468

19 L

MFH 7925~9296

25 L

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09-1-2

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Group 09, Hydraulic System

Section 2 Hydraulic System

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09-2-1

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Group 09, Hydraulic System Theory of Operation The hydraulic system consists of a compact hydraulic unit, including mechanical valves, electric proportional (solenoid) valve, manual release valve and cylinders for the lift of the forks. The lift/lower potentiometer commands the operator platform to lift or lower. Hydraulic fluid is placed in the reservoir tank to be circulated throughout the hydraulic hoses.

Lift When the lift potentiometer is rotated forward, the lift/ lower proportional (solenoid) valve (normally open) stays open while the lift contactor closes. After the contactor

closes and the lift pump motor turns on, the proportional (solenoid) valve ramps closed which forces hydraulic fluid into the cylinders and increases lift speed. The proportional (solenoid) valve provides a smooth transition between zero speed lift and full speed lift and back to zero speed lift.

When the lift potentiometer is released, the proportional solenoid ramps open and the lift contactor opens turning off the lift pump motor. During lift, the load-holding proportional (solenoid) valve remains closed (de-energized).

The truck has a two-speed lift system. Rotate the lift/lower potentiometer slightly forward to lift at the lower speed.

Rotate the lift potentiometer completely forward to lift at the faster speed.

Lift Hydraulic Circuit

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09-2-2

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Group 09, Hydraulic System Lower When the lower potentiometer is rotated in reverse, the lift/ lower proportional (solenoid) valve closes and the load holding proportional (solenoid) valve opens. The proportional valve ramps open and allows hydraulic fluid to return from the lift cylinders to the reservoir. The truck has

a two-speed lowering system. Rotate the lower potentiometer slightly backwards to lower at the slower speed.

Rotate the lower potentiometer completely backward to lower in the faster speed. When lowering is no longer requested, the proportional (solenoid) valve ramps closed and the load holding valve closes.

Lower Hydraulic Circuit

OpuTY_[`XP

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09-2-3

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Group 09, Hydraulic System 8. Remove female half of diagnostic fitting and hose.

Maintenance When checking voltage at the solenoids, make sure hydraulic lines and components are fully installed. Whenever possible, keep the key switch (S1) OFF and the battery connector disconnected. Replace worn hoses. Drain and add hydraulic fluid as necessary.

9.

If it is necessary to flush reservoir, remove reservoir.

10. Dispose of old hydraulic fluid according to local regulations for hazardous materials.

Check for proper fluid level and make sure proper oil/ lubricant has been selected for the hydraulic reservoir.

Before adding or changing hydraulic fluid, determine the environment and usage of truck.

Changing Hydraulic System Fluid NOTE!

Be sure truck is in a clean area, away from possible contaminating elements that could enter the hydraulic system during the changing process.

1. Lower the platform fully.

2. Drain hydraulic reservoir completely. Drain as much fluid as possible from hydraulic lines and cylinders.

3. Fill hydraulic reservoir with proper fluid.

4. With lift system running, operate lift/lower and functions for approximately two minutes to purge the system.

5. Check for possible hydraulic leaks.

Refilling System

6. Bleed entire hydraulic system before placing truck into service.

7. Check reservoir fluid level.

The remainder of the original hydraulic fluid left in the system, (approximately 5%), should not be harmful to the operation of the truck.

1. If reservoir was removed for flushing, install reservoir.

2. Install hydraulic filter.

3. Fill hydraulic reservoir tank with fluid.

- MFH 4953 ~ 7468 : 19 L - MFH 7925 ~ 9296 : 25 L 4. Reconnect battery connector to the truck. Energize EPO switch and turn key switch ON.

System Draining 1. Lower the platform fully.

5. Bleed hydraulic system.

2. Turn the key switch OFF and energize EPO switch.

Disconnect battery connector from the truck.

6. Install chassis covers.

3. Remove chassis covers.

Load bounces excessively when lowering

4. Use female half of the diagnostic fitting (24 inch [610 mm] hose) and direct the hydraulic fluid into a waste container with a capacity greater than 6.6 gallons (25 liters).

•

Air in hydraulic system, TSU cylinders; set capacity load on upright and lift form fully collapsed to full lift height for 10-15 cycles.

5. Reconnect battery connector to the truck. Energize EPO switch and turn key switch ON.

•

Defective upright load-lowering flow valve; check, clean and replace valve if necessary.

6. Operate lift until air in the system is heard.

•

Defective velocity fuse; remove fuse from cylinder hydraulic port, clean and recheck for proper operation.

7. Turn the key switch OFF and energize EPO switch.

Disconnect battery connector from the truck.

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Group 09, Hydraulic System Troubleshooting

Repair and Rebuild

When checking voltage at solenoids, make sure hydraulic lines and components are fully installed. Inspect hydraulic system for leakage, worn hoses, and fluid level in the hydraulic reservoir tank. Inspect the hydraulics hose and tubing for leaks, nicks, cuts, chafing and bulges. Inspect all fittings for leaks.

The lift manifold, hydraulic reservoir, manual release valve, and lift pump can not be repaired or rebuilt. Replace items as necessary.

The reservoir tank can not be repaired or rebuilt. Replace reservoir tank as necessary.

Hydraulic Component Mounting

OzpT[`Y[[P

!

WARNING

DO NOT use your hands to check for hydraulic leakage. Use a piece of cardboard or paper to search for leaks. Escaping fluid under pressure can penetrate the skin causing injury. Relieve pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure.

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09-2-5

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Group 09, Hydraulic System Lift Valve Assembly

Lift Valve

4. Remove mast supply hose from lift valve.

Removal

5. Remove control wires from lift manifold solenoid coils.

1. Lower the platform fully.

6. Drain reservoir.

2. Turn key switch OFF and depress EPO switch. Disconnect battery connector from truck.

7. Remove hose and pipe fitting from lift manifold.

3. Remove chassis covers.

!

8. Remove lift valve assembly from mounting bracket assembly.

WARNING

Verify pressure is released from system; press and hold manual release valve (see page 09-28).

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Group 09, Hydraulic System Valve Replacement

Installation

1. Remove applicable valve(s).

1. Apply Loctite 587® to the top of reservoir tank.

2. Clean, inspect and if necessary replace valve(s).

2. Install control wires onto lift valve solenoid coils.

!

3. Install mast supply hose to lift valve.

CAUTION

DO NOT over tighten proportional valve. If overtighten, it could result in the valve not functioning properly.

NOTE!

To assure proper installation, take notice of the flow arrows pointing outward on the control valve.

4. Fill reservoir tank with fluid if necessary.

5. Install chassis covers.

6. Reconnect battery connector to truck. Energize EPO switch and turn key switch ON. Test truck for proper operation before returning to service.

Hydraulic Main Lines

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09-2-7

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Group 09, Hydraulic System Hydraulic Reservoir

Manual Release Valve

Removal 1. Turn key switch OFF and depress EPO switch. Disconnect battery connector from truck.

2. Remove chassis covers.

3. Remove mast supply hose from lift manifold.

4. Remove pump motor power cables.

5. Remove control wires from lift manifold solenoid coils.

6. Remove pump / motor, and lift manifold as an assembly from chassis.

7. Remove oil filter from lift manifold.

8. Remove reservoir tank mounting bolts from chassis mounting bracket.

9. Remove reservoir 10. Drain reservoir.

Installation 1. Install reservoir tank to the chassis mounting bracket.

2. Install pump / motor, and lift manifold as an assembly onto the chassis.

3. Install oil filter onto lift manifold.

4. Install control wires onto lift manifold solenoid coils.

5. Install pump motor power cables.

6. Install the mast supply hose to lift manifold.

This truck is equipped with a hydraulic manual release valve located on the hydraulic control valve. When electrical functions do not operate, the platform can be lowered manually. Proceed as follows: NOTE!

7. Fill reservoir tank with fluid.

8. Install chassis covers.

9. Reconnect battery connector to truck. Energize EPO switch and turn key switch ON. Test truck for proper operation before returning to service.

The operator should stay on the operator platform. Another qualified person in the area should manually release the valve.

1. Remove the rear cover.

2. Twist the release valve 180° counterclockwise. The valve will then pop out and the operator platform will safely lower to the floor.

NOTE!

After lowering the operator platform, push in the valve and twist 180° clockwise to retighten the valve.

Replacement 1. Lower the platform fully.

2. Turn key switch OFF and depress EPO switch. Disconnect battery connector from truck.

3. Disconnect wires from proportional (solenoid) valve.

4. Remove coil and valve (SP2).

5. Place new valve in lift manifold and secure.

6. Place coil on valve barrel.

7. Reconnect wires to proportional (solenoid) valve.

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09-2-8

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Group 09, Hydraulic System Cleaning 1. Remove valve from lift manifold.

!

WARNING

When using compressed air, wear effective chip-guarding and personal protective equipment. Compressed air used for cleaning MUST be reduced to less than 30 psi (207 kPa).

2. Clean valve with compressed air. If necessary, use a blunt instrument (such as a wooden dowel) and push bottom of internal spool to blow air into valve barrel.

3. Install valve in lift manifold.

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09-2-9

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GROUP 10

GROUP 10 MAST CYLINDER

Three Stage Mast Staging Cylinder.............. Section 1

Three Stage Mast Primary Cylinder .............Section 2

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Group 10, Mast Cylinder

Section 1 Three Stage Mast Staging Cylinder

Bearing

Tube

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10-1-1

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Group 10, Mast Cylinder not blocked, unexpected movement could occur resulting in personal injury or death.

Theory of Operation Two port cylinders are mounted on the outer column. The range of mast height allows the platform to raise.

Mast Height 89.5 / 195 inch (2273 / 4953 mm)

4. Use pendant to raise mast until approximately 12 inches (305 mm) of the staging cylinder rods are extended out of the cylinder tubes.

5. Using a chain (minimum 4,000 pounds (192 kPa) rated capacity), route the chain over the top of the upper tie bar on the outer mast column. Continue routing the chain around the lower tie bar on the intermediate mast column. Secure the chain to prevent the intermediate column from lowering.

95 /210 inch (2413 / 5334 mm) 107 / 240 inch (2718 / 6096 mm) 119 / 276 inch (3023 / 7010 mm) 125 / 294 inch (3175 / 7468 mm) 131 / 312 inch (3327 / 7925 mm) 149 / 348 inch (3785 / 8839 mm)

6. Use pendant to lower mast assembly until the weight of the intermediate mast column, and the platform are supported by the chain.

155 / 366 inch (3937 / 9296 mm)

7. Remove bolts from the top of the staging cylinders.

143 / 330 inch (3632 / 8382 mm)

Maintenance Inspect cylinders for leakage. Inspect cylinder rod for gouges or pits. Lubricate bearings on cylinders.

Troubleshooting Check cylinders for leakage.

.NOTE! New cylinder assemblies may not lower under their own weight. It may be required that manual assistance is needed to fully lower the cylinder rods.

8. On the lift manifold, loosen the check valve at port 4 on the topside of the manifold. While holding the manual lowering release valve in the fully upward position, loosen the check valve three full turns. DO NOT remove check valve. The staging cylinder rods will begin to lower.

Repair and Rebuild If cylinders contains gouges or pits, it can be repaired. The bearing, seal, wear ring, O ring and rod wiper need to be replaced with new as necessary.

NOTE!

Call-outs in the following procedures refer to illustration on page 10-1-1.

Bearing and Seals Removal 1. Before removing bearing and replacing seals, fully extend the cylinder to inspect rod for gouges or pits.

If gouges or pits are detected, remove cylinder for repair. If no gouges or pits are evident, the bearing seals may be replaced.

2. Park the truck on a level surface and apply the brake.

3. To use maintenance switch, lifting and lowering of the mast assembly is working easily.

!

DANGER

Securely block mast columns to reduce risk of lowering when working on or near mast. If

9. When cylinders are fully lowered, release the manual lowering release valve and tighten the check valve.

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10-1-2

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Group 10, Mast Cylinder

!

tube, making sure not to drop dust and debris into the cylinder tubes.

WARNING

When using compressed air, wear effective chip-guarding and personal protective equipment. Compressed air used for cleaning MUST be reduced to less than 30 psi (207 kPa).

10. Using compressed air, thoroughly clean all dirt and debris from top and sides of the bearing where bearing meets cylinder tubes.

11. Using a chain wrench, loosen bearing until it can be threaded out of the cylinder tubes by hand.

12. Before removing bearing from the cylinder tube, use compressed air hose to thoroughly blow all dust and debris away from the bearing and the cylinder tube assembly.

13. Remove bearing by sliding it up the cylinder rods.

14. For bearing seal kit removal and installation procedures (see page 10-1-3).

Installation 1. Inspect the chamfered area of the staging cylinder for burrs, scratches, or chrome flaking. Use an emery cloth to remove particles.

2. Cover the exposed cylinder tubes with a shop rag or cloth before sanding is applied Chamfered Area

4. Thoroughly lubricate the wiper, seal, and wear ring using hydraulic fluid.

5. Lubricate cylinder rods with hydraulic fluid and slide bearing down cylinder rod until the threads meet.

6. Thread bearing into cylinder tubes and tighten with wrench.

7. Thoroughly clean any excess oil from bearing and cylinder tubes exterior.

8. Use the pendant and slowly raise the staging cylinder rods until they meet the underside of the intermediate mast column. Install bolts into the top of the cylinder rods and torque to 30-33 ft-lbs (70-80 N.m).

9. Raise mast assembly until there is slack in the chain, which was used to support the mast columns and platform during bearing removal.

10. Remove chain and fully lower mast assembly.

11. Reconnect battery connector to truck. Energize EPO switch and turn key switch ON. Test truck for proper operation before returning to service.

Bearing Seal Kit Removal 1. Using a cotter pin/seal removal tool, carefully remove the wiper, seal, and wear ring from the inside of the bearing. Remove backup ring and O ring from the outside of the bearing. Take special care when extracting the parts from the bearing, to not scratch, nick or gouge the grooves in bearing.

Cotter Pin/Seal Re Remova val Too ool

!

WARNING

When using compressed air, wear effective chip-guarding and personal protective equipment. Compressed air used for cleaning MUST be reduced to less than 30 psi (207 kPa).

3. Thoroughly clean the cylinder rods of dust and debris.

Carefully remove the shop rag or cloth from cylinder

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Group 10, Mast Cylinder 5. Wrap threaded end of bearing using masking or electrical tape to reduce the risk of cutting the O ring when installing.

Bearing Seal Kit Installation

6. Thoroughly lubricate the O ring with the same type of oil as in the truck hydraulic reservoir.

7. Slide O ring over the threaded part of bearing until it makes contact with the base of the bearing. Remove tape from threads.

Bearing

8. Thoroughly lubricate the inside of the bearing with the same type of oil as in the truck hydraulic reservoir.

9. Place bearing on a clean flat stable surface with the threaded end of the bearing facing upward.

10. Using your index finger and thumb compress the wear ring enough to slide inside the bearing. Continue sliding the wear ring into the bearing, using your index fingers, until the wear ring has seated into its groove.

1. Thoroughly clean all dust and debris from bearing.

Wear Ring

Wear Ring Inserted in Bearing

2. Thoroughly inspect grooves inside the bearing for visual scratches, nicks, or gouges. If upper and lower grooves have any visual deformations such as a scratch, nick, or gouge, lightly sand with a 400 grit sandpaper until smooth. If the center groove has any visual deformations such as a scratch, nick or a groove, bearing replacement is recommended.

11. Turn the bearing over. The threaded end of the bearing will now be resting on the clean flat stable surface.

Middle Groove Upper Groove

12. Thoroughly lubricate the seal with the same type of oil as in the truck hydraulic reservoir.

Lower Gr Groove

13. Using a seal installation tool, collapse the seal and install into the middle groove of the bearing with the O ring side of the seal entering the bearing first. Using your index finger work the seal into its seated position.

Be Bearing Base Ba

Backup Ring Back

Seal Installation Tool

Seal

ng O Ring

Seal

3. If any sanding has been performed on the upper and lower bearing grooves, thoroughly clean the bearing internally and externally of dust and debris.

14. Place bearing onto a small press with the threaded end of the bearing resting on the table of the press.

4. Thoroughly lubricate the inside of the bearing with the same type of oil as truck hydraulic reservoir.

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10-1-4

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Group 10, Mast Cylinder

Wiper

Press

Bearing

15. Thoroughly lubricate the wiper with the same type of oil as in the truck hydraulic reservoir.

16. Place wiper onto the top of the bearing with the grooved rubber side facing in the upward position and lightly press into position.

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10-1-5

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Group 10, Mast Cylinder

Section 2 Three Stage Mast Primary Cylinder

Bearing

Tube

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10-2-1

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 10, Mast Cylinder Theory of Operation The primary cylinder is the positive displacement type, meaning there are NO seals on the lower end of the cylinder rod. The primary cylinder can be resealed without being removed from truck. The range of mast height allows the platform to raise

tions before applying pressure. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure.

NOTE!

Call-outs in the following procedures refer to illustration on page 10-2-1.

Removal Mast Height

1. Before removing bearing and replacing seals, fully extend the cylinder to inspect rod for gouges or pits.

If gouges or pits are detected, remove cylinder for repair. If no gouges or pits are evident, the bearing seals may be replaced.

89.5 / 195 inch (2273 / 4953 mm) 95 /210 inch (2413 / 5334 mm) 107 / 240 inch (2718 / 6096 mm) 119 / 276 inch (3023 / 7010 mm)

2. Park truck on a level surface and apply brake.

125 / 294 inch (3175 / 7468 mm)

3. Place a chain and hoist strap around the mast assembly to support it. Using a 2-ton (1814 kg) hoist (minimum) lift the platform approximately 6 inches (152 mm).

131 / 312 inch (3327 / 7925 mm) 143 / 330 inch (3632 / 8382 mm) 149 / 348 inch (3785 / 8839 mm)

4. Lower cylinder so chains, hoses, and electric cables are loose.

155 / 366 inch (3937 / 9296 mm)

5. Attach a hoist to the rear of the center bar of the overhead guard on the platform.

Maintenance Inspect cylinder for leakage. Inspect cylinder rod for gouges or pits. Lubricate bearings on cylinder.

6. Locate a 4 x 4 (102 x 102 mm) block long enough in length to cover the outside dimension of the straddle arms.

Troubleshooting

!

Check cylinder for leakage.

Use a suitable sling (minimum rated capacity 3 ton [2721 kg]) and suitable hoist (minimum rated capacity 2 ton [1814 kg]) for lifting.

Repair and Rebuild If primary cylinder contains gouges or pits, it can be repaired. The bearing, seal, wear ring, backup ring, O ring and rod wiper can not be repaired and need to be replaced with new as necessary.

!

WARNING

!

CAUTION

Use caution not to pinch the mast cable behind the platform,

DANGER

HOT OIL under pressure may be present. Be certain truck is safely blocked and pressure is released. Some spillage of hydraulic oil may occur.

!

WARNING

DO NOT use your hands to check for hydraulic leakage. Use a piece of cardboard or paper to search for leaks. Escaping fluid under pressure can penetrate the skin causing injury.

Relieve pressure before disconnecting hydraulic or other lines. Tighten all connec-

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10-2-2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 10, Mast Cylinder

Bracket

Sheave 4 X 4 Block

Chain

Anchor Bolt

Primary cylinder Platform

11. Remove the primary chains from the chain sheaves.

7. Raise the platform high enough above the straddle arms so that a 4 x 4 (102 x 102 mm) block may be inserted between the bottom of the platform and the top of the straddle arms. Place the 4 x 4 (102 x 102 mm) block towards the rear of the platform.

8. Lower the platform onto the 4 x 4 (102 x 102 mm) block. Leave hoist attached to the overhead guard on the platform. There will be slack in the mast cable and freelift chains for ease of removal.

9. Turn key switch OFF and depress EPO switch. Disconnect battery connector from truck.

10. Remove the mast cable from the mast cable sheave.

12. Remove the flanged nut and chain sheave from the primary cylinder.

13. Remove flathead screw, bumper and washer from primary cylinder.

14. Loosen setscrew enough so that the shaft with the remaining chain sheave and mast cable sheave may be removed from primary cylinder.

!

WARNING

When using compressed air, wear effective chip-guarding and personal protective equipment. Compressed air used for cleaning MUST be reduced to less than 30 psi (207 kPa).

15. Use compressed air and thoroughly clean all dirt and debris from the top and the side of the bearing where the bearing meets the cylinder tube.

16. With a chain wrench, loosen the bearing until it can be threaded out of the cylinder tube by hand.

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10-2-3

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 10, Mast Cylinder 17. Before removing the bearing from the cylinder tube, use compressed air and thoroughly blow all dust and debris from the bearing and tube assembly.

8. Carefully tighten the setscrew into the index hole on the shaft. Install washer and bumper to the top of the cylinder rod with screw.

18. Remove bearing by sliding it up the cylinder rod.

9. Install remaining chain sheave onto shaft. Install flanged nut and tighten.

19. For bearing seal kit removal and installation see page 10-2-4.

10. Install freelift chains onto the chain sheaves.

11. Install mast cable onto the mast cable sheave.

Freelift Cylinder Bearing Installation 1. Inspect the chamfered area of the primary cylinder for burrs, scratches, or chrome flaking. Use 400 grit sandpaper to remove particles.

2. Cover the exposed cylinder tube with a shop rag or cloth before sanding is applied to the chamfered edge of the cylinder rod.

12. Reconnect battery connector to truck. Energize EPO switch and turn key switch ON.

!

WARNING

Use a suitable sling (minimum rated capacity 3 ton [2721 kg]) and suitable hoist (minimum rated capacity 2 ton [1814 kg]) for lifting.

13. Raise platform until the 4 inch x 4 inch (102 x 102 mm) block can be removed from under the platform.

14. Carefully lower the platform, watching the back side of the platform so as not to pinch mast cable assembly until the platform is fully lowered.

Chamfered Area

15. Remove hoist from overhead guard on platform.

16. Test truck for proper operation before returning to service.

Bearing Seal Kit Removal

!

WARNING

When using compressed air, wear effective chip-guarding and personal protective equipment. Compressed air used for cleaning MUST be reduced to less than 30 psi (207 kPa).

3. Using compressed air, thoroughly clean the cylinder rod of dust and debris. Carefully remove the shop rag or cloth from cylinder tube, making sure not to drop dust and debris into the cylinder tube.

4. Lubricate cylinder rod with hydraulic fluid and slide bearing down cylinder rod until the threads meet.

5. Thread bearing into cylinder tube and tighten with wrench.

6. Thoroughly clean any excess oil from bearing and cylinder tube exterior.

7. With the chain and mast cable sheave attached to the shaft assembly, slide the shaft from the right to the left into the cylinder rod. Make sure index hole is in the upward position.

1. Using a cotter pin/seal removal tool, carefully remove the wiper, seal, and wear ring from the inside of the bearing. Remove backup ring and O ring from the outside of the bearing. Take special care when extracting the parts from the bearing, to not scratch, nick or gouge the grooves in bearing.

Cotter Pin/Seal Re Remova val Too ool

Bearing Seal Kit Installation 1. Thoroughly clean all dust and debris from bearing.

2. Thoroughly inspect grooves inside the bearing for visual scratches, nicks, or gouges. If upper and lower grooves have any visual deformations such as a scratch, nick, or gouge, lightly sand with a 400 grit sandpaper until smooth. If the center groove has any visual deformations such as a scratch, nick or a groove, bearing replacement is recommended.

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10-2-4

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 10, Mast Cylinder

Middle Groove

Wear Ring

Wear Ring Inserted in Bearing

Upper Groove Lower Gr Groove Be Bearing Base Ba

12. Turn the bearing over. The threaded end of the bearing will now be resting on the clean flat stable surface.

Backup Ring Back

13. Thoroughly lubricate the seal with the same type of oil as in the truck hydraulic reservoir. ng O Ring

3. If any sanding has been performed on the upper and lower bearing grooves, thoroughly clean the bearing internally and externally of dust and debris.

4. When installing backup ring, make sure to install flat side of backup ring towards the base of bearing and cupped-side of backup ring facing the O ring.

14. Using a seal installation tool, collapse the seal and install into the middle groove of the bearing with the O ring side of the seal entering the bearing first. Work the seal into its seated position using your index finger.

Seal Installation Tool

Seal

5. Wrap threaded end of bearing using masking or electrical tape to reduce the risk of cutting the backup ring or O ring when installing.

6. Thoroughly lubricate the backup ring or O ring with the same type of oil as in the truck hydraulic reservoir.

7. Slide backup ring or O ring over the threaded part of bearing until it makes contact with the base of the bearing. Remove tape from threads.

Seal

15. Place bearing onto a small press with the threaded end of the bearing resting on the table of the press.

8. Thoroughly lubricate the inside of the bearing with the same type of oil as in the truck hydraulic reservoir.

9. Place bearing on a clean flat stable surface with the threaded end of the bearing facing upward.

Wiper

Press

Bearing

10. Thoroughly lubricate the wear ring with same type of oil as in the truck hydraulic reservoir.

11. Using your index finger and thumb, compress the wear ring enough to slide inside the bearing. Continue sliding the wear ring into the bearing, using your index fingers, until the wear ring has seated into its groove.

16. Thoroughly lubricate the wiper with the same type of oil as in the truck hydraulic reservoir.

17. Place wiper onto the top of the bearing with the grooved rubber side facing in the upward position and lightly press into position.

SM 844

10-2-5

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

GROUP 11

GROUP 11 ATTACHMENT AND PLATFORM

Mast ................................................................. Section 1

Fork Assembly.................................................Section 2

Platform Mounting..........................................Section 3

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11-0

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 11, Attachment and Platform

Section 1 Mast

SM 844

11-1-1

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 11, Attachment and Platform Theory of Operation The mast, and associated components, provide the lifting function in the truck. These components consist of the mast columns, lift cylinders, lift chains, chain rollers, and operator platform. The hydraulic system provides the necessary force and controls to do the work. When lifting, the lift cylinders extend as hydraulic pressure and volume is applied.

On a three-stage, the primary cylinder extends before the staging cylinders, due to the physics involved with the weight of the platform and the mast column. The primary cylinder extends pushing the mast chain rollers up. Lift chains, attached to the inner column and routed over the chain rollers, pull the operator platform up. When the primary cylinder has fully extended, the staging cylinders will begin to extend. The staging cylinders, working in parallel, push the intermediate column up. Staging lift chains, attached to the top of the outer column and routed over the chain rollers on the intermediate column, pull the inner column and operator platform up. Lifting stops when no more volume of hydraulic fluid is put into the lift cylinder, either by stopping the pump or by extending the lift cylinders to their maximum height.

Refer to the hydraulic section (see page 09-2-1) for further information.

Maintenance Visual Inspection Visually inspect the mast columns for abnormal wear (0.09375 inch [2.38 mm] mast column flange wear) in the bearing contact area. Inspect column assemblies and weldments for cracks.

When performing inspection, observe the following chain conditions: chain wear, rust and corrosion, cracked plates, protruding or turned pins, and chain side wear.

Wear

Chain Wear Gauge 12”

New Chain

As the chain flexes on and off the sheaves, the joints gradually wear. The “stretch” a chain develops in service is due to material being worn off the pin on the outside diameter and the pitch hole inside diameter on the inside plates.

Chain wear can be measured by using a chain wear gauge or a steel tape measure. Discard chains when elognated 3%. (For example, one foot of chain may contain 16 pitches [links]. When 16 pitches measures 12 inches, replace chains.) When checking chain wear, measure a segment of chain that operates over a sheave.

NOTE!

Chain Inspection Unsatisfactory chain performance can be traced directly to inadequate maintenance. Highly stressed precision chains require periodic maintenance to deliver maximum service life.

The chain system on the mast was designed for efficient, reliable transmission of lifting force from the hydraulic cylinder to the forks. Safe, uninterrupted use of the truck depends on proper care and maintenance of lift chains.

Lift chains are very important components of the truck.

After every 100 hours of truck operation, lift chains should be inspected and lubricated. When operating in a corrosive environment, inspect chains every 50 hours.

Stretched Chain

Do not repair chains by cutting out the worn section and splicing in a new piece.

Rust and Corrosion Lift chains are highly stressed precision components. It is very important that maintenance is performed throughout the chain service life. Corrosion will cause a major reduction in the load-carrying capacity of the lift chain because corrosion may cause sideplate cracking. It is extremely important to protect the lift chain from corrosion, whether in service or in storage.

NOTE!

SM 844

Do not steam clean or degrease new lift chains.

11-1-2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 11, Attachment and Platform

Stress-corrosion Cracking Lift chain lubricant serves both as a joint lubricant and corrosion inhibitor. During inspection, carefully examine the external lift chain surfaces for the presence of an oily film.

Under normal operating conditions, oil lift chains every 100 hours, and more frequently under adverse conditions.

NOTE!

Broken Plate Caused by Overload

All joints in the lift chain should flex freely. Tight joints resist flexing, increasing internal friction. This accelerates wear and fatigue problems. In lift chains, tight joints are usually caused by rust. Replace chains if rusty.

In all cases, the external surface of the lift chains must be protected with a film of oil.

Outside plates are susceptible to stress-corrosion cracking.

If lift chains are rusted or corroded, remove them from the mast to thoroughly inspect for cracked plates. Replace all lift chains on the truck if any plate is cracked. Lubricate the chains when reinstalled on the truck.

Cracked Plates Fatigue failure is the most common cause of plate cracking. After many repeated heavy loads (loads higher than the truck’s capacity), the plates may crack causing the chains to eventually break. Fatigue cracks are almost always found through the pitch holes perpendicular to the pitch line. If cracks are present, replace all lift chains on truck.

Tight joints reduce proper flexing of lift chain

Bent or peened plates on lift chains can cause tight joints and reduce flexing.

Ultimate Strength Failure This type of failure is caused by overload in excess of the truck design load.

Tight joints in lift chains may also be caused by the following: •

Bent pins or plates

•

Rusty joints

•

Peened plate edges

Peening of plate’s edges may be caused by worn or seized sheaves, or unusually heavy loads.

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11-1-3

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 11, Attachment and Platform Protruding or Turned Pins

Lubrication

Heavily loaded chains operating with too little lubrication causes wear between the pin and plates. In some extreme cases, the torque in the joint can turn pins in the press-fit outside plate.

Lubrication of the lift chain in field maintenance is a very important duty. Lift chains must be lubricated for acceptable service life. Specialty “chain lubes” are recommended. Heavy motor oil (40 weight) may also be used.

Lubricate the entire length of all lift chains every 100 hours/50 hours in corrosive environment.

If the chain is allowed to operate in this condition, the pins slowly work out of the chain, causing chain failure. Turned pins can be quickly spotted because the flats on the “V” head are no longer in line.

NOTE!

Chains with turned pins or with protruding pins, should be replaced. Do not attempt to repair the chain by driving the pins back into the chain.

The oil must penetrate the chain joint. Applying oil to the external surface will reduce rust, but oil must flow into the live bearing surface for maximum wear life.

Lubricate

Protruding Pins

Lubricate

Turned Pins Out-of-line flats on “V” heads indicate that pins have turned in place.

Chain Side Wear A wear pattern on pin heads and outside plates indicates misalignment. This condition damages chain and sheaves as well as increasing internal wear in the chain system.

Chain Anchors and Sheaves

Apply oil to chains with an applicator. If using motor oil, a small brush or squirt applicator should be used. Flood the chain with oil over its entire length.

An inspection of the chain system includes a close look at the chain anchors and sheaves. Check chain anchors for wear, breakage, and misalignment. Anchors with worn, cracked, or broken fingers should be replaced. Anchors should be adjusted to eliminate twisting or misalignment in the chain. When the chain is misaligned, the load is not spread uniformly between the plates. Prolonged operation will result in premature failure. Worn or seized sheaves should be replaced. Heavy flange wear indicates chain misalignment.

SM 844

11-1-4

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 11, Attachment and Platform Adjustment

Troubleshooting

Three-stage Mast

Troubleshooting of mast and platform lift problems must be divided into hydraulic and mechanical functions. Generally, hydraulic problems will be evident of slow or no lift depending upon load weight. For problems that appear to be related to hydraulics, see page 09-2-5. Mechanical troubleshooting consists primarily of inspection. Except in the case of disastrous mechanical failure, mechanical troubleshooting consists of physical inspection for the cause of unusual noises (pops and grindings) and excessive lateral motion (shimming). To help determine mechanical failures see page 11-1-2.

The three-stage mast has two pairs of lift chains that may be adjusted. Each pair should be adjusted so that they have equal tension and the proper length as described as follows: The staging chains must be adjusted first; correct length is defined by the tops of the mast columns being equal and level when fully lowered. The freelift chains should be adjusted so that they have equal tension and the top of the fork tips are 2.75 ± 0.025 inch (70mm ± 0.635mm) above the floor when fully lowered. The operator platform must not “bottom-out” when fully lowered.

Repair and Rebuild Replace bearings and chains as necessary. The mast columns can not be rebuilt. DO NOT WELD ON MAST. DO NOT REPAIR BROKEN MAST COLUMNS. Replace mast as necessary.

Adjusting Nut

Locking Nut

1. Fully lower platform.

2. Turn key switch OFF and depress EPO switch. Disconnect battery connector from truck.

3. Loosen locking nuts on staging chain anchors.

4. Turn adjusting nuts until mast columns are level and equal across the top (± 0.50 inch [13 mm]).

5. Tighten adjusting nuts until both staging chains have equal tension.

6. Retighten locking nuts to hold adjusting nuts in position.

7. Align chains square to sheaves.

8. Loosen locking nuts on freelift chains.

9. Turn adjusting nuts until fork tips are at the proper height and level.

10. Tighten adjusting nuts until both chains have equal tension.

11. Retighten locking nuts to hold adjusting nuts in position.

12. Align chains square to sheaves.

SM 844

11-1-5

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

OzpT[`Y\`PGTGXVY

Assembly of slider and adjustment of shim: Assemble the slider as the backside of rail and the friction surface of slider are in parallel.

Match the outer rail end and inner rail end, and then make the gap between the flange face of inner rail and the slider will be within 0.5mm.

Assembly of slider and adjustment of shim: Assemble the slider as the backside of rail and the friction surface of slider are in parallel.

Match the outer rail end and inner rail end, and then make the gap between the flange face of inner rail and the slider will be within 0.5mm.

Group 11, Attachment and Platform

Mast Assembly

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11-1-6

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 11, Attachment and Platform

OzpT[`Y\`PGTGYVY

SM 844

11-1-7

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 11, Attachment and Platform Mast Mounting

OzpT\WW[[P

Mast Removal

!

Mast

DANGER

Securely block mast columns to reduce risk of lowering when working on or near mast. If not blocked, unexpected movement could occur resulting in personal injury or death.

NOTE!

Many mast repairs require removal of the operator platform. If removal is necessary, the operator platform should be removed before the mast is removed from the truck.

Platform

SM 844

11-1-8

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 11, Attachment and Platform 1. Fully lower mast.

2. Turn key switch OFF and depress EPO switch. Disconnect battery connector from truck. Remove battery from truck.

3. Remove chassis cover.

NOTE!

Before removal of any hydraulic hose, thoroughly clean off all external dirt and debris around the hose fitting. Have on

hand appropriate caps and plugs to cover fittings and hose ends.

4. Disconnect hose from the elbow on the battery compartment. Cap hose end. Tie hose back to reduce interference when mast is lifted.

5. Remove nut from the elbow fitting. Push the elbow fitting through the battery box wall and cap elbow fitting.

OzpT[`Y[\P

6. Loosen mast cable clamp adjacent to the battery box by sliding cable braid down cable, releasing the spring tension

SM 844

11-1-9

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 11, Attachment and Platform .

!

Sheave-Chain Sheave Anchor Bolt Cable Inner Rail Hose

CAUTION

Use a double-leg sling for lifting mast. One sling leg should go to each side of the mast rail. The sling or chain must be secured around all mast rail top cross bars. Attempting to lift with the sling secured to only a single cross bar, or secured offcenter, can cause the mast to tilt out of alignment or to extend when lifted.

13. Remove lower mast bolts in the battery box.

14. Remove bolts and retainer plates from the sides of the truck frame.

15. Raise mast until the stub shafts on the sides of the outer mast rail clear the saddles of the truck frame.

Make sure the mast lifts straight up.

!

7. Remove nut and spring from stud on battery compartment wall.

8. Remove the mast cable harness connectors from w/ harness platform.

9. If truck is equipped with a fan/light package or work lights removed connectors from w/harness platform.

If truck is equipped with any other optional features, wire(s) will need to be disconnected.

10. Separate mast cable from wire harness in chassis, cutting and removing wire ties as necessary.

NOTE!

Ensure that all necessary wires are disconnected; i.e., AAA and BBB if accessory power is connected.

11. Remove mast cable and wire harnesses through battery box frame. Tie back wires as necessary, so they clear the truck.

!

WARNING

Use a suitable sling (minimum rated capacity 3 ton [2721 kg]) and suitable hoist (minimum rated capacity 2 ton [1814 kg]) for lifting.

12. Attach a chain or sling around the top tie bars of the mast assembly. Raise with hoist until the slack is out of the hoist chain.

CAUTION

Strap or otherwise secure columns to reduce moving of the platform and columns when laid down.

16. Lay the mast down on the floor with the platform side of the mast facing in the upward position so shimming can be correctly checked.

Mast Installation

!

CAUTION

Use a double-leg sling (rated capacity 3 ton [2721 kg)) for lifting mast. One sling leg should go to each side of the mast rail. The sling or chain must be secured around all mast rail top cross bars. Attempting to lift with the sling secured to only a single cross bar, or secured off-center, can cause the mast to tilt out of alignment or to extend when lifted.

1. Attach chain or sling around top tie bars of mast assembly.

!

CAUTION

Always watch for pinch points when raising mast assembly. Use caution to not damage mast cable during installation.

2. Use a hoist to raise the mast assembly high enough to clear the saddles of the main frame.

SM 844

11-1-10

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 11, Attachment and Platform 3. Lower mast into the saddles of the main frame and install lower mast bolts.

4. Install block and bolts.

5. Set cable braid on cable so that spring end is about 3 inches (76 mm) from stud on battery compartment wall.

6. Stretch spring and place end over stud. Secure in place with nut.

7. Install elbow fitting to battery compartment and attach hose assembly from the lift pump to elbow fitting.

8. Install mast cable and switch harness through the grommets in the battery box.

NOTE!

10. Wire tie mast cable neatly into place (see photos below). Pull excess mast cable back into battery box and neatly tie back excess wire.

11. Install steer/tractor manager cover to chassis with screws.

12. Install battery into truck.

13. Reconnect battery connector to truck. Energize EPO switch and turn key switch ON. Test truck for proper operation before returning to service.

14. Install chassis cover.

Mast Disassembly 1. Remove platform.

2. Remove mast from truck.

The mast cable will have three multiple pin connectors attached to it.

3. Lay the mast on the floor with the platform side of the mast facing upward.

9. Connect mast cable and switch harness to w/harness platform.

NOTE!

4. Remove the mast wiring harness.

5. Remove the primary and staging chains.

Make sure all wires are reconnected properly; i.e., AAA to wire 15 and BBB to wire 40 if accessory power is required.

Outer Rail

6. Remove primary cylinder mounting bolts. Remove hose assembly. Cap the flow limit valve. Remove the primary cylinder from the mast assembly.

Nut

Inner Rail Tee

Hose Valve

Hose Hose Secondary Cylinder

Tee Connector

Bolt Primary Cylinder

Valve

Fitting

SM 844

Capscrew

11-1-11

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 11, Attachment and Platform 7. Remove fitting, nut, and hose assembly. Cap the flow valve on the lefthand staging cylinder.

!

WARNING

Use a suitable sling (minimum rated capacity 3 ton [2721 kg]) and suitable hoist (minimum rated capacity 2 ton [1814 kg]) for lifting.

8. Place a chain or sling around the mast rails. With a hoist, roll mast over to the opposite side.

Mast Rails

10. Remove the tee fitting from the flow limit valve at the base of the left-hand staging cylinder and cap the flow limit valve.

11. Remove the bolts from the top of the staging cylinders. Remove the staging cylinders.

12. Remove hose sheave.

13. Remove lower mast cable sheave.

14. Remove staging chain sheaves.

15. Remove upper mast cable sheave.

16. Place a chain or sling around mast rails. With a hoist, roll mast back over so that platform side (inner column) is on top.

NOTE!

Mast bearings may be shimmed without fully separating mast columns. However, it is recommended to complete mast disassembly and do a thorough cleaning before shimming. To separate mast columns continue to step 17.

17. Support inner mast column with hoist and slide column out bottom of intermediate rail.

18. Support intermediate column with hoist and slide column out bottom of outer rail.

Shim

Mast Shimming and Assembly

Bearing

!

WARNING

When using compressed air, wear effective chip-guarding and personal protective equipment. Compressed air used for cleaning MUST be reduced to less than 30 psi (207 kPa).

Sheave -Hose

!

Sheave -Chain

CAUTION

Roller to flange contact may cause flaking of metal on new columns. This is normal and will continue until the surface becomes work hardened. Apply grease in these areas to reduce new columns from flaking.

Inner Rail

NOTE!

Inner Rail Inner Rail

9. Remove hose assembly from the right-hand staging cylinder flow limit valve and cap the flow limit valve.

SM 844

Mast must be removed, disassembled and thoroughly cleaned before shimming mast bearings.

Mast rails must be shimmed properly during assembly.

For the following procedures, except where noted, refer to drawing on page 11-1-12.

11-1-12

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 11, Attachment and Platform 1. Thoroughly clean all parts and air dry.

2. Replace mast bearings, as necessary. Reuse original shims behind bearings if they are usable. Shimming will be set in a later step.

3. Place outer mast column, platform side up, on solid work surface or floor.

4. Support intermediate mast column with hoist, platform side up, and slide it into outer column from the bottom.

Shim Here

bearing and web on one side. Add shims until no more can be added, allowing a maximum of 0.030 inch (0.762 mm) of free play clearance. Mark these shims for where they are to be used and set them aside.

6. Support intermediate column with hoist and slide it out the bottom of outer column only far enough to expose bearings top and bottom.

Working at the top, and then at the bottom, remove all bearings and shims. Add the additional shims determined in step 5 and divide entire shim pack as equally as possible on both sides. Install shims under bearings and install bearings.

7. Reinstall intermediate column in outer column. Support intermediate column at top with hoist and extend column out the top as far as it will go. Recheck bearing shimming as column is extended. If tight spots are encountered where the mast will not move freely, remove shims as necessary.

8. Repeat steps 4 through 7 with inner column.

NOTE!

Contact Area on Flange

Lower End of Column

Continue with mast assembly after bearing shimming is complete.

9. Install upper mast cable sheave (see page 461).

10. Install staging chain sheaves.

Shim Here

11. Install lower mast cable sheave.

12. Install hose sheave.

13. Install staging cylinders and install bolts into top of each cylinder rod.

14. Install tee fitting onto the lower left-hand flow limit valve.

15. Install hose assembly into tee fitting and to the lower right-hand flow limit valve.

Contact Area on Flange

16. Wrap a chain or sling around the mast rails and with a hoist roll the mast over to the opposite side.

Upper End of Column

5. With the intermediate column installed in outer column, determine the amount of shims required.

At lower end of column, pry column to one side and then the other. Be certain that bearings are fully seated on shaft. Slip additional shims between bearing and web on one side. Add shims until no more can be added, allowing a maximum of 0.030 inch (0.762 mm) of free play clearance. Mark these shims for where they are to be used and set them aside.

At upper end of column, support intermediate column with hoist attached to upper cross bar; lift only till bearings are in contact with flange. Pry column to one side and then the other. Be certain that bearings are fully seated on shaft. Slip additional shims between

17. Install fitting and nut.

18. Install the primary cylinder into the inner rail assembly and install mounting bolts.

19. Install hose assembly to the fitting and then to the flow limit valve at the base of the primary cylinder.

20. Install the primary and staging chains.

21. Install mast onto truck frame.

SM 844

11-1-13

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 11, Attachment and Platform Lift Chain Replacement 1. All chains should be replaced if any length has wear elongation of 3% or if any of the conditions listed in “Wear” on page 11-1-2 are evident during inspection.

2.

Replace all chains as a set.

3.

Do not degrease or paint new chains.

4. Replace anchors and anchor pins when installing new chains.

5. Adjust chains properly (see page 11-1-5).

Platform

Freelift Cylinder Bearing Removal 1. Turn key switch OFF and depress EPO switch. Disconnect battery connector from truck.

2. Attach a hoist to the rear of the center bar of the overhead guard on the platform.

3. Locate a 4 x 4 inch (102 x 102 mm) block long enough in length to cover the outside dimension of the straddle arms.

!

WARNING

Use a suitable sling (minimum rated capacity 3 ton [2721 kg]) and suitable hoist (minimum rated capacity 2 ton [1814 kg]) for lifting.

!

4. Raise the platform high enough above the straddle arms so that a 4 x 4 (102 x 102 mm) block may be inserted between the bottom of the platform and the top of the straddle arms. Place the 4 x 4 (102 x 102 mm) block towards the rear of the platform.

5. Lower the platform onto the 4 x 4 (102 x 102 mm) block. Leave hoist attached to the overhead guard on the platform. There will be slack in the mast cable and freelift chains for ease of removal.

6. Remove the mast cable from the mast cable sheave.

CAUTION Bracket

Use caution not to pinch the mast cable behind the platform,

Sheave

Chain

4 X 4 Block

Anchor Bolt

Primary cylinder

7. Remove the primary chains from the chain sheaves.

SM 844

11-1-14

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 11, Attachment and Platform 8. Remove the nut and chain sheave from the primary cylinder.

!

WARNING Bearing

When using compressed air, wear effective chip-guarding and personal protective equipment. Compressed air used for cleaning MUST be reduced to less than 30 psi (207 kPa).

9. Use compressed air and thoroughly clean all dirt and debris from the top and the side of the bearing where the bearing meets the cylinder tube.

10. With a chain wrench, loosen the bearing until it can be threaded out of the cylinder tube by hand.

11. Before removing the bearing from the cylinder tube, use compressed air and thoroughly blow all dust and debris from the bearing and tube assembly.

12. Remove bearing by sliding it up the cylinder rod.

Tube

13. For bearing seal kit removal and installation see page 11-1-18.

Primary Cylinder Bearing Installation 1. Inspect the chamfered area of the primary cylinder for burrs, scratches, or chrome flaking. Use 400 grit sandpaper to remove particles.

2. Cover the exposed cylinder tube with a shop rag or cloth before sanding is applied to the chamfered edge of the cylinder rod.

Chamfered Area

!

WARNING

When using compressed air, wear effective chip-guarding and personal protective equipment. Compressed air used for cleaning MUST be reduced to less than 30 psi (207 kPa).

3. Using compressed air, thoroughly clean the cylinder rod of dust and debris. Carefully remove the shop rag or cloth from cylinder tube, making sure not to drop dust and debris into the cylinder tube.

4. Lubricate cylinder rod with hydraulic fluid and slide bearing down cylinder rod until the threads meet.

5. Thread bearing into cylinder tube and tighten with wrench.

SM 844

11-1-15

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 11, Attachment and Platform 6. Thoroughly clean any excess oil from bearing and cylinder tube exterior.

7. With the chain and mast cable sheave attached to the shaft assembly, slide the shaft from the right to the left into the cylinder rod. Make sure index hole is in the upward position.

8. Carefully tighten the setscrew into the index hole on the shaft. Install washer and bumper to the top of the cylinder rod with flathead screw.

9. Install remaining chain sheave onto shaft. Install flanged nut and tighten.

6. Remove bolts from the top of the staging cylinders.

NOTE!

New cylinder assemblies may not lower under their own weight. It may be required that manual assistance is needed to fully lower the cylinder rods.

7. On the lift manifold, loosen the check valve at port on the topside of the manifold. While holding the manual lowering release valve in the fully upward position, loosen the check valve three full turns. DO NOT remove check valve. The staging cylinder rods will begin to lower.

10. Install primary chains onto the chain sheaves.

11. Install mast cable onto the mast cable sheave.

!

WARNING

Use a suitable sling (minimum rated capacity 3 ton [2721 kg]) and suitable hoist (minimum rated capacity 2 ton [1814 kg]) for lifting.

12. Raise platform until the 4 x 4 (102 x 102 mm) block can be removed from under the platform.

13. Carefully lower the platform, watching the back side of the platform so as not to pinch mast cable assembly until the platform is fully lowered.

14. Remove hoist from overhead guard on platform.

15. Reconnect battery connector to truck. Energize EPO switch and turn key switch ON. Test truck for proper operation before returning to service.

Staging Cylinder Bearing Removal 1. Reconnect battery connector to truck. Energize EPO switch and turn key switch ON. 2. To use maintenance switch, lifting and lowering of the mast assembly is working easily.

3. Use pendant to raise mast until approximately 12 inches (305 mm) of the staging cylinder rods are extended out of the cylinder tube.

4. Using a chain (minimum 4,000 pounds (192 kPa) rated capacity), route the chain over the top of the upper tie bar on the outer mast column. Continue routing the chain around the lower tie bar on the intermediate mast column. Secure the chain to prevent the intermediate column from lowering.

5. Use pendant to lower mast assembly until the weight of the intermediate, inner mast column, and the platform are supported by the chain.

8. When cylinders are fully lowered, release the manual lowering release valve and tighten the check valve.

!

WARNING

When using compressed air, wear effective chip-guarding and personal protective equipment. Compressed air used for cleaning MUST be reduced to less than 30 psi (207 kPa).

9. Using compressed air, thoroughly clean all dirt and debris from top and sides of the bearing where bearing meets cylinder tube.

10. Using a chain wrench, loosen bearing until it can be threaded out of the cylinder tube by hand.

11. Before removing bearing from the cylinder tube, use compressed air hose to thoroughly blow all dust and

SM 844

11-1-16

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 11, Attachment and Platform debris away from the bearing and the cylinder tube assembly.

12. Remove bearing by sliding it up the cylinder rod.

Bearing

13. For bearing seal kit removal and installation procedures (see page 11-1-18).

Staging Cylinder Bearing Installation 1. Inspect the chamfered area of the staging cylinder for burrs, scratches, or chrome flaking. Use 400 grit sandpaper to remove particles.

2. Cover the exposed cylinder tube with a shop rag or cloth before sanding is applied to the chamfered edge of the cylinder rod.

Tube

Chamfered Area

!

WARNING

When using compressed air, wear effective chip-guarding and personal protective equipment. Compressed air used for cleaning MUST be reduced to less than 30 psi (207 kPa).

3. Thoroughly clean the cylinder rod of dust and debris.

Carefully remove the shop rag or cloth from cylinder tube, making sure not to drop dust and debris into the cylinder tube.

4. Thoroughly lubricate the wiper, seal and wear ring using hydraulic fluid.

5. Lubricate cylinder rod with hydraulic fluid and slide bearing down cylinder rod until the threads meet.

SM 844

11-1-17

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 11, Attachment and Platform 6. Thread bearing into cylinder tube and tighten with wrench.

Bearing Seal Kit Installation

7. Thoroughly clean any excess oil from bearing and cylinder tube exterior.

8. Use the pendant and slowly raise the staging cylinder rods until they meet the underside of the intermediate mast column. Install bolts into the top of the cylinder rods and torque to 30-33 ft-lbs (70-80 N.m).

Bearing

9. Raise mast assembly until there is slack in the chain, which was used to support the mast columns and platform during bearing removal.

10. Remove chain and fully lower mast assembly.

11. Reconnect battery connector to truck. Energize EPO switch and turn key switch ON. Test truck for proper operation before returning to service.

Bearing Seal Kit Removal 1. Using a cotter pin/seal removal tool, carefully remove the wiper, seal, and wear ring from the inside of the bearing. Remove backup ring, if applicable, and O ring from the outside of the bearing. Take special care when extracting the parts from the bearing, to not scratch, nick or gouge the grooves in bearing.

Cotter Pin/Seal Re Remova val Too ool

1. Thoroughly clean all dust and debris from bearing.

2. Thoroughly inspect grooves inside the bearing for visual scratches, nicks, or gouges. If upper and lower grooves have any visual deformations such as a scratch, nick, or gouge, lightly sand with a 400 grit sandpaper until smooth. If the center groove has any visual deformations such as a scratch, nick or a groove, bearing replacement is recommended.

Middle Groove Upper Groove Lower Gr Groove Be Bearing Base Ba

Backup Ring Back

ng O Ring

3. If any sanding has been performed on the upper and lower bearing grooves, thoroughly clean the bearing internally and externally of dust and debris.

SM 844

11-1-18

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 11, Attachment and Platform 4. When installing applicable backup ring, make sure to install flat side of backup ring towards the base of bearing and cupped-side of backup ring facing the O ring.

5. Wrap threaded end of bearing using masking or electrical tape to reduce the risk of cutting the backup ring or O ring when installing.

Seal Installation Tool

Seal

Seal

6. Thoroughly lubricate the backup ring or O ring with the same type of oil as in the truck hydraulic reservoir.

7. Slide backup ring or O ring over the threaded part of bearing until it makes contact with the base of the bearing. Remove tape from threads.

15. Place bearing onto a small press with the threaded end of the bearing resting on the table of the press.

8. Thoroughly lubricate the inside of the bearing with the same type of oil as in the truck hydraulic reservoir.

9. Place bearing on a clean flat stable surface with the threaded end of the bearing facing upward.

Wiper

Press

Bearing

10. Thoroughly lubricate the wear ring with same type of oil as in the truck hydraulic reservoir.

11. Using your index finger and thumb compress the wear ring enough to slide inside the bearing. Continue sliding the wear ring into the bearing, using your index fingers, until the wear ring has seated into its groove.

Wear Ring

Wear Ring Inserted in Bearing

16. Thoroughly lubricate the wiper with the same type of oil as in the truck hydraulic reservoir.

17. Place wiper onto the top of the bearing with the grooved rubber side facing in the upward position and lightly press into position.

12. Turn the bearing over. The threaded end of the bearing will now be resting on the clean flat stable surface.

13. Thoroughly lubricate the seal with the same type of oil as in the truck hydraulic reservoir.

14. Using a seal installation tool, collapse the seal and install into the middle groove of the bearing with the O ring side of the seal entering the bearing first. Using your index finger work the seal into its seated position.

SM 844

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Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 11, Attachment and Platform

Section 2 Fork Assembly

OzpT[`Y_`P

SM 844

11-2-1

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 11, Attachment and Platform 4. Install correct amount of washers or shim at back side of fork to maintain a level fork.

Theory of Operation The forks are raised by means of an electric powered hydraulic pump unit. The lift and lower forks thumb knob is on the end of the control handle. Rotating the thumb knob up will lift the forks and rotating the thumb knob down will lower the forks.

5. Install socket head cap screw at chassis end of fork.

6. Remove block from platform.

7. Lower platform to floor and make sure forks are level.

If forks are not level, add more shim to fork.

Maintenance See “Planned Maintenance Schedule” on page 01-2-2.

Troubleshooting Make sure forks are in good condition.

Repair and Rebuild The forks and pallet can not be rebuilt. Replace forks and pallet as necessary.

Forks Removal 1. Raise platform high enough to reach bottom of forks.

2. Block platform with 4 inch x 4 inch (10 x 10 cm) upright block.

3. Secure fork to hoist using a suitable strap or chain.

4. Remove one socket head cap screw from underneath fork at chassis end.

5. Remove snap ring from pivot pin in mounting block of fork.

!

CAUTION

The fork weighs approximately 114 pounds (51 kg), use caution when it drops.

6. Drive out pivot pin. The fork washer(s) or shim(s) will drop.

7. Replace damaged fork.

Install 1. Hold new fork in place underneath platform.

2. Install pivot pin through fork.

NOTE!

Always use new snap rings when assembling components.

3. Install new snap ring in pivot pin.

SM 844

11-2-2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 11, Attachment and Platform

Section 3 Platform Mounting

OzpT[`ZWXP

SM 844

11-3-1

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 11, Attachment and Platform Theory of Operation

Troubleshooting

The operator platform attaches to the mast columns and chains.

Check fork frame mounting and inspect platform for damage and crack formation every six months.

Maintenance

Repair and Rebuild

Platform Shimming

Replace bearings and chains on platform as necessary. The platform can not be rebuilt. Replace platform with new as necessary.

!

WARNING

Removal

When blocking mast columns to reduce the risk of lowering or when working on or near mast, always block both sides of the column.

Otherwise, the truck could tip over on its side.

1. Reconnect battery connector to truck. Energize EPO switch and turn key switch ON. 2. To use maintenance switch, lifting and lowering of the mast assembly is working easily.

3. Raise platform up inner column as far as it will go under normal operation. Check bearing shimming as the platform is lowered in six inch increments. With a 0.030 inch (0.762 mm) feeler gauge, (a shim works well), check bearing clearance between bearings and the web of the column (as a pry bar is used to pry the bearings plates of the platform side to side). Maximum clearance must not exceed 0.030 inch (0.762 mm).

1. Reconnect battery connector to truck. Energize EPO switch and turn key switch ON. 2. Attach pendant to steer/tractor manager card at pin location.

3. Remove forks from platform.

4. Remove dash panel.

5. Remove the mast cable harness connectors from w/ harness platform.

6. Remove wire ties holding the mast cable harness to the platform. Raise the mast assembly until the cable clamp can be accessed at the base of the latform, holding the mast cable harness to the platform. Block mast assembly. Loosen the clamp and remove the harness.

Sheave-Chain Sheave

4. Once the number of shims have been determined, divide the shims equally as possible between the upper bearings or the lower bearings as needed to keep the platform centered in the mast.

Anchor Bolt Cable

5. Remove the platform.

Inner Rail

6. Install shims behind bearings as needed.

Hose

7. Install platform into mast.

8. Remove hoist from platform and test operation of platform in the mast. Check operation first with no load, by checking the bearing clearance for tight spots. If tight spots are encountered, shims will need to be removed as required. If shimming is correct, test operation of platform in the mast with a capacity rated load.

9. Test truck for proper operation before returning to service.

SM 844

11-3-2

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Group 11, Attachment and Platform 7. Remove mast cable harness from the freelift sheave and pull back towards the truck frame.

13. Fully lower mast assembly.

Hoist

Overhead Guard

Bracket

Sheave

Chain

Assembly Anchor Bolt

1. Carefully raise mast assembly far enough to clear the upper bearings on the platform.

2. Install platform into mast assembly.

Primary cylinder

8. Remove blocks from mast assembly. Fully lower mast assembly, being careful not to pinch the recently removed mast cable harness.

9. Attach a hoist to the platform overhead guard. Hoist platform up far enough to release pressure on the freelift chains.

3. Install primary chains on chain anchor bolts located on either side of the primary cylinder. Adjust primary chains.

4. Install mast cable harness. Attach the harness cable clamp to the platform.

5. Install the mast cable harness connectors.

6. Lower platform until hoist chain is slack. Remove the hoist chain.

10. Remove freelift chains from chain anchor bolts located on either side of the freelift cylinder.

7. Connect the mast cable harness connector to w/harness platform.

11. Carefully raise mast assembly to clear the upper bearings on the platform.

8. Install forks on platform.

12. Remove platform from mast assembly.

9. Test truck for proper operation before returning to service.

10. Reconnect battery connector to truck. Energize EPO switch and turn key switch ON. Test truck for proper operation before returning to service.

SM 844

11-3-3

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute