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Clark CMP50-75sDL Forklift Service Repair Manual

service repair manual

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Clark CMP50-75sDL Forklift Service Repair Manual

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  1. SF50-75SD/L CMP50-75sD/L SERVICE MANUAL RATED CAPACITY : 5000~7500kg Part No. 8034927 Manual No. SM690 Rev.2 Jun,2004 Manufactured by #40–1, Ungnam-Dong, Changwon-City, Kyungnam, Korea

  2. G E N E R A L FOREWORD 00 02 FOREWORD 1 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 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. is used to mark safety precautions in this 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)

  3. G E N E R A L 00 FOREWORD PAGE 02 2 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 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 Remarks Special safety precautions are necessary when performing the work. Safety Special technical precautions or other precautions for preserving standards are necessary when performing the work. Caution Tightening torque Places that require special attention for the tightening torque during assembly. Places that require proper tools used in assembling and disassembling. Tool Adhesive Places to be applied with adhesive. Lubricating Places where oil or lubricant must be added.

  4. G E N E R A L SAFETY 00 03 1 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.

  5. G E N E R A L 00 SAFETY PREPARE FOR EMERGENCIES 03 2 • 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, ambul- ance 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. 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

  6. G E N E R A L SAFETY 00 03 AVOID HARMFUL ASBESTOS DUST 3 • Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled asbestos fibers may cause lung cancer. EX025

  7. G E N E R A L 00 SAFETY PREPARATIONS FOR WORK 03 4 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 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. EX033 FX1008 • 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. EX042

  8. G E N E R A L SAFETY 00 03 USE HANDHOLDS AND STEPS 5 • 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 repaired. • Never operate with wet or oily hands and feet. FX019 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. FX020

  9. S P E C I F I C A T I O N S GENERAL LOCATION OF COMPONENTS 01 01 1 1. Mast 2. Lift cylinder 3. Control lever (Tilt, Lift) 4. Carriage 5. Forks 6. Overhead guard 7. Steering wheel 8. Driver’s seat 9. Engine hood 10. Counterweight 11. Steering tire 12. Tilt cylinder 13. Driving wheel 14. Frame 15. Steering axle 16. Driving axle 17. Rear hood 18. LPG tank (LPG only)

  10. P O W E R T R A I N GENERAL INFORMATION GENERAL INFORMATION This section describes the method of detaching the transmisson from the vehicle, and the diassembling, assembling, and overhauling of it. CAUTION Cleanliness is of extreme importance in the servicing, repair and overhaul of the transmission. Before attempting any repairs thoroughly clean the exterior housing to prevent the possibility of dirt entering the unit. Always conduct repairs in a clean, dust free environment. GENERAL FEATURES The torque delivered by the engine is multiplied by the torque converter and powershift transmission to a maximum of 2.00 times, and is transmitted via the drive shaft to the axle differential, axle shaft, final drives and driving wheels. 20 01 OPERATION PRINCIPLE AND FUNCTION 1 Engine → → → Torque converter Transmission Drive shaft → → → → Differential Axle shaft Final drive Driving wheel

  11. P O W E R T R A I N GENERAL INFORMATION • The torque converter is a type of hydraulic coupling that consists of an impeller connected to the engine crankshaft, a turbine connected to the converter output shaft, and a stator which redirects the oil from the turbine for recirculation into the impeller. As the load increases slippage will occur between the impeller and turbine, so the rotational speed of the turbine will approach O rpm (stall). Therefore as the output shaft is decreasing in speed the torque multiplication will increase to a maximum of 2.0 times when the output shaft is at O rpm. • The electric shift control unit located on the steering wheel column energizes the selected solenoid valves thus directing pressurized oil to the directional and range (gear) clutches. The range and directional clutches direct the power flow through the gear train to provide the desired speed range and direction. The reduction ratio for the range clutches are : 5.02–1st, 2.56–2nd, and 1.00–3rd. • The differential gear assembly consists of the pinion/bevel ring gear set and the differential gear set. Power delivered from the transmission is reduced by the pinion/ring gear set and then transmitted to the left/right axle shafts by the differential gear set. • The final reduction of the power transmitted to the axle shafts occurs in the planetary unit of each axle hub. 20 01 2

  12. P O W E R T R A I N TRANSMISSION TRANSMISSION DISASSEMBLY • Remove drive plate attaching capscrews and washers. Remove drive plate and backing ring. • Remove torque converter plug retainer ring. 20 02 1 • Remove plug and O–ring. • Remove torque converter to turbine shaft retainer ring.

  13. P O W E R T R A I N TRANSMISSION • Remove torque converter assembly. • Remove torque converter to shaft locating ring. 20 02 • Remove filter assembly. 2 • Remove sleeve. pressure regulator and regulator Special tool can be fabricated.

  14. P O W E R T R A I N TRANSMISSION • Remove charging pump permanent pump hole cover. (Not used when auxiliay pump is used.) • Remove washers. Remove pump and gasket. pump mounting capscrews and 20 02 • Remove converter housing to transmission case capscrews and washers. 3 • Remove converter housing and gasket.

  15. P O W E R T R A I N TRANSMISSION • Remove impeller hub gear. • Remove solenoid valve cartridge retainer nut and O–ring. 20 02 • Remove solenoid coil and O–ring. 4 • Loosen solenoid valve cartridge.

  16. P O W E R T R A I N TRANSMISSION • Remove remaining solenoid valves. valve. Repeat procedures for • Remove bore plug and O–rings. This plug is used in the middle bore position in the 3 speed version only. 20 02 • Remove spacer plate capscrews and washers. 5 • Pry spacer plate away from transmission case at dowel pin holes. Remove spacer plate and gasket. Note aligning studs to facilitate spacer removal.

  17. P O W E R T R A I N TRANSMISSION • Remove 1st and 2nd clutch assembly. • Remove forward and reverse clutch assembly. 20 02 • Remove 3rd clutch assembly. 6 • Remove 3rd speed clutch shaft pilot bearing.

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  19. P O W E R T R A I N TRANSMISSION • Remove oil baffle capscrew and washer. • Remove oil baffle. 20 02 • Remove oil supply tube O–ring. 7 • Remove supply tube and screen assembly.

  20. P O W E R T R A I N TRANSMISSION • Remove 3rd clutch gear and output shaft. • Remove 1st and 2nd clutch shaft rear roller bearing. Remove 3rd gear roller bearing. 20 02 • Remove roller bearing locating ring. 8 • Remove inner case set screw plug. Remove clutch shaft distributor sleeve set screw.

  21. P O W E R T R A I N TRANSMISSION • Use a hammer puller (or any suitable puller) as shown to remove distributor sleeve and shaft pilot bearing. • Pilot bearing and distributor sleeve removed. 20 02 • Remove modulator housing sleeve and O–ring. 9 • Remove inner, middle, and outer valve springs and valve stop pin.

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