Clark SF20-30DLG Forklift Service Repair Manual #2

RATED CAPACITY : 2000~3000kg

SF20-30D/L/G CMP20-30D/L/G

SERVICE MANUAL

#40–1, Ungnam-Dong, Changwon-City, Kyungnam, Korea

Part No. 8034924

Manual No. SM688

FOREWORD

This shop manual has been prepared as an aid to improve quality of repairs by giving the serviceman an accurate understanding of the product and by illustrating the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to the full effect at every opportunity. This shop manual mainly contains the technical information necessary for operations performed in a service workshop.

For ease of understanding, the manual is divided into sections for each main system of the machine, and the sections are further divided into groups.

•Improper operation and maintenance of this machine could result in serious injury or death.

•Read the Operation and Maintenance Manual carefully BEFORE operating the machine.

•Always keep the Operation and Maintenance Manual and Parts catalogue near the work area.

•Obey precautions concerning flammable liquids, hazardous fluids, oils, lubricants and cleaning solvents.

•To prevent injury to workers, this symbol is used to mark safety precautions in this manual. The precautions accompanying this symbol should always be followed carefully.

•The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your SAMSUNG distributor for the latest information.

HOW TO READ THIS MANUAL

CHAPTER AND SECTION

This manual is issued as a guide to carrying out repair and maintenance. To easily understand this manual it is divided as follows:

Example) 10 – 01

Section number(01:Structure and function)

Chapter number(10:Engine)

Page numbering is started from each section. Therefore, revised pages can be easily inserted. Also, additional pages and revision number can be indicated.

Ex) 15 – 1 ③

3rd revision

Additional page from page 15 15th page of the section

For the revision status in this manual, refer to REVISION HISTORY.

SYMBOLS

The following symbols as defined below are used in this manual to convey the intent of the instructions concerning safety and repair.

Remarks

Safety

Special safety precautions are necessary when performing the work.

Caution

Tightening torque

Tool

Special technical precautions or other precautions for preserving standards are necessary when performing the work.

Places that require special attention for the tightening torque during assembly.

Places that require proper tools used in assembling and disassembling.

Adhesive

Places to be applied with adhesive.

Lubricating

Places where oil or lubricant must be added.

W A R N I N G !

SERIOUS OR FATAL INJURY MAY RESULT TO YOURSELF OR OTHERS IF NOT FOLLOWED

This fork lift should not be operated by anyone who is not authorized and properly trained. Read the Operators Manual carefully, and make yourself familiar with your fork lift. Inspect and check your fork lift daily before and after use. Do not operate a faulty or damaged fork lift. Repair work should be done by authorized and trained persons only.

To protect from falling objects, make sure that the Overhead Guard and Load Backrest are correctly mounted and in good condition.

Before starting engine, always set forward/reverse lever in neutral, with hand brake on.

Drive carefully, keeping forks and attachments as low as possible & fully tilted back.

Keep a careful lookout for people, obstructions and the path of travel. Watch clearance, especially overhead and tail swing. Do not stick hands, feet and other parts of your body outside the Operatorls compartment.

Drive forward when you are climbing a slope with a load. Drive in reverse when you are descending with loads. Do not turn while on a slope.

Slow down before turning. Avoid any sudden start, stop or turning. Lateral tipover can occur if the fork lift is improperly operated.

Do not load fork lift over capacity limit designated on the load chart. Do not lift unstable loads.

This fork lift is not designed for raising or transporting people. Do not use fork lift for those purposes under any circumstances. Before you get off fork lift, make sure the hand brake is set, lower forks or attachments, put forward/reverse lever in neutral position and turn off key switch. Do not park on a slope.

GENERAL PRECAUTIONS

SAFETY PRECAUTIONS

P/NO.6092-13130

•When carrying out any operation or maintenance, have trained and experienced personnel carry out the work.

•When carrying out any operation or maintenance, carefully read the Operation and Maintenance Manual.

Read all the precautions given on the decals which are fixed to the machine.

SAFETY DEVICE

•Make sure that all guards and covers are mounted in their proper position. Repair or replace if damaged.

•Pay attention to the method of using any safety locking device or safety belt.

SAFETY CLOTHES AND HELMET

•Wear the specified work clothes in the correct manner.

•Use the specified protective gear (helmet, safety glasses, safety shoes, mask, gloves). Guard against injury from flying pieces of metal or debris, wear goggles, gloves and helmet. Always have a trained and experienced welder carry out any welding work.

When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suitable for welding work.

PREPARE FOR EMERGENCIES

•Know where fire extinguishers are located and how to use them.

•Keep a first aid kit and an eye wash kit near the work area.

•Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

HANDLE FLUIDS SAFELY–AVOID FIRES

•Handle fuel with care it is highly flammable.

•Do not refuel the machine while smoking or when near open flame or sparks. Always stop the engine before refueling machine. Fill the fuel tank outdoors.

•Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers.

DISPOSE OF FLUIDS PROPERLY

•Improperly disposing of fluids can harm the environment and ecology. Before draining any fluids, find out the proper way to dispose of waste from your local environmental agency.

•Catch draining fuel, oil, or other fluids in suitable containers. Do not use food or beverage containers that may mislead someone into drinking from them. Wipe up spills at once.

•Do not pour oil into the ground, down a drain, or into a stream, pond, or lake. Observe relevant environmental protection regulations when disposing of oil, fuel, coolant, brake fluid, filters, batteries, and other harmful waste.

AVOID HARMFUL ASBESTOS DUST

•Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled asbestos fibers may cause lung cancer.

PREPARATIONS FOR WORK

WARN OTHERS OF SERVICE WORK

•Unexpected machine movement can cause serious injury.

•Before performing any work on the machine, attach a “Do Not Operate” tag to the steering wheel or the right control lever.

•When carrying out any operation with two or more workers, always agree on the operating procedure before starting.

USE TOOLS PROPERLY

•Use a tool only for its designed application.

•Keep all tools in good condition and know the correct way to use them.

•Decide on a place in the repair workshop to keep tools and removed parts.

•Always keep the work area clean and make sure that there is no dirt or oil on the floor.

•Before adding oil or making any repairs, park the machine on hard, level ground and put blocks under the wheels or tracks to prevent the mahcine from moving.

•Before starting work, lower the forks or any other work equipment to the ground.

•Turn the engine OFF, remove the start key, and apply the parking brake.

•Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.

USE HANDHOLDS AND STEPS

•Do not jump onto or down from the fork lift.

•When getting on or off the fork lift, use the step provided.

•Do not grasp an operating lever or steering wheel when getting on or off.

•Always keep the step clean and repair it if damaged.

•Never operate with wet or oily hands and feet.

OPERATE FROM THE OPERATOR’S SEAT

•Do not operate the fork lift from any place other than the designated operator’s position.

•Improper seating may cause serious injury.

CONSTRUCTION

TA18 Transaxle assembly includes:

•Torque converter

•Single–speed forward and reverse powershift transmission with integral differential and drive axle

•Full–floating straight drive axle

•Automotive–type drum and shoe brakes

•Gear–driven pump drive

•Electric shift control, hydraulic inching control

Power flow is from torque converter turbine, to turbine(clutch) shaft and gears, then through either forward gear or reverse idler shaft, to the output gear mounted on final drive pinion shaft. Transmission and differential are housed in a one–piece transmission case.

Torque converter housing joined to transmission case through an adaptor(or spacer) plate holds the converter stator support and reverse idler outer bearing.

Pump drive is from converter impeller hub gear, through an idler gear to the pump gear mounted on charging pump shaft.

Final drive pinion gear shaft, mounted in tapered roller bearings at both ends in transmission case, is adjusted for mounting distance, and ring and pinion gear contact by, shim a pack installed behind the pinion gear inner tapered roller bearing cup in the transmisson case. Pinion shaft bearing preload is adjusted with shims behind outer bearing cone on the pinion shaft.

Final drive ring gear is bolted to differential carrier. Differential support is by opposed tapered roller bearings mounted on inner end of wheel end housings, which are bolted to openings in transmission case at the sides of the differential. Differential bearing preload and ring gear clearance(backlash) is maintained by shims placed behind differential bearing cones on wheel end housings. Adjustment of differential bearing preload or ring gear backlash requires trial assembly, checking, and disassembly of wheel end housings until correct adjustment is obtained.

Drive axle wheel hubs/brake drums are supported by double tapered roller bearings on outer end of wheel end housings. Drive axle shaft flange bolted to wheel hubs are full–floating in differential. Service brake backing plates are bolted to mounting flanges on wheel end housings. Wheel bearings are lubricated from the transaxle sump.

Control valve is mounted on pad at top of transmission case. Oil from charging pump flows via filter and pressure regulator to control valve through an external oil supply line. Oil from control valve is delivered to clutches through passages in housing and oil distributor sleeve and seal rings at forward–clutch end of turbine/clutch shaft. Excess pump oil volume and converter–out oil, flows to oil cooler and returns to transmission housing at base of control valve, then through center of turbine/clutch shaft back to converter.

SERVICE MAINTENANCE

SERVICE

The transaxle has two service openings:

1.Dipstick/oil fill tube in central side axle housing.

2.Drain plug, in bottom of transmission case.

FLUID LEVEL CHECK

Check the transaxle fluid level with:

•Fork lift on a level surface

•Engine idling with transmission in NEUTRAL

•Oil at operating temperature 82~93°C (180~200°F)

① Remove the transaxle oil level plug the front of central housing of driving wheel.

② The oil level is correct when the oil reaches the full mark on dipstick.

③ Add recommended fluid only, as required.

FLUID AND FILTER CHANGE

It is recommended to:

•Drain and replace the transaxle fluid every 1000 operating hours.

•The oil should be drained when warmed to operating temperature, 82~93°C (180~200°F)

•Replace the transaxle oil filter every 500 operating hours. See NOTICE below.

IMPORTANT

When the transaxle is new or rebuilt, it is recommended to change the oil filter after the first 50 hours and again after 100 operating hours.

① Remove drain plug from bottom of transmission case. Drain old oil into suitable drain pan.

② Remove old oil filter. The oil filter is mounted near the top of converter housing above transmission.

Take special care when removing the filter to avoid oil remaining in filter from draining onto floor. Loosen the filter using a filter wrench. Remove filter while holding a pad of cloth or other absorbent material under the open end to absorb any excess oil that may drain out of filter.

③ Install a new oil filter. Follow the installation instructions printed on filter. Always use genuine SAMSUNG parts

REFILLING THE TRANSAXLE

After drive axle and transmission housing has drained completely,

•Install drain plug.

•Loosen the oil level plug and fill the oil upto the plug hole.

•Start the engine and run at idle speed(700~800rpm) in NEUTRAL for 2~3minutes to prime the converter and cooler lines.

•Recheck oil level with engine running at idle speed.[82~93°C (180~200°F)]

•Check for leaks at drain plug and oil filter.

SPECIFICATION

PRESSURE SPECIFICATION

•Regulator valve pressure:1108~1451kPa (160~210psi)@1800rpm

Check Point:Oil supply line at converter

•Converter In/Lube Pressure:176~314kPa (26~45psi)@1800rpm

Check Point:Return from cooler

•Converter Safety Valve Pressure:729~827kPa (105~120psi)@ (Trans in NEUTRAL) 1800rpm(Refefence only)

Check Point:None with line to cooler blocked

•Clutch Pressure:1034kPa (150psi) @ (Forward, Reverse applied)

700~800rpm idle

Check Point:At control valve Normally 103kpa(15psi) less than regulator (1/8 NPTF) pressure 1000kpa(145psi min)

•Clutch Pressure:Regulator pressure (in NEUTRAL)

NOTES

• All rpm’s noted are engine speed.

• All clutch pressures are at engine idle speed with clutch engaged, unless otherwise noted.

• Oil at operating temperature 82~93°C (180~200°F)

• Refer to following illustrations for check point locations.

PRESSURE CHECK POINTS

SERVICE BRAKE ADJUSTMENT

PREPARATION

1. The service brakes on the transaxle may be adjusted from the inner side through the backing plate(all models), or from the outer side through access openings in the wheel hub/brakedrum(later models).

2. Brake clearance is measured between brake shoe and drum, with brakes fully released. Brake clearance:0.255~0.304 mm (.010~.012in)

CAUTION:Be sure transmission directional control is in NEUTRAL and fork lift prevented from moving when parking brake is released.

3. Release parking brake.

IMPORTANT–Do not overtighten brakes. It is very difficult to release the ratchet wheel pawl and back off adjustment of the brake.

ADJUSTMENT AT BACKING PLATE

1. Remove the 4 dust plugs in brake backing plate.

2. Use a feeler(thickness) gauge to check the clearance between each shoe and drum. Use a brake adjuster tool to rotate the adjuster ratchet wheel in the brake.

3. Use a screwdriver to push on and release the ratchet pawl when it is necessary to back off adjustment(increase clearance) of the brake.

4. Carefully adjust clearance between brake shoes and drum to 0.255~0.304 mm (.010~.012in) measured at dust plug openings at outer sides of backing plate.

5. Replace the dust plugs in brake backing plate when adjustment is completed.

ADJUSTMENT AT WHEEL HUB

Openings in the wheel hub/brake drum have been provided for easier access to check and adjust the service brakes from the outer side. Requires removal of drive wheel and tire assembly. Some models may have only a slot for measuring brake clearance;adjustment is made through the plug openings on backing plate. Later models have a slot and circular opening for access also to the adjuster. The opening is enclosed with a dust cover held in place by a single screw.

1. Remove wheel and tire assembly from wheel hub.

WARNING–Pneumatic Tire Wheels

Before loosening wheel mounting bolts or nuts, release the air pressure from the tire. Failure to release the air pressure from the tire can result in serious injury or death.

2. Remove dust cover from access opening in wheel hub/brake drum.

3. Use feeler(thickness) gauge to check the clearance between each shoe and drum. Use a brake adjuster tool to rotate the adjuster ratchet wheel in the brake.

4. Use a tool with a hook to pull on and release the ratchet pawl when it is necessary to back off adjustment(increase clearance) of the brake.

IMPORTANT–Do not overtighten brakes. It is very difficult to release the ratchet wheel pawl and back off adjustment of the bake.

5. Carefully adjust clearance between brake shoes and drum to 0.255~0.304 mm (.010~.012in) measured at slot opening. Move slot by rotating brake drum to check clearance at the illustrated position for each brake shoe.(20–01–6)

6. After adjusting brakes, install dust cover over access opening in the wheel hub.

7. Install wheel and tire assembly on the drive axle wheel hub.

8. Install wheel mounting lug nuts and tighten to spec:637~718Nm(471~531lbf·ft)

PRECAUTION

• Before attempting any repairs or overhaul of this assembly, please read through the entire disassembly and assembly procedures first.

Cleanliness is of extreme importance in the repair and overhaul of this assembly.

• The exterior surface of the unit MUST be thoroughly cleaned of all dirt and foreign substances to prevent contamination of the parts during disassembly and overhaul. Perform all disassembly and assembly work in a clean area. Protect all components from dust and dirt while repairs are being made.

• Keep all parts in order as disassembly progresses. Take care to properly identify each part and its order of removal. If necessary, keep notes and put marking on parts using a nondestructive marker such as a felt–tipped pen.

REMOVE AUXILIARY SUBASSEMBLIES

1. Remove torque converter assembly by carefully sliding it off the turbine(clutch) shaft and stator support.

2. Disassemble converter drive plate and adaptor, as needed. Remove the:

3. Oil filter

4. Charging pump

5. Oil supply line assembly

6. Transmission control valve assembly

WHEEL END

1. Loosen and remove the axle shaft fasteners.

2. Remove axle shaft.

3. Unbend(straighten) the lockplate tabs from the bolt heads of the wheel bearing retainer plate fasteners.

4. Remove the bearing retainer plate fasteners.

5. Remove the lockplate, bearing retainer plate and wheel bearing shims.

6. Pull wheel hub out to loosen bearing(you may have to tap on hub or pry at brake backing plate), remove outer wheel bearing, then remove the wheel hub/brake drum assembly with inner wheel bearing and oil seal.

IMPORTANT

This oil seal is a type that seals internally, and is lined with sealing compound on the inner diameter that sticks and seals to the spindle. Removing the wheel hub from the spindle breaks that seal. Replace with new seal each time that the wheel hub is removed from wheel end housing.

7. Before removal of wheel end housing, mark the housing and the transmission case for same–location matching at reassembly. Loosen and remove the housing bolts and washers.

8. Remove wheel end housing from transmission case.

9. If the differential bearing on the inner end of the wheel end housing is to be removed and replaced, use a bearing puller, if necessary. Wire bearing shims to wheel end housing for storage until reassembly.

10. Repeat procedures of Steps 1 through 9 for opposite wheel end disassembly.

11. Remove the differential assembly from transmission case.

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BRAKE ASSEMBLY REMOVAL

Brake removal is optional for brake overhaul as necessary.

1. Remove the upper brake shoe return springs.

2. Remove lower return spring.

3. Remove brake shoe hold–down(guide) springs.

4. Disconnect parking brake cable. Remove the brake shoes.

5. Remove brake backing plate fasteners and washers.

6. Remove backing plate and parking brake cable assembly from wheel end housing.

7. Remove drive axle support and spacer from wheel end housing.

SEPARATION OF CONVERTER HOUSING AND ADAPTOR PLATE

1. Remove the fasteners and washers which mount the converter housing to transmission case through the adaptor plate.

2. From other side, remove the bolts and washers which mount adaptor(spacer) plate to converter housing.

3. Remove the clutch pressure–regulating valve assembly(also oil filter mounting base).

IMPORTANT

Pry only at the dowel pins to remove adaptor plate. Dowel pins must be removed before reassembly. See later instructions.

4. Separate converter housing from adaptor plate.

5. Remove impeller hub gear from stator support.

6. Remove pump drive idler gear and bearing, outer and inner thrust washers, and idler shaft.

7. Remove adaptor plate from transmission case.

STATOR SUPPORT REMOVAL FROM ADAPTOR PLATE

1. The stator support is held in place by two retaining rings, one on each side of the adaptor plate.

2. To remove stator support:

–Remove front(converterend) retaining ring from ring groove and move ring and impeller gear thrust washer toward stator support seal surface.

–Push stator support to the rear(towards transmission side) far enough to expose rear retainer ring.

–Remove rear retaining ring.

–From the front, pull stator support from adaptor plate.

CLUTCH ASSEMBLY, IDLER GEAR&PINION SHAFT REMOVAL

1. Move the reverse idler gear and clutch assembly apart far enough to allow the idler shaft to be pulled out of the inner bearing.