1 / 23

Clark CQ202530 D Forklift Service Repair Manual

service repair manual

km76dnmop7mk
Download Presentation

Clark CQ202530 D Forklift Service Repair Manual

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. SERVICE MANUAL CQ 20/25/30 D/L RATED CAPACITY: 2000 – 3000kg Book No. SM 794 Aug. 2008

  2. Truck Models Covered by this Manual This manual consists of “base” module that pertains to all CQ20-30 models and other modules that per- tain only to specific models. Manuals shipped with the truck contain the base module and the modules specific to the purchased truck. You may, however, purchase specific modules and expand your manual to fully cover multiple models. To do so, order the desired modules as you would any other Clark part. Arrangement and Use of this Manual Clark arranges parts and service procedures by stan- dardized Groups. In this manual, Groups are similar to “chapters”. You can quickly locate a specific point in the manual by using the headers and footers that appear on every Section page. The following illustration points out these areas. Each Group begins with a table of contents that shows the Sections contained within the Group. Lengthy Sections also begin with a table of contents. Group ID Each Group and Section has an identifying name and number, or “ID”. Each page also has a unique ID. The page ID con- sists of three numbers separated by hyphens. The three numbers represent the Group number, the Sec- tion number, and the page number. For example, “00-1-2” on the lower corner of the page indicates Group 00, Section 1, page 2. The Group number sometimes has a letter or letters added to it in parentheses if one or more variations of the Group exist. For example, if the truck has a stan- dard transaxle, Group 06 is expressed as “06(S)”; if the truck has a hydrostatic transmission, Group 06 is expressed as “06(H)”. Manual ID Group-Section-Page This manual is intended for the use of trained service personnel. Please read Group SA, “Safe Mainte- nance”, and the Operator’s Manual before working on or operating the truck.

  3. CONTENTS CONTENTS (Group Index) Group 23. Brake / Inching System Group PS. Periodic Service Group 25. Steering Column and Gear Group 00. Engines Group 26. Steer Axle Group 01. Cooling System Group 29. Hydraulic Pump, Sump, and Filters Group 02. Fuel System Group 30. Hydraulic Control Valve/Lift Circuit Group 03. Air Induction System Group 32. Tilt Cylinders Group 06. Transaxle Group 34. Upright Group 12. Ignition System Group 38. Counterweight, Sheet Metal & Chassis Group 13. Electrical System Group 22. Wheels and Tires 34 32 23 06 25 30 13 02 00 03 29 13 01 22 26 38 SM 794 CONTENTS

  4. GROUP PS GROUP PS PERIODIC SERVICE Maintenance Schedules ............................ Section 1 The Planned Maintenance Program ....... Section 2 SM 794 PS-0

  5. Group PS, Periodic Service Section 1 Maintenance Schedules “Periodic Service” and “Planned Maintenance” Determining Maintenance Intervals Time intervals on the charts on the next four pages and elsewhere in this manual relate to truck operating hours as recorded on the hourmeter, and are based on experience Clark has found to be convenient and suitable under nor- mal operation. Standard operating condition classifica- tions are: The term “periodic service” includes all maintenance tasks that should be performed on a regularly scheduled basis. The term “Planned Maintenance” indicates a formalized program of basic inspections, adjustments, and lubrica- tions that the Clark service organization provides custom- ers at a prescribed interval, usually 50-250 hours. The recommended basic “Planned Maintenance” procedure is given in Section 2 of this Group. Normal Operation: Eight-hour material handling, mostly in buildings or in clean, open air on clean, paved surfaces. Severe Operation: Prolonged operating hours or constant usage. The current Section,“Maintenance Schedules,” specifies all maintenance tasks—including Planned Maintenance tasks—that should be performed periodically, and sug- gests intervals at which they should be performed. Extreme Operation: • In sandy or dusty locations, such as cement plants, lumber mills, and coal dust or stone crushing sites. High-temperature locations, such as steel mills and foundries. Sudden temperature changes, such as constant trips from buildings into the open air, or in refrigeration plants. • • If the lift truck is used in severe or extreme operating con- ditions, the maintenance intervals should be shortened accordingly. IMPORTANT MAINTENANCE INTERVALS. If the lift truck is used in severe or extreme operating conditions, the maintenance intervals should be shortened accordingly. Since the operating environments of lift trucks vary widely, the above descriptions are highly generalized and should be applied as actual conditions dictate. SM 794 PS-1-1

  6. Group PS, Periodic Service LUBRICATION Perform periodic maintenance, replacement and lubricating according to following lubrication chart to maintain optimum condition. Otherwise service, life will be reduced and breakdowns may occur frequently. LUBRICATION CHART CO Antifreeze G Lubricant Grease HO Hydraulic oil EO Replace Engine oil FO Fuel Check Transaxle oil TO Brake fluid BO Transaxle oil filter Lift chain RH, LH(2points) Mast mounting RH, LH(2points) EO G Tilt cylinder end RH, LH(2points) Brake fluid BO BO G Transaxle oil TO TO Hydraulic oil HO HO Engine oil EO EO Hydraulic oil filter Engine oil filter Air cleaner Coolant CO CO Steer king pin RH, LH(4points) G Hydraulic breather Steering linkage RH, LH(4points) G Wheel bearing RH, LH(2points) Fuel (LPG) FO Every 10 hours or daily Every 200 hours or monthly Every 500 hours or every 3 months Every 1000 hours or every 6 months Every 2000 hours or yearly SM 794 PS-1-2

  7. GROUP 06 GROUP 06 TRANSAXLE Structure and Maintenance......................Section 1 Disassembly................................................Section 2 Assembly......................................................Section 3 SM 794 06-0

  8. Group 06, TRANSAXLE Section 1 Structure and Maintenance Construction Pump drive is from converter impeller hub gear, through an idler gear to the pump gear mounted on charging pump shaft. 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 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 pin- ion gear inner tapered roller bearing cup in the trans- misson case. Pinion shaft bearing preload is adjusted with shims behind outer bearing cone on the pinion shaft. • • • • Power flow is from torque converter turbine, to tur- bine (clutch) shaft and gears, then through either for- ward 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 bear- ing. SM 794 06-1-1

  9. Group 06, TRANSAXLE backing plates are bolted to mounting flanges on wheel end housings. Wheel bearings are lubricated from the transaxle sump. Final drive ring gear is bolted to differential carrier. Differential support is by opposed tapered roller bearings mounted on inner end of wheel end hous- ings, which are bolted to openings in transmission case at the sides of the differential. Differential bear- ing preload and ring gear clearance (backlash) is maintained by shims placed behind differential bear- ing cones on wheel end housings. Adjustment of dif- ferential bearing preload or ring gear backlash requires trial assembly, checking, and disassembly of wheel end housings until correct adjustment is obtained. Control valve is mounted on pad at top of transmis- sion case. Oil from charging pump flows via filter and pressure regulator to control valve through an exter- nal oil supply line. Oil from control valve is delivered to clutches through passages in housing and oil dis- tributor 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 con- verter. 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 Hydraulic Circuit SM 794 06-1-2

  10. Group 06, TRANSAXLE 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. ! IMPORTANT When the transaxle is new or rebuilt, it is rec- ommended to change the oil filter afterthe first 50 hours and again after 1000 operating hours. ① Remove drain plug from bottom of transmission case. Drain old oil into suitable drain pan. Fluid Level Check ② Remove old oil filter. The oil filter is mounted near the top of converter housing abovetrans- mission. Check the transaxle fluid level with: • Fork lift on a level surface • Engine idling with transmission in NEUTRAL • Oil at operating (180~200°F) ! Take special care when removing the filter to avoid oil remaining in filter from drainingonto floor. Loosen the filter using a filter wrench. Remove filter while holding a padof cloth or other absorbent material under the open end to absorb any excess oil thatmay drain out of filter. temperature 82~93°C 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 Install a new oil filter. Follow the installation instructions printed on filter. ③ Add recommended fluid only, as required. ! Always use genuine CLARK parts Fluid and Filter Change It is recommended to: • Drain and replace the transaxle fluid every1000 operating hours. • The oil should be drained when warmed tooper- ating temperature, 82~93°C (180~200°F) • Replace the transaxle oil filter every 1000oper- ating hours. See NOTICE below. SM 794 06-1-3

  11. Group 06, TRANSAXLE 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 (700~800 rpm) in NEUTRAL for 2~3 minutes to primethe 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 (160~210 psi) @ 1800 rpm Check Point : Oil supply line at converter • Converter In/Lube Pressure : 176~314kPa (26~45 psi ) @ 1800 rpm Check Point : Return from cooler • Converter Safety Valve Pressure (Trans in NEU- TRAL) : 729~827kPa (105~120 psi) @ 1800 rpm (Refefence only) with line to cooler blocked. Check Point : None • Clutch Pressure (Forward, Reverse applied) : 1034kPa (150 psi) @ 700~800 rpm idle Normally 103kpa (15 psi) less than regulator pressure 1000kpa (145 psi min) Check Point : At control valve (1/8 NPTF) • Clutch Pressure (in NEUTRAL) : Regulator pres- sure SM 794 06-1-4

  12. Group 06, TRANSAXLE ! NOTICE • Oil at operating temperature 82~93C(180~200F) • All rpm’s noted are engine speed. • Refer to following illustrations for check pointlocations. • All clutch pressures are at engine idle speed withclutch engaged, unless otherwise noted. Pressure Check Points SM 794 06-1-5

  13. Group 06, TRANSAXLE Service Brake Adjustment Preparation Adjustment at Backing Plate 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 wheelhub/brake drum (later models). 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. 2. Brake clearance is measured between brake shoe and drum, with brakes fully released. Brake clearance : 0.255~0.304 mm (.010~.012 in) 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~.012 in) measured at dust plug openings at outer sides of backing plate. ! CAUTION Be sure transmission directional control is in NEUTRAL and fork liftprevented from moving when parking brake is released. 5. Replace the dust plugs in brake backing plate when adjustment is completed. 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. SM 794 06-1-6

  14. Group 06, TRANSAXLE Adjustment at Wheel Hub Openings in the wheel hub/brake drum have been provided for easier access to check andadjust 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 throughthe plug openings on backing plate. Later models have a slot and circular opening for accessalso 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. ! IMPORTANT Do not overtighten brakes. It is very difficult to release the ratchet wheel pawl and back off adjustment of the bake. ! 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. 5. Carefully adjust clearance between brake shoes and drum to 0.255~0.304 mm (.010~.012 in) measured at slot opening. Move slot by rotating brake drum to check clearance at theillustrated position for each brake shoe. (20–01–6) 2. Remove dust cover from access opening in wheel hub/brake drum. 6. After adjusting brakes, install dust cover over access opening in the wheel hub. 3. Use feeler (thickness) gauge to check the clear- ance between each shoe and drum. Use a brake adjuster tool to rotate the adjuster ratchet wheel in the brake. 7. Install wheel and tire assembly on the drive axle wheel hub. 8. Install wheel mounting lug nuts and tighten to spec : 637~718 Nm (471~531 lbf·ft) 4. Use a tool with a hook to pull on and release the ratchet pawl when it is necessary to backoff adjustment (increase clearance) of the brake. SM 794 06-1-7

  15. Group 06, TRANSAXLE Section 2 Disassembly Precaution assembly and overhaul. Perform all disassembly and assembly work in a clean area. Protect all components from dust and dirt while repairsare being made. • Before attempting any repairs or overhaul of this assembly, please read through the entire disassembly and assembly procedures first. • Keep all parts in order as disassembly progresses. Take care to properly identify each partand its order of removal. If necessary, keep notes and put marking on parts using anonde- structive marker such as a felt–tipped pen. ! Cleanliness is of extreme importance in the repair and overhaul of this assembly. • The exterior surface of the unit MUST be thor- oughly cleaned of all dirt and foreign substances to prevent contamination of the parts during dis- Remove Auxiliary Subassemblies 1. Remove torque converter assembly by carefully sliding it off the turbine (clutch) shaft andstator support. 4. Charging pump 5. Oil supply line assembly 6. Transmission control valve assembly 2. Disassemble converter drive plate and adaptor, as needed.Remove the : 3. Oil filter SM 794 06-2-1

  16. Group 06, TRANSAXLE Wheel End 8 7 4 5 3 6 2 1 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 withinner wheel bearing and oil seal. 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. SM 794 06-2-2

  17. Group 06, TRANSAXLE Removing the wheel hub from the spindle breaks that seal. Replace with new sealeach time that the wheel hub is removed from wheel end hous- ing. ! IMPORTANT This oil seal is a type that seals internally, and is lined with sealing compound onthe inner diame- ter that sticks and seals to the spindle. 7. Before removal of wheel end housing, mark the housing and the transmission case forsame– location matching at reassembly. Loosen and remove the housing bolts and washers. 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. 8. Remove wheel end housing from transmission case. 10. Repeat procedures of Steps 1 through 9 for opposite wheel end disassembly. 11. Remove the differential assembly from trans- mission case. SM 794 06-2-3

  18. Group 06, TRANSAXLE Brake Assembly Removal Brake removal is optional for brake overhaul as nec- essary. 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 brakecable assembly from wheel end housing. 7. Remove drive axle support and spacer from wheel end housing. SM 794 06-2-4

  19. Group 06, TRANSAXLE Separation of Converter Housing andAdaptor Plate 1. Remove the fasteners and washers which mount the converter housing to transmission casethrough the adaptor plate. 2. From other side, remove the bolts and washers which mount adaptor (spacer) plate toconverter housing. 3. Remove the clutch pressure–regulating valve assembly (also oil filter mounting base). ! IMPORTANT 2. To remove stator support : Pry only at the dowel pins to remove adap- tor plate. Dowel pins must be removed before reassembly. See later instructions. − Remove front (converter end) retaining ringfrom ring groove and move ring and impellergear thrust washer toward stator supportseal surface. − Push stator support to the rear (towardstrans- mission side) far enough to expose rearretainer ring. − Remove rear retaining ring. − From the front, pull stator support fromadaptor plate. 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 AdaptorPlate 1. The stator support is held in place by tworetain- ing rings, one on each side of theadaptor plate. SM 794 06-2-5

  20. Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.

  21. Group 06, TRANSAXLE Clutch Assembly, Idler Gear & Pin- ionShaft Removal 5. Remove the oil distributor. Note the recessin distributor for retaining set screw. 6. Loosen and remove the pinion shaft nut. Hold or block the pinion shaft with a brassbar or similar soft material to preventturning. 1. Move the reverse idler gear and clutchassem- bly apart far enough to allow the idlershaft to be pulled out of the inner bearing. 7. Remove the pinion shaft outer bearing and shims. Keep the shims with the bearing andpin- ion shaft. 8. Remove output gear retaining ring frompinion shaft (inside transmission case). 9. Remove output gear (move pinion shaftaway). 10. Remove pinion shaft and inner bearingthrough differential housing. 11. If pinion bearings are to be replaced, drive the cups from the housing inside transmissoncase. 12. Remove inner pinion bearing cup and shims from differential side. 2. Remove the clutch assembly and reverseidler shaft together. 3. Remove the turbine (clutch) shaft rearbearing. 4. Remove the clutch shaft oil distributorretaining set screw (internal hex) from valvemounting base. ! Wire shims to transmission housing for stor- age until reassembly. 13. As required, remove oil suction (pickup) tube assembly from transmission case. SM 794 06-2-6

  22. Group 06, TRANSAXLE Clutch Disassembly (Forward & Reverse Clutch Procedure Are The Same) • Reverse Clutch Disassembly Illustrated 1. Remove outer clutch hub gear thrust bearing and thrust washers, clutch hub gear, and inner clutch hub thrust bearing and thrust washers. 2. Disassemble the two clutch gear bearings and spacer from internal bore of clutch gear hub. 3. Remove clutch disc end plate retainer ring and clutch disc end plate. 4. Remove inner and outer clutch discs. 5. Remove clutch return spring retainer ring. 6. Remove (Belleville washers). Note assembly arrange- ment. clutch return (release) springs 7. Remove clutch piston wear plate. 8. Remove clutch piston by turning clutchupside down and tapping the shaft on ablock of wood. 9. Remove and discard clutch piston sealingrings. 10. Repeat procedures, steps 1 through 9, forfor- ward clutch disassembly. SM 794 06-2-7

  23. Group 06, TRANSAXLE Differential Disassembly 1. Use a small drift pin or rod to remove thediffer- ential pinion pin, lock pin. 2. Remove the pinion pin. 3. Rotate the pinion gears and washers toremove them from the differential housing. SM 794 06-2-8

More Related