Clark C500, Y250S Forklift Service Repair Manual

SM-575 C5OOYlSO-200-225S-225L 25OS-25OL-3OOS-3OOL-350

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

Pictorial Index

C500 Y2235 Series

Group

30

Group

29

Hydraulic Sump, Filters

Hydraulic Valves, Circuit Pres-

1

Group

32

Tilt Cylinders, Low-Tilt and Hi-Tilt Models.

Tilt Cylinder Adjustment Tilt Cylinder Lines; Drift Test

Group 33 Hydraulic Relief Valve (M arina Models) Tilt Lock !2 Relief Valves.

Group

34

Upright....

Carruage & Forks.

Lift Circuit Pressure Check.

I

Group 06 Transmission

Group 20 Drive Axle

Group 21 Univ. Joints

Group 39 Group 40

Decal Replacement and Placement Truck and Engine Specifications. Lubrication Specifications and Grease Chart PM Inspection and Drivers Daily Inspection Forms

SM575

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

July 97

INDEX

GROUP

SECTION

DESCRIPTION

Forward Introduction PM Section ENGINE Engine Troubleshooting Engine Removal Ford Engine Specifications Cummins Engine Specifications

00 00 00 00

00

01 01

01 01 01

COOLING SYSTEM Troubleshooting Radiator Removal Testing and Maintenance Radiator Repair

02 02 02 02 02 02

FUEL SYSTEM Troubleshooting Induction System Accelerator Linkage lmpco LPG Lock-off Valve lmpco LPG Vaporizer-Regulator

06 06 06 06 06 06 06

TRANSMISSION Troubleshooting Transmission Stall Test Transmission Removal Transmission Clutch Modulation Transmission Maintenance and Service Linkage and Controls

14 14 14 14 14 14

ELECTRICAL General Troubleshooting Starter and Battery Troubleshooting Alternator Troubleshooting Wiring Diagram Electrical Tools

20 20 20 20 20

DRIVE AXLE Troubleshooting Drive Axle Removal Drive Axle Wheel Bearing Adjustment Clark-Hurth and Rockwell Drive Axle Maintenance and Service

0 Clark Material Handling Company 1997

Copyrighted1Material Intended for CLARK dealers only Do not sell or distribute

INDEX

GROUP

SECTION

21 21 21 21

1 2 3

PROP SHAFT Troubleshooting Prop Shaft Removal Prop Shaft Overhaul

22 22 22 22

1 2 3

WHEELS AND TIRES Lifting, Jacking and Blocking Wheel and Tire Mounting Safe Handling of Split Rim Wheels

23 23 23

1 2

PARKING BRAKE System Troubleshooting Mechanical Release of Parking Brake

DESCRIPTION

24 24 24 24 24 24 24

SERVICE BRAKE Troubleshooting Air Brake System Air Brake Treadle Valve Air Brake Chambers Air Brake Compressor Rockwell Cam Brakes

25

STEERING COLUMN AND STEERING GEAR Troubleshooting Removing Steering Handwheel Removing Column and Gear and Gear From Column Steering Pump Removal and Overhaul

25 25 25

1 2 3

25

4

26 26 26 26

1 2 3

26 26 26

4 5 6

STEER AXLE Troubleshooting Steer Axle Removal Steer Axle Overhaul 2-Piece Kingpin Design-26-3-l Single Piece Kingpin Design-26-3-l 1 Steer Cylinder Removal and Overhaul Steer Cylinder Overhaul (Lot 7056 and above) Steering System Pressure Check

2

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

INDEX

GROUP

SECTION

29

1 2

29

DESCRIPTION

Hydraulic Filters (Prior to lot 8506) Hydraulic Filters (Lot 8506 and above)

HYDRAULIC COMPONENTS Troubleshooting Hydraulic Pump-General Tyrone Hydraulic Pump Overhaul J. S. Barnes Hydraulic Pump Overhaul Vickers Control Valve Overhaul Lift & Tilt Control Valve Overhaul Commercial Inter-tech Control Valve Overhaul Hydraulic System Pressure Check Hydraulic Diagrams

30 30 30 30 30 30 30 30 30 30

32 32 32 32 32

1 2 3 4 5

Tilt Cylinder Remove and Replace Tilt Cylinder Service Procedures (Thru Lot 7045) Tilt Cylinder Service Procedures (Lot 7055 & above) Tilt Cylinder Drift Test Tilt Cylinder Adjustment

33 33

1 2

Hydraulic Relief Valve Hydraulic Tilt Lock Valve(s)

34 34 34

1

UPRIGHT-CARRIAGE-FORKS Troubleshooting Fork Removal and Inspection

2

37 37

COUNTERWEIGHTS Counterweight Removal and Installation

39 39

DECAL REPLACEMENT AND PLACEMENT Decal Replacement and Placement

40 40 40

1 2

SPECIFICATIONS General Specifications PM Inspection and Drivers Daily Inspection Forms

Copyrighted3Material Intended for CLARK dealers only Do not sell or distribute

INTRODUCTION

SAFETY SIGNS AND MESSAGES

USER SAFE MAINTENANCE PRACTICES

Safety signs and messages are placed in this manual and also on the lift truck to provide instructions and to identify specific areas where potential hazards exist and special precautions should be taken. Be sure you know and understand the meaning of these instructions, signs and messages. Damage to the truck or death or serious injury to you or other persons may result if these messages are not followed.

NOTICE This message is used when special information, instructions or identification is required relating to procedures, equipment, tools, pressures, capacities and other special data.

IMPORTANT This message is used when special precautions should be taken to ensure a correct action or to avoid damage to or malfunction of the truck or a component.

The following instructions have been prepared from current industry and government safety standards applicable to industrial truck operation and maintenance.

These recommended procedures specify conditions, methods, and accepted practices that aid in the safe maintenance of industrial trucks. They are listed here for the reference and safety of all workers during maintenance operations. Carefully read and understand these instructions and the specific maintenance procedures before attempting to do any repair work.

When in doubt of any maintenance procedure, please contact your local Clark dealer.

1. Powered industrial trucks can become hazardous if maintenance is neglected. Therefor, suitable maintenance facilities, trained personnel and procedures must be provided.

2. Maintenance and inspection of all powered industrial trucks shall be done in conformance with the manufacturers recommendations.

3. A scheduled planned maintenance, lubrication and inspection program shall be followed.

A

CAUTION This message indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

A

WARNING This message indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

4. Only trained and authorized personnel shall be permitted to maintain, repair, adjust and inspect industrial trucks and in accordance with the manufacturer’s specifications.

5. Properly ventilate work area, vent exhaust fumes and keep shop clean and floor dry.

6. Avoid fire hazards and have fire protection equipment present in the work area. Do not use an open flame to check for level or leakage of fuel, electrolyte or coolant. Do not use open pans of fuel or flammable cleaning fluids for cleaning parts.

7. Before Starting Work On Truck:

A

DANGER This message indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations.

NOTE: The above terms have been adopted by Clark

Material Handling Company. The same terms may be used in different context in service literature supplied directly or indirectly by vendors of truck components.

(a) Raise drive wheels off of floor or disconnect power source and use blocks or other positive truck positioning devices. (b) Disconnect battery before working on the electrical system.

8. Before working on engine fuel system of gasoline or diesel powered trucks, be sure the fuel shut-off valve is closed.

9. Operation of the truck to check performance must be conducted in an authorized, safe, clear area.

Copyrighted Material -1 INTRODUCTION-1 Intended for CLARK dealers only Do not sell or distribute

July 97

INTRODUCTION

10. Before Starting To Drive Truck: (a) Be in operating position. (b) Be sure parking brake is engaged. (c) Put direction control in neutral. (d) Start engine. (e) Check functioning of direction and speed controls, steering, brakes, warning devices and any load handling attachments.

Before Leaving The Truck Stop truck.

Put directional control in neutral.

Apply the parking brake.

Stop the engine by turning off the ignition circuit.

Put blocks at the wheels if truck is on an incline.

Brakes, steering mechanisms, control mechanisms, warning devices, lights, governors, guards and safety devices and frame members must be carefully and regularly inspected and maintained in a safe operating condition.

13. Special trucks or devices designed and approved for hazardous area operation must receive special attention to ensure that maintenance preserves the original approved safe operating features.

14. Fuel systems must be checked for leaks and condition of parts. Extra special consideration must be given in the case of a leak in the fuel system. Action must be taken to prevent the use of the truck until the leak has been corrected.

20. Care must be taken to assure that all replacement parts, including tires, are interchangeable with the original parts and of a quality at least equal to that provided in the original equipment. Parts, including tires, are to be installed per the manufacturer’s procedures. Always use genuine CLARK or CLARK-approved parts.

21. Use special care when removing heavy componentsfromthe truck, such ascounterweight, seatdeck, upright, etc. Be sure that lifting and handling equipment is of the correct capacity and in good condition.

NOTICE -- You should also be familiar with additional operating and maintenance safety instructions contained in the following publications: ANSVASME B56.1 - Operator Control-Industrial Tow Tractors (Safety Standard For Powered Industrial Trucks). Published by: Society of Mechanical Engineers, United Engineering Center, 345 E. 47th Street, New York, N. Y. 10017.

NFPA 505-1982: Fire Safety Standard for Powered Industrial Trucks: Type Designations, Areas of Use, Maintenance and Operation. Available from: National Fire Protection Assoc., Inc., Batterymarch Park, Quincy, Ma 02269.

General Industrial Standards, OSHA 2206: OSHA Safety and Health Standards (29 CFR 1910), Subpart N-Materials Handling and Storage, Section 1910.178 Powered Industrial Trucks. For sale by: Superintendent of Documents, U.S. Government Printing Office, Washington, D. C. 20402.

15. The truck manufacturer’s capacity, operation and maintenance instruction plates, tags or decals must be maintained in legible condition.

16. Batteries, motors, controllers, limit switches, protective devices, electrical conductors and connections must be inspected and maintained in conformance with good practice. Special attention must be paid to the condition of electrical insulation.

17. To avoid injury to personnel or damage to the equipment, consult the manfacturer’s procedures in replacing contacts on any battery connection.

18. Industrial trucks must be kept in a clean condition to minimize fire hazards and help in the detection of loose or defective parts.

19. Modifications and additions that affect capacity and safe truck operation must not be done without the manufacturer’s prior written approval. Capacity, operation and maintenance instruction plates, tags or decals must be changed accordingly.

July 97

INTRODUCTION-l-2 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

SM575

CLclRK

PM Section

PM - PLANNED MAINTENANCE

A planned maintenance program of regular, routine inspections and lubrication is important for long life and trouble-free operation of your lift truck. Make and keep records of your inspections. Use these records to help establish the correct PM intervals for your application and to indicate maintenance required to prevent major problems from occurring during operation.

PROGRAM.

HOW TO PERFORM THE PM PERIODIC INSPECTION AND MAINTENANCE Visual Inspection First, perform a visual inspection of the lift truck and its components. Walk around the truck and take note of any obvious damage and maintenance problems.

Check for loose fasteners and fittings.

PM Report Form As an aid in performing and documenting your PM inspections, Clark has prepared a “GAS, LPG OR DIESEL PLANNED MAINTENANCE REPORT” form.

Copies of this form may be obtained from your authorized Clark dealer. We recommend that you use this form as a checklist and to make a record of your inspection and truck condition.

The periodic maintenance procedures outlined in this manual are intended to be used with the PM report form. They are arranged in groupings of maintenance work that are done in a logical and efficient sequence.

A check mark or entry is made on the PM Report Form when the PM is performed. Please note the special coding system for indicating the importance of needed repairs and/or adjustments.

When you have finished the PM inspections, be sure to give a copy of the report to the designated authority or the person responsible for lift truck maintenance.

Check to be sure all capacity, safety and warning plates and decals are attached and legible.

NOTICE: Do not operate a lift truck with damaged or missing decals and nameplates. Replace them immediately. They contain important information.

Inspect the truck, before and after starting engine, for any signs of external leakage: fuel, engine oil or coolant, transmission fluid, etc.

Check for hydraulic oil leaks and loose fittings. DO NOT USE BARE HANDS TO CHECK. Oil may be hot or under pressure.

Do not make repairs or adjustments unless authorized to do so.

Remove all jewelry (watch, rings, bracelets, etc.) before working on the truck.

Disconnect the batterygroundcable (-) fromthe engine or frame before working on electrical components.

Always wear safety glasses. Wear a safety (hard) hat in industrial plants and in special areas where protection is necessary or required.

SM575

A CAUTION

HYDRAULIC FLUID PRESSURE Do not use your hands to check for hydraulic leakage.

Fluid under pressure can penetrate your skin and cause serious injury.

Copyrighted Material PM-l-ldealers only Intended for CLARK Do not sell or distribute

July 97

CL’IRK

PM Section

Be sure that the driver’s overhead guard and any other safety devices are in place, undamaged and attached securely.

Forks

Inspect the load forks for cracks, breaks, bending and wear. The fork top surface should be level and even with each other. The height difference between both fork tips should be no more that 3% of the fork length.

A

WARNING If the fork blade at the heel is worn down more than 10 per cent, the load capacity is reduced and the fork must be replaced.

Check the overhead guard for damage. Be sure that it is properly positioned and all mounting fasteners are in place and tight. inspect the welds on the carriage and upright for cracks. Report any cracks noted immediately. Be sure that the mounting fasteners are in place and tight.

Inspect the upright assembly: rails, carriage rollers, lift chains, lift and tilt cylinders. Lookforobvious wear and maintenance problems, damaged or missing parts.

Check for any loose parts or fittings. Check for leaks, any damaged or loose rollers and rail wear (metal flaking). Carefully check the lift chains for wear, rust and corrosion, cracked or broken links, stretching, etc.

Check that the lift and carriage chains are correctly adjustedto have equal tension. Checkthatthe lift chain anchor fasteners and locking means are in place and tight.

Be sure all safety guards and chain retainers are in place and not damaged. Inspect the carriage stops and cylinder retainer bolts. Check all welded connections.

Inspect the forks for twists and bends. Put a 2” thick metal block, at least 4” wide by 24” long on the blade of theforkwith the 4” surface against the blade. Put a24” carpenters square on the top of the block and against the shank. Check the fork 20” above the blade to make sure it is not bent more than 1 inch maximum.

If the fork blades are obviously bent or damaged, have them inspected by a trained maintenance person before operating the truck.

Inspect all lift line hydraulic connections for leaks.

Check the lift cylinder rods for wear marks, grooves and scratches. Check the cylinder seals for leaks.

A

CAUTION Uprights and lift chains require special attentionand maintenance to maintain them in a safe operating condition. Refer to Lift Chain Maintenance section for addition information.

July 97

Inspect the fork locking pins for cracks or damage.

Reinsert them and note wherther they fit properly.

Copyrighted Material PM-1 -2 Intended for CLARK dealers only Do not sell or distribute

SM575

PM Section

Wheels and Tires Check the condition of the drive and steer wheels and tires. Remove objects that are embedded in the tread.

Inspect the tires for excessive wear or breaks or “chunking out”.

Function Tests Now be sure that all controls and systems are functioning correctly.

After checking that the parking brake is set, test horn, lights and all other safety equipment and accessories.

Be sure they are properly mounted and working correctly.

Press the horn button to check horn function. If the horn or any other part does not operate, report the failure and have it repaired before the truck is put in operation.

.:::.. g::: l!ciqpiB Y:::..

Y:.,

..:?

2

“$

.::,

Check all wheel lug nuts or bolts to be sure none are loose or missing. Have missing bolts or lug nuts replaced and tightened to the the correct torque before operating truck. Torque to 100-l 20 Ibf ft [135,6 - 162,7 f&m]. _

.,,,.:.:g$c?.‘..

:“‘~::::i::i::i:,::, ‘

:<A’

Check the operation of the neutral start switch by placing direction control lever in forward or reverse and turning key switch to START position. Starter must not engage until direction control lever is moved to NEUTRAL position.

Water Temperature

Oil Pressure _

Hour Meter

Brake Air Pressure

y

Converter

A

WARNING Check tire pressure from a position facing the tread of the tire, not theside. Usea long handled gauge to keep your body away from the side. If tires are low, do not add air.

Check with a mechanic. The tire may require removal and repair.

Incorrect (low) tire pressure can reduce stability of your lift truck.

Proper cold inflation is 100 p.s.i.

SM575

Copyrighted Material PM-l-3dealers only Intended for CLARK Do not sell or distribute

/ Key/Start Switch

Light

July 97

USE PERMATEX & CRANE SEALER ONLY WHERE SPECIFIED. ALL LEAD IN CHAMFERS FOR OIL SEALS, PISTON RINGS & 0’ ‘ RINGS MUST BE SMOOTH & FREE FROM BURRS. INSPECT AT ASSEMBLY. LUBRICATE ALL PISTON RING GROOVES & 0” BEFORE ASSEMBLY.

RINGS WITH OIL

APPLY VERY LIGHT COAT OF PERMATEX NO. 2 TO O.D. OF ALL OIL SEALS BEFORE ASSEMBLY. AFTER ASSEMBLY OF PARTS USING PERMATEX OR CRANE SEALER, THERE MUST NOT BE ANY FREE OR EXCESS MATERIAL THAT COULD ENTER THE OIL CIRCUIT. APPLY LIGHT COAT OF CRANE SEALER TO ALL PIPE PLUGS. APPLY A THIN COATING OF GREASE BETWEEN SEAL LIPS ON LIP TYPE SEALS PRIOR TO ASSEMBLY. APPLY A LIGHT COAT OF PERMATEX NO. 2 TO ALL THRU HOLE STUD THREADS.

BEFORE ASSEMBLY

OF BVSHING

TO COVER

-(

TIGHTEN 3. _TURBINE 35 Lb_FTBOLTS

\

NOTE

POSITION

OF SEAL

/ GEAR

[40,7 - 47,4 N.m]

MUST

SE LOOSE/INTERNAL

TOWARD

FIT

RETAINER

RING

BRG.

a/f

/

/ _$PPLY

SEE ELASTIC STOP NUT TORQUE CHART PERMATEX

OF PLUG

BEFORE

NO. 2 TO 0.0.

ASSEMBLY.

LOW CLVTCH S-OUTER STEEL PLATES 9 INNER FRICTION PLATES ASSEMBLE ALTERNATELY STARTING WITH OUTER STEEL PLATE.

OUTPUT

II

k7. “~

/

1-I

-;3K$LM~“‘CAL

1

TIGHTEN OIL SCREEN ASSY. 10 - 15 Lb-FT [13,6 - 20.3 N-m] 28310

SERIES

POWER SHIFT

TRANSMISSION

SEE ELASTIC STOP NUT TORQUE CHART

WITH

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

VARIOUS

OPTIONS

NOTE METRIC DIMENSIONS SHOWN !N BRACKETS [ 1

COOLER INSTALL GAUGE FOR CONVERTER

CLUTCH PRESSURE CHECK POINT**

ii FROM COOLER TRANSMISSION DISTRIBUTOR

OIL LEVEL CHECK POINT

/

TO LUBE

IN THIS LINE “OUT” PRESSURE*

CHARGING PUMP OIL SUCTION SCREEN

28000

SERIES

FROM

PLUMBING

DIAGRAM

CONVERTER

TYPE “A” FILTER USE REPLACEMENT ELEMENT 215502 DO NOT SUBSTITUTE

INSTALL GAUGE IN THIS LINE FOR CONVERTER “OUT” PRESSURE*

CLUTCH PRESSURE CHECK POINT**

FROM COOLER TO TRANSMISSION LUBE DISTRIBUTOR

CHECK

NOTE: ALL TYPE “A” FILTERS USE CLARK FILTER REPLACEMENT ELEMENT PART NO. 215502.

w CHARGING PUMP OIL SUCTION SCREEN

*CONVERTER PRESSURE

**CLUTCH

OUT

PRESSURE

CONVERTER

POINT

DO NOT

28000

SERIES PLUMBING DIAGRAM (WITH REMOTE FILTER)

OUTLET

OIL

TEMP.

160°-2OO=‘F

SUBSTITUTE.

[82,3°-93,30C1TRANSMlSS10N

OPERATING SPECIFICATIONS: 25 P.S.I. [172,4 kPa] MINIMUM PRESSURE AT 2000 AND A MAXIMUM OF 70 P.S.I. L482.6 kPa1 OUTLET WITH ENGINE OPERATING AT NO-LOAD GOVERNED

R.P.M. ENGINE PRESSURE SPEED.

IN

NEUTRAL

SPEED

240-280 PSI [I 654,8 - 1930,5 kPa1 WITH PARKING BRAKE SET (SEE NOTE). OIL TEMPERATURE 180-200” F. [82,2 - 93,3 o C.], ENGINE AT IDLE (400 TO 600 RPM). SHIFT THRU DIRECTION AND SPEED CLUTCHES. ALL CLUTCH PRESSURE MUST BE EQUAL WITHIN 5 PSI. [34,5 kPa] IF CLUTCH PRESSURE VARIES IN ANY ONE CLUTCH MORE THAN 5 PSI. [34,5 kPa1 REPAIR CLUTCH. NOTE: NEVER USE SERVICE BRAKES WHILE MAKING HAVING BRAKE ACTUATED DECLUTCHING IN FORWARD TRUE READING. ALWAYS

USE

PARKING

BRAKE

WHEN

MAKING

CLUTCH AND/OR

CLUTCH

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

PRESSURE CHECKS. UNITS REVERSE WILL NOT GIVE A

PRESSURE

CHECKS.

MAINTENANCE The instructions contained herein cover the disassembly and reassembly of the transmission in a sequence that would normally be followed after the unit has been removed from the machine and is to be completely overhauled. It must also be understood that this is a basic 28000 transmission with many options. Companion flanges and output shafts with and without disconnect assemblies may vary on specific models. The units are very similar to trouble shoot, disassemble, repair, and reassemble.

AND SERVICE CAUTION: Cleanliness is of extreme importance and an absolute must in the repair and overhaul of this unit. Before attempting any repairs, the exterior of the unit must be thoroughly cleaned to prevent the possibility of dirt and foreign matter entering the mechanism.

DISASSEMBLY

Figure

Side view of Transmission.

1

3-speed short drop

output

power

shift

Figure 3 Remove charging pump to regulating valve stud nuts.

Remove pump and filter adaptor.

Figure 4

Figure 2 Remove filter housing and filter element.

Remove pressure regulating valve assembly.

NOTE: See lubrication section for filter cartridge change interval.

Copyrighted 1Material Intended for CLARK dealers only Do not sell or distribute

Figure 8 Install two bolts in threaded holes 180’ apart to remove cover from impeller. NOTE: Some units may have pry slots instead

Figure 5

Remove pump drive sleeves.

of threaded

holes.

Figure 6

Remove control valve bolts and washers. Remove control valve. Use caution as not to lose detent springs and balls.

Figure 9

Remove impeller cover.

Figure 7

Remove impeller cover bolts.

Figure

IO

If impeller cover bearing is to be replaced, remove retainer ring. Pry bearing from pocket.

Copyrighted Material 2 Intended for CLARK dealers only Do not sell or distribute

Figure

Remove turbine

retaining

Figure

Remove

Figure

locating ring.

reaction

member

NOTE:

For special turbine

Remove reaction

member

Figure

oil baffle

Copyrighted3 Material Intended for CLARK dealers only Do not sell or distribute

15

and spacer.

13

Remove

14

retainer

Figure

12

Remove turbine and hub assembly. to hub assemblv see Daae 33.

Remove turbine

Figure

11

ring.

retainer

ring.

16

ring.

Figure

20

Remove pump drive gear bearing support bolts.

Figure

17

Using pry slots in converter housing, pry oil baffle and impeller from housing.

NOTE: Impeller, oil baffle removed as an assembly.

and impeller

hub gear are

Figure

21

Move center gear toward the rear of converter housing.

Remove pump drive gear on the right.

Figure

18

Remove stator support to housing bolts.

Figure

19

Remove stator support.

Figure

NOTE:

Support must be turned to clear pump drive gear.

22

Remove pump drive gear on the left.

Copyrighted Material 4 Intended for CLARK dealers only Do not sell or distribute

Figure 26 Figure 26 shows forward & 2nd clutch locating ring with forward and 2nd clutch in position.

Figure 23 Remove center pump drive gear.

Figure 24 Remove bolts securing converter housing to transmission housing.

Figure 25 Support converter housing with a chain fall. Using spreading type snap ring pliers, spread ears on forward clutch front bearing retaining ring. Holding snap ring open pry converter housing from transmission housing.

Figure 27 Figure 27 shows forward and 2nd clutch in converter housing. If clutch remained in converter housing, spread ears on snap ring as explained in Figure 25 and remove clutch. If clutch assembly remained in transmission case remove same by pulling straight out.

Figure 28 Remove turbine shaft gear retainer ring and gear.

Copyrighted 5Material Intended for CLARK dealers only Do not sell or distribute

Figure 29

From rear of converter housing tap turbine bearing from housing.

shaft and

Figure 32

Remove impeller hub gear.

Figure 33

Figure 30

Remove turbine shaft and bearing from converter housing.

Lift oil baffle and oil seal assembly from impeller.

Figure 31

Remove impeller hub gear retainer ring.

Figure 34 Remove impeller

to hub bolts.

Copyrighted Material 6 Intended for CLARK dealers only Do not sell or distribute

Figure

35

Remove impeller hub O-Ring.

Figure

38

Remove output flange nut, washer and O-Ring.

Figure

39

Remove output flange.

Figure

36

Remove 2nd gear retaining ring and 2nd gear.

Figure

NOTE: If parking brake is used, remove brake drum and flange, upper and lower brake shoe return springs, brake shoes, and actuator arm. Remove brake backing plate bolts and backing plate.

37

Remove 2nd speed clutch shaft pilot bearing.

Figure

40

Remove low shaft bearing cap bolts and bearing cap.

Copyrighted 7 Material Intended for CLARK dealers only Do not sell or distribute

Figure

Figure

41

Remove output shaft bearing cap bolts and bearing cap.

CAUTION:

Figure

44

Remove rear cover bolts. Using pry slots provided, pry cover from transmission housing tapping on low clutch and output shaft to allow cover to be removed without shaft binding.

Do not lose output shaft rear bearing lock ball.

42

Remove low shaft rear bearing locating ring.

Figure

45

Remove low shaft rear bearing retainer ring.

Figure

43

Remove output shaft rear bearing locating ring.

Figure

Remove low clutch rear bearing.

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

46

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F iaure 50 Remove output shaft assembly from housing.

Figure 47

Remove low speed drive gear snap ring and drive gear.

Figure 51 Remove low clutch assembly

CLUTCH

from housing.

DISASSEMBLY

NOTE: Two clutches are shown being disassembled.

The low

clutch, and the forward and second. All clutches are disassemFigure 48

bled in a similar manner. The quantity of clutch discs will differ

Remove reverse and 3rd clutch assembly.

between

the low clutch and the forward,

reverse, second and

third. Do not mix the friction discs in the low clutch with the fric-

tion discs of any of the other clutches. (See note, Figure 86.)

LOW

CLUTCH

DISASSEMBLY

Figure 49

From the front of the transmission housing, tap the output shaft, gear and bearing from pilot location in case.

Figure 52 Remove

low clutch shaft rear bearing.

Copyrighted9 Material Intended for CLARK dealers only Do not sell or distribute

Figure Figure

53

Remove low speed gear retainer ring.

Figure

56

Remove clutch end plate and inner and outer clutch disc.

See Note Figure 86.

54 Figure

Remove low speed gear and outer bearing.

57

Remove low gear inner bearing.

Figure

Figure

55

Remove clutch end plate retainer ring.

58

Remove clutch piston return spring. A sleeve with a portion removed is recommended for removing the clutch piston return spring, washer, and retainer ring. Sleeve shown is a common pipe, with a l-1/2” . wide x 1” high (39,Ox26,0mm) opening. The pipe is 6” long, 3-l/4” O.D., 2-314” I.D. (155,Ox85,0x78,0mm).

Compress spring retainer washer. Through opening remove spring retainer snap ring. Release tension on spring retainer. Remove spring retainer and spring. Turn clutch over and tap clutch shaft on a block of wood to remove clutch piston.

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

FORWARD

& 2ND CLUTCH DISASSEMBLY

Figure 62 Remove front

bearing locating ring.

Figure 59 Remove clutch shaft piston rings and expander springs.

Figure 63 Figure 60 Remove front

bearing retainer

Remove front

bearing.

Remove clutch driven gear and outer bearing.

ring.

Figure 64

Figure 61 Remove

inner bearing.

Copyrighted Material 11 Intended for CLARK dealers only Do not sell or distribute