SF35-45D/L CMP40-50sD/L
SERVICE MANUAL
RATED CAPACITY : 3500~5000kg
Part No. 8034283 Manual No. SM712 Mar,2004 Manufactured by
#40–1, Ungnam-Dong, Changwon-City, Kyungnam, Korea
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FOREWORD
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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.
SAFETY • 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)
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PAGE
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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
âž‚ 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. Symbol
Item
Safety
Remarks Special safety precautions performing the work.
are
necessary
when
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing the work.
Tightening torque
Places that require special attention for the tightening torque during assembly.
Tool
Places that require proper tools used in assembling and disassembling.
Adhesive
Lubricating
Places to be applied with adhesive.
Places where oil or lubricant must be added.
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!
WARNING
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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 objecs, 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 OperatorÕs 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. P/NO.6092-13130
GENERAL PRECAUTIONS SAFETY PRECAUTIONS • 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. EX048
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PREPARE FOR EMERGENCIES
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• 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.
EX036
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.
EX028
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.
EX043
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AVOID HARMFUL ASBESTOS DUST
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• Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled asbestos fibers may cause lung cancer.
EX025
S P E C I F I C A T I O N S GENERAL
LOCATION OF COMPONENTS
01 01 1 10
17 9 6 3
18
8 7
2 1
4 5
15 11
1. 2. 3. 4. 5. 6. 7. 8. 9.
14
16
13
Mast Lift cylinder Control lever (Tilt, Lift) Carriage Forks Overhead guard Steering wheel Driver’s seat Engine hood
12
FX983
10. 11. 12. 13. 14. 15. 16. 17. 18.
Counterweight Steering tire Tilt cylinder Driving wheel Frame Steering axle Driving axle Rear hood LPG Tank(LPG Only)
S P E C I F I C A T I O N S GENERAL
OPERATOR’S CAB
01
POWERSHIFT TRANSMISSION
01 2 3
1
8
7
9
2
4 13 6
5
10
11
14
1. Instrument panel 2. Turn signal lever 3. Shift lever (forward–reverse and speed) 4. Parking brake lever 5. Lift control lever 6. Tilt control lever 7. Horn
12
8. 9. 10. 11. 12. 13. 14.
Steering knob Steering wheel Inching pedal Brake pedal Accelerator pedal Floor plate Start key
S P E C I F I C A T I O N S GENERAL
INSTRUMENT PANEL
01
POWERSHIFT TYPE
01 3
1
9
14
11
2
3
4
5
6
15
7
12
8
1
10
13 FX986
1. Turn signal pilot lamps 2. Transmission abnormality warning lamp 3. Transmission oil pressure warning lamp 4. Engine oil pressure warning lamp 5. Air preheating pilot lamp 6. Parking brake pilot lamp 7. Transmission oil temperature warning lamp
8. 9. 10. 11. 12. 13. 14. 15.
Battery discharging warning lamp Beacon switch (Option) Panel check switch Fuel level gauge(Diesel) Hour meter Coolant temperature gauge Auto/Manual switch LPG Gauge(LPG)
S P E C I F I C A T I O N S GENERAL
DIMENSION AND WEIGHT
01 01 4
Standard mast mounted Specification Item
Dimension
Weight
Unit Sym.
kg (lb)
CMP40D CMP45D CMP50SD CMP40L CMP45L CMP50SL SF35D SF40D SF45D SF35L SF40L SF45L
–
6341 [6586] (13980 [14520])
6569 [6814] (14482 15022])
6981 [7226] (15390 [15931])
6341 [6586] (13980 [14520])
6569 [6814] (14482 15022])
6981 [7226] (15390 [15931])
4160 (164)
4200 (165)
4390 (173)
4160 (164)
4200 (165)
4390 (173)
Overall length (including forks)
mm (in)
A
Overall width
mm (in)
B
1550[1900] (61[75])
Overall height
mm (in)
H
2257[2221] (89[87])
Min. ground clearance
mm (in)
J/K
173[149] (7[6])
Overhead guard height
mm (in)
C
2243[2227] (88[87.5])
Wheel base
mm (in)
D
1950(77)
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MAIN SPECIFICATION Classification
Specification
Rated input
81 hp
Rated input rotational speed
2700 rpm
Max. input torque
30 kgf·m
Gear shifting step
Forward/Reverse 2nd
Gear shifting method
Clutch pack
Gear shifting means
Direct
Increasing the speed
Forward
Gear shifting pattern
Reverse Decreasing the speed
20 01 4
Service brake
Hydraulic wet multi disc
Parking brake
Mechanical drum brake
Total
Forward
reduction ratio
Reverse
1st
30.395
2nd
17.132
1st
30.395
2nd
17.132
Total weight
440 kg
Transmission Oil Axle
Kind
CLARK OIL#2776236
Capacity
13 l
Replacing period
Initial 50hr, after every 1000hr
Kind
Total T/M DA 80W/90, TORQUE FLUID 56,#2776236
Capacity
9l
Replacing period
Initial 50hr., after every 1000hr.
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DRIVE AXLE DISASSEMBLY • Remove the magnetic plug in each axle hub and drain the oil.
• Remove the magnetic plug on the center axle housing and drain the oil.
20 02 1 • Remove the capscrews and lock washers for hub the assembly.
! Warning The hub assembly is heavy, support it with a sling and crane that are in good condition and of adequate load rating.
• Remove the hub assembly with a crane. ! Warning Match mark the hub flange and the axle housing flange prior to disassembly.
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• Remove the axle shaft. ! CAUTION The length of right and left is different. Pay attention to it. • The lengths of shafts are different. Take a mark on the shaft for assembly.
• Remove the hexagon socket capscrews and lock washers from the differential carrier.
20 02 2
• Separate the differential carrier assembly and axle housing assembly.
DISASSEMBLY AND ASSEMBLY OF AXLE HOUSING ASSEMBLY Disassembly • Remove the air breather.
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• Remove the plug.
• Remove the brake bleeder screw.
20 02 • Remove the brake line fitting.
• Remove the brake piston return spring and spring locking ring. Push each spring inward with the plunger, reach through the center of the piston into the housing and unhook the spring from the lock ring located behind the flange.
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• Remove the brake piston, then pull out the lock ring.
• Remove the 1st square ring.
20 02 4
• Remove the 2nd square ring.
Assembly • Apply grease onto both new square rings, and install carefully so they do not twist.
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• Insert the lock ring into the housing behind the flange.
• Insert the brake piston. ! CAUTION Take care to prevent the square rings from being pushed out of the grooves.
• To install the piston return springs, reach throught the center of the piston into the housing, pick up and hold the lock ring in place then push each spring inward and hook it onto the lock ring as shown. Ensure that each spring is securely locked into the slot in the end of the plunger.
20 02 5
• Install the copper washer onto the brake line fitting and tighten it.
! CAUTION If the copper washer isn't installed properly, the brake will not work due to brake oil leakage.
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• Apply Loctite #569 onto the brake bleeder screw fitting and tighten it.
• Supply air to the brake line fitting and check the operating condition of the brake piston.
20 02 6
• Apply Loctite #569 onto the air breather and tighten it.
• Tighten the drain plug.
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DISASSEMBLY AND ASSEMBLY OF HUB Disassembly • Remove the disc carrier gear.
• Pull out the snap ring with snap ring pliers. Disassemble the sun gear and disc carrier.
20 02 7 • Remove the retaining ring.
• Remove the brake plate.
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• Remove the friction brake discs and steel discs.
• Remove the plate cover capscrews of the wheel flange and remove the plate.
20 02 8
• Remove
the capscrews.
lock
plate
• Remove the lock plate.
hexagon
socket
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• Remove the bearing adjusting nut.
• Remove the center adjusting spacer.
• Disassemble the wheel flange hub.
20 02 9
• Remove the O–ring.
• Remove the bearing and wheel studs from the flange. (Remove the studs only if required.)
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• Remove the carrier shaft/planetary from the ring gear hub.
• Remove the bearing with a proper puller.
20 02 10
• Remove the planetary pins, gears and thrust washers.
• Remove the bearings.