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Clark ESM 25 Forklift Service Repair Manual

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Clark ESM 25 Forklift Service Repair Manual

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  1. SM-596 ESM 12/25

  2. Service Manual SM596 ESM-II 12 thru 25

  3. Truck Models Covered by This Manual This manual consists of a “base” module that pertains to ESM-II models and other modules that pertain only to specific models. Manuals shipped with the truck contain the base module and the module 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 standard- ized Groups. In this manual, Croups are similar to “chap- ters.” Croups are listed in the indexes on the next page. 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 Croup begins with a table of contents that shows the Sections contained within the Croup. Lengthy Sections also begin with a table of contents. Group ID’ ‘Group ID Each Croup and Section has an identifying name and num- ber, or “ID.” Each page also has a unique ID. The page ID consists of three numbers separated by hyphens. The three numbers represent the Croup number, the Section number, and the page number. For Example, “00-1-2” on the lower corner of the page indicates Croup 00, Section 1, Page 2. Page ID’ .Page ID Manual ID Sectioi ID Se&ion ID The Croup number sometimes has a letter or letters added to it in parentheses if one or more variations of the Croup exist. For example, if the truck has a standard transaxle, Croup 06 is expressed as “06(S);” if the truck has a hydro- static transmission, Croup 06 is expressed as “06(H).” This manual is intended for the use of trained service personnel. Please read Croup SA, “Safe Maintenance” and the Operator’s Manual before working on or operating the truck. Copyright Clark Material Handling 1995 SM 596, Aug ‘95

  4. C1RRK Foreword Foreword Procedures have been made easier to use by providing specific steps only when necessary and general instructions required to explain the activity, component, assembly, or process being worked on. The technician is expected to include obvious additional steps of standard procedure for removal, disassembly, cleaning, inspection, reassembly, in- stallation, etc., as needed. This service publication provides information covering nor- mal service, maintenance and repair of the Clark industrial lift trucks noted on the cover. It has been specifically prepared to help owners and service personnel maintain these trucks in efficient and safe operating condition. This manual is intended for use by persons who are trained and authorized to do lift truck maintenance. It is designed to provide essential information about the correct and safe service maintenance and repair of the truck by trained mechanics or service technicians. To be better prepared to do the necessary service work, take time to completely read the entire procedure, including any special instructions, before starting any work. The Pictorial Contents lists components or systems by Basic Group Number of Major Parts. Additional content listings are placed at the beginning of each Section in the manual. Before beginning to work, the technician is cautioned and expected to: . Do all necessary service work. Take time to read entire procedures, including any special instructions. . General and detailed service and repair procedures are outlined (as required) for each component or subsystem. Some procedures include explanations that are common to several components or subsystems. NOTICE The descriptions and specifications included in this manual were in effect at the time of printing. Clark reserves the right to discontinue models at any time, or make improvements and changes in specifications or design without notice and without incurring measurements, adjustments, illustrations and other items may change at any time. Contact your authorized CLARK dealer for information on possible updates or revisions. obligation. Specifications, torques, pressures, Foreword ? i SM 596, Aug ‘95

  5. CLllRK CONTENTS CONTENTS Group SA - Safe Maintenance Group PS - Periodic Service Group 12 - Battery Group 13 - Electrical Control Handle Group 16 - Electrical Motors Group 17 - Electrical Schematics Group 19 - Electrical Controls Group 20 - Drive Axle Group 22 - Wheels and Tires Group 23 - Brake System Group 25 - Steering Gear Group 26 - Steering Axle Group 29 - Hydraulic Pump, Sump and Filters Group 30 - Hydraulic Control Valves Group 31- Hydraulic Supply System Group 32 - Cylinders Group 33 - Selector Solenoid Valve Group 34 - Upright Group 40 - Specifications Contents-l SM 596, Aug ‘95

  6. CIRRU CONTENTS ESM-II Pictorial Contents Group PS - Periodic Service Group 12 - Battery Group 13 - Electrical Control Handle lectrical Control Valve Group 16 - Electrical Motors Group 17 - Electrical Schematics Group 19 - Electrical Controls Pressure Swi SM 596, Aug ‘95 Contents-2

  7. ClRRK- CONTENTS Group 20 - Drive Axle Contactor Panel Electrical Contr Group 22 -Wheels and Tires Control Handle Group 23 - Brake System I Horn Group 25 - Steering Gear Group 26 - Steering Axle scillator Card Solenoid Function Control Card Group 26 ’ Steering Axle Wheels and Tires SM 596, Aug ‘95 Contents-3

  8. CIRRK CONTENTS Group 29 - Hydraulic Pump, Sump and Filters Group 30 - Hydraulic Control Valves Group 31 - Hydraulic Supply System Group 32 - Cylinders Group 33 - Selector Solenoid Valve Group 34 - Upright - Group34 Upright and Lift Cylinders Group 40 - Specifications Contents-4 SM 596, Aug ‘95

  9. ElMIt Group 20, Drive Axle ? Refer to Croup 40 Specifications, for recommended transmission fluid specification. General Description The drive axle consists of right hand and left hand axle end assemblies. The two axle ends are fastened together to form the drive axle assembly. Each axle end half contains a ring gear and pinion and final drive gearing. The drive motors are mounted directly to the axle ends. Fluid Change Procedure IMPORTANT Drain drive axle when fluid is at operating temperature. A WARNING Make certain blocks are secure and installed under carriage so that carriage can not fall. Service Notes The drive axle contains metric fasteners. Use only metric tools to service unit. Service instructions refer to one axle end, unless otherwise noted Raise upright carriage only to height that will permit access to plugs on axle. Block carriage. Refer to Croup SA, Lifting, Jacking, and Blocking. Turn key switch OFF. Disconnect battery. Place a low flat drain pan under drive axle. Pan should have a capacity of more than 6.5 L (6.8 qt). Remove dipstick cap. Remove drain plug from each axle end and allow fluid to drain. While fluid is drain- ing, check condition of vent in dipstick cap. Replace dipstick cap if vent is damaged or plugged. Install drain plugs. Fill drive axle to proper level with specified fluid through dipstick hole. DO NOT OVERFILL. Connect battery, remove blocking and lower carriage. Drive Axle Maintenance When troubleshooting a drive axle problem, it should be kept in mind that the drive axle is only one main component in a group of related powertrain components. Proper operation of drive axle depends on condition and correct function of other components of group. It is neces- sary to consider transmission fluid, drive motors and con- nections to properly diagnose and repair a problem. Fluid Level Check Check fluid level. It must be at correct level. ? Check fluid level by removing dipstick on the right hand axle end. Wipe dipstick clean and reinstall. ? Remove dipstick and examine. Fluid level should be between the two marks on dipstick. If fluid level is low, add enough fluid to bring level up to full mark on dipstick. DO NOT OVERFILL. - Combination Fill Plug and Drain Pan + SM 596, Aug ‘95 ? Drive Axle 20-l-2

  10. CLMK Group 20, Drive Axle Drive Axle Removal 13. Identifyanddisconnectmotorpowercables.Tiecables out of way to avoid damage. Park truck on hard, level surface. 1. A WARNING 2. Lower upright. Remove forks. 3. Use only approved hoist, chains and straps to lift the drive axle and motors. Be sure hoist and accessories have correct capacity to safely support the load. 4. Turn key switch OFF and disconnect battery. 5. Remove battery. 6. Block steer wheels front and rear. 14. Put lift straps on drive motors and hook straps to chain hoist. Remove slack from hoist chain to stablize drive axle assembly. 7. Lift truck with ajack and put blocks under each side of frame just behind drive wheels. Refer to truck jacking in Group SA, Section 2, for details. CAUTION /\ ! A WARNING To avoid injury, remove all the axle fasteners in the order listed. Make sure blocks are secure and placed so that there is clearance without interfering with blocking or truck. to remove axle 15. Remove axle rear mounting fasteners (items 90.358, 94.085 and 20.377) from each side of frame. 16. Remove axle front mounting fasteners (items 90.358, 94.085 and20.377) fromeach side of frame. Rockaxle until axle is free of alignment pins. 8. Remove two front and top compartment covers. Remove drive wheels. 9. Put a drip pan under drive axle to catch any fluid. 10. 17. Lower axle to floor and remove it from under truck. Store axle in a safe manner. 11. Remove upright. Refer to Group 34 Uprights, for details. 18. If drive motors are to be removed, refer to Motors Group 16 for details. 12. Disconnect hydraulic brake lines. - 20.377 - 94.085 - 20.379 94.085 & - Alignment Pin” * Apply General Purpose Threadlocker (Clark Part No. 1802300) to nut threads prior to assembly. *go-35 * Alignment Pins: When removing drive axle, rock axle until free of the alignment pins. Drive Axle ? 20-l-3 SM 596, Aug ‘95

  11. CMRK Group 20, Drive Axle Drive Axle Special Tools Special Socket / 1’ /-. ‘$1 “J+ I\& \ \ +’ \ \ I \ l,_-/’ _A’ ,‘A / I j \ \ \ \ \ I J <,\I \ \ I I \ \ \ \ \ \ ‘. ._ < 20-l-4 ? Drive Axle SM 596, Aug ‘95

  12. C1cIRK Group 20, Drive Axle Special Socket -. 71mm (2-3/4”) 1 t- 75.5mm , __ --- -- -- - xm lrrl -I (2-7/8”) : - (3-3/4”) --\J BB VOO24C SM 596, Aug ‘95 Drive Axle ? 20- l - 5

  13. ClMtU Group 20, Drive Axle Q Special Socket Q t 31.5mm (1 -l/4”) f 19.5mm (314” (I-l 5/l 6”) VOO24C CC SM 596, Aug ‘95 ? Drive Axle 20-I -6

  14. CUIRK Group 20, Drive Axle Pinion RetainerTool A 50mm (l-15/16”) A- I 20mm @l/64”) Application 20mm_ (31/64’?+, I (&Eyp] 20mm d31/64”) . --_--_--_--_ t L20mm (31”64”) Drive Axle ? 20-l-7 SM 596, Aug ‘95

  15. ClMK Group 20, Drive Axle NOTE Drive Axle Disassembly In order to remove item 20.819, it will be necessary to fabricate a tool to keep the output shaft (item20.586) from turning. Refer to Drive Axle Special Tools. Disassemble drive axle only on a work table strong enough to support the weight of the axle. Drain drive axle fluid, if has not been done previously. Block axle to stablilize it on the work surface. 1. 2. Clean exterior of axle before beginning disassembly. 11. Use a soft hammer to drive the pinion from the motor mountingflange.Theupperbearingcone(item20.230) will come off thepinion shaft in theprocess. Clean and inspect bearing for wear or damage. Replace as re- quired. Bearing cone and cup should be replaced as a set. Remove drive motors, if they have not been removed previously. Refer to Croup 16, Motor for details. 3. 4. Examine entire assembly for damage. Note if there is any evidence of cracks or broken parts. 5. Remove housing flange cap screws (items 20.227 and 20.228), refer to illustrations on next two pages. 12. Remove backing washers (items 20.238 and 20.240) and spacer (item 20.288). Press lower pinion bearing cone (item 20.252) from pinion (item 20.248). 6. With a drift pin and hammer, drive out housing flange roll pins (item 90.663). Draw pinion bearing cups (items 20.316 and 20.649) from the motor mounting flange. 13. NOTE Loosen bevel gear nut (item 20.835), using fabricated tool to keep output shaft (item 20.586) from turning. Refer to previous pages. 14. Sealant was applied to the axle end housing flanges at assembly. Force may be required to separate the two housings. Remove locking cap screw (item 95.782). 15. With special tool, remove output shaft nut (item 20.565). Use fabricated tool to keep output shaft (item 20.586) from turning. 16. 7. Separate the two axle end assemblies. 8. Remove the motor mounting flange cap screws (item 20.239). t7 Remove housing cover cap screws (item 20.546). 17. 20.239 - I L 20.546 Use two housing cover cap screws (item 20.546) to remove housing cover from axle housing. Install cap screws into tapped holes “B” in housing cover (shown above). Turn cap screws alternately into tapped holes until housing cover is extracted from axle housing. After the housing cover assembly is off, reach into the axle end housing and remove loose inner bearing cone (item 20.553) 18. Use two mounting flange cap screws (item 20.239) to remove motor mounting flange from axle housing. Thread cap screws into tapped holes “A” in motor mounting flange. Turn cap screws alternately into tapped holes until mounting flange is extracted from axle housing. 9. 10. With special tool, remove pinion shaft lock nut (item 20.819). With special tool, remove output shaft nut (item 20.520). Use fabricated tool to keep output shaft from turning. Slide output gear (item 20.522) off shaft (item 20.586). 19. SM 596, Aug ‘95 20-l-8 ? Drive Axle

  16. CUIRK Group 20, Drive Axle 20. 586 REV FEB 91 20-420 DRIVE AXLE - RH 20.376 20.201 20.212 20.227 20.228 20.230 20.236 20.238 20.239 20.240 20.248 20.252 20.288 20.316 20.387 20.427 20.520 20.522 20.524 20.539 20.542 Axle Assembly, Drive RH Shim, Differential Pinion Bearing Carrier Seal, Differential Pinion Bearing Carrier Fastener, Thick Flange to Axle Housing Fastener, Thin Flange to Axle Housing Cone, Differential Pinion Bearing Carrier, Differential Pinion Bearing Shim Kit, Differential Pinion Bearing Cage Fastener, Differential Pinion Bearing Carrier Spacer, Differential Pinion Bearing Ring and Pinion Set, Differential Cone, Differential Pinion Inner Bearing Spacer, Pinion Bearing Cone Cup, Differential Pinion Outboard Bearing Housing, Drive Axle-RH Plug, Drive Axle Drain Retainer, Drive Axle Shaft Gear Gear, Drive Axle Shaft Bearing, Drive Axle Ring Gear Shaft Housing, Drive Axle End-RH Bearing, Drive Axle Shaft-Outer 20.544 20.546 20.553 20.565 20.579 20.586 20.636 20.638 20.646 20.647 20.649 20.666 20.667 20.668 20.819 20.835 20.837 22.270 90.663 95.782 Seal, Drive Axle Shaft Fastener, Drive Axle End Housing Cone, Drive Axle Shaft Inboard Bearing Retainer, Drive Axle Shaft Bearing Cup, Drive Axle Shaft inboard Bearing Shaft, Drive Axle Shaft, Drive Axle Ring Gear Cone, Ring Gear Shaft Outboard Bearing Cup, Ring Gear Shaft Inboard Bearing Locator, Drive Axle Shaft Inboard Bearing Cup, Differential Pinion Inboard Bearing Spacer, Drive Axle Ring Gear Shaft Inboard Brg Spacer, Drive Axle Ring Gear Shaft Spacer, Drive Axle Shaft Inboard Bearing Nut, Drive Axle Pinion Shaft Lock Retainer, Drive Axle Ring Gear Cup, Ring Gear Shaft Outboard Bearing Seal, Drive Axle End Housing Dowel Ring, Axle Housing Fastener Fastener, Drive Axle Shaft Bearing Retainer SM 596, Aug ‘95 Drive Axle ? 20-I-9

  17. Cu1RU Group 20, Drive Axle 20.239 20. 246 20. 669 7 i 20. 666 20. 635 nne?, l , 20. 248 7 20. 649 - 90.663 -!l - 20. 636 L 20. 370 20. 427 20. 566 REV FEB 91 20-421 DRIVE AXLE - LH 20.546 20.553 20.565 20.579 20.586 20.627 20.636 20.638 20.646 20.647 20.649 20.666 20.667 20.668 20.669 20.819 20.835 20.837 22.270 90.663 95.782 Axle Assembly, Drive LH Shim, Differential Pinion Bearing Carrier Seal, Differential Pinion Bearing Carrier Fastener, Thick Flange to Axle Housing Fastener, Thin Flange to Axle Housing Cone, Differential Pinion Bearing Shim Kit, Differential Pinion Bearing Cage Fastener, Differential Pinion Bearing Carrier Spacer, Differential Pinion Bearing Ring and Pinion Set, Differential Cone, Differential Pinion Inner Bearing Spacer, Pinion Bearing Cone Cup, Differential Pinion Outboard Bearing Housing, Drive Axle-LH Plug, Drive Axle Drain Retainer, Drive Axle Shaft Gear Gear, Drive Axle Shaft Bearing, Drive Axle Ring Gear Shaft Housing, Drive Axle End-LH Bearing, Drive Axle Shaft-Outer Seal, Drive Axle Shaft Fastener, Drive Axle End Housing Cone, Drive Axle Shaft Inboard Bearing Retainer, Drive Axle Shaft Bearing Cup, Drive Axle Shaft Inboard Bearing Shaft, Drive Axle Vent, Differential and Axle Shaft, Drive Axle Ring Gear Cone, Ring Gear Shaft Outboard Bearing Cup, Ring Gear Shaft Inboard Bearing Locator, Drive Axle Shaft Inboard Bearing Cup, Differential Pinion Inboard Bearing Spacer, Drive Axle Ring Gear Shaft Inboard Brg Spacer, Drive Axle Ring Gear Shaft Spacer, Drive Axle Shaft Inboard Bearing Carrier, Differential Pinion Bearing Nut, Drive Axle Pinion Shaft Lock Retainer, Drive Axle Ring Gear Cup, Ring Gear Shaft Outboard Bearing Seal, Drive Axle End Housing Dowel Ring, Axle Housing Fastener Fastener, Drive Axle Shaft Bearing Retainer 20.370 20.201 20.212 20.227 20.228 20.230 20.238 20.239 20.240 20.248 20.252 20.288 20.316 20.388 20.427 20.520 20.522 20.524 20.540 20.542 20.544 ? Drive Axle SM 596, Aug ‘95 20-l-10

  18. CII1RK Group 20, Drive Axle 5. 20. Remove the output shaft (item 20.586) from housing cover. Press outer bearing cone (item20.542) off output shaft (item 20.586). Clean and inspect bearing for wear or damage. Replace as required. Bearing cone and cup should be replaced as a set. Remove oil seal (item 20.544) and outer bearing cup (item 20.542) from housing cover (item 20.539). Remove snap ring and back-up ring (items20.647 and 20.668) from housing cover (item 20.539). Pull inner bearing cup (item 20.579) out of drive axle housing (item 20.388 or 20.387). Remove and discard bevel gear nut (item 20.835). Remove bevel gear and spacer (items 20.248 and 20.666) from output gear pinion (item 20.636). From inside the drive axle housing, use a soft hammer to remove the output gear pinion (item 20.636) out of the housing (item 20.388 or 20.387). Remove loose inner bearing cone (item 20.524) from housing. Re move bearing cup (20.646) using a puller if necessary. Clean andinspect bearing for wear or damage. Replace as required. Bearing cone and cup should be replaced as a set. Remove spacer (item20.667) from output gear pinion. Press outer bearing cone (item20.638) off output gear pinion (item 20.636). Remove outer bearing cup (20.837) using a puller if necessary. Clean and inspect bearing for wear or damage. Replace as required. Bearing cone and cup should be replaced as a set. Use PermatexTM and General Purpose Threadlocker (Clark Part No. 1802300) only where specified. Spray threads of fasteners with Primer “T” 5 minutes before applying Threadlocker. 21. 6. All lead-in chamfers for oil seals and O-rings must be smooth and free from burrs. Inspect at assembly. Correct as necessary. 22. 7. Coat all bearings with transmission fluid before in- stalling. 23. Assembly 1. 24. Install pinion bearing cups (items 20.837 and 20.646) into drive axle housing (item 20.388 or 20.387). Press outer bearing cone (item 20.638) onto output gear pinion (item 20.636). 3. Slide spacer (item 20.667) onto output gear pinion (item 20.636). Install pinion into drive axle housing (item 20.388 or 20.387). 4. Install inner bearing cone (item 20.524) onto pinion (item 20.636). Install spacer (item 20.666), and bevel gear (item 20.248), Apply Threadlocker (Clark Part No. 1802300) to a new bevel gear nut (item 20.835) and install. Tighten bevel gear nut to give a rolling torque of 0.7 Nom (6.2 lb-in.) on the pinion bearing. Install pinion bearing cups (items 20.316 and 20.649) into motor mounting flange (item 20.236). Press inner bearing cone (item 20.252) onto pinion (item 20.248) and insert pinion into motor mounting flange (item 20.236). 7. Slide backing washer (item 20.240), spacer (item 20.288), backing washer (item 20.238), and outer bearing cone (item 20.230) onto pinion (item20.248). Apply Threadlocker (Clark Part No. 1802300) to pin- ion shaft lock nut (item 20.819) and install on pinion. Tighten nut to give arolling torque of 0.5 N*m (4.4 lb- in.) on the pinion bearing. Use special tool to torque nut. 9. Check motor pinion and bevel gear mesh adjustment. 25. 2. 26. 27. 28. 5. 6. Drive Axle Assembly Assembly Notes 8. IMPORTANT Perform procedures in a clean environment. Make sure all parts are cleaned before disassembly and kept clean during assembly. CLEANLINESS! NOTE Mesh adjustment motor mounting flange shims (item 20.201) and bevel gear spacer (item 20.666). Mark teeth of motor pinion and bevel gear with gear checking compound. Compare chart on following pages. is made with Clean all parts with a good grade of solvent and dry thoroughly. DO NOT let bearings spin if drying parts with compressed air. Remove all PermatexTM and General Purpose Threadlocker residue from threads and machined sur- faces. gears with Inspect all components for wear or damage. Replace as required. ? Install flange and pinion assembly into axle end hous- ing (item 20.388 or 20.387), using shim (item 20.201) to align assembly with housing. Install and tighten only two flange cap screws (item 20.239). Replace all oil seals and O-rings. SM 596, Aug ‘95 Drive Axle ? 20-l-l 1

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  20. Group 20, Drive Axle Emu Tooth Bearing Contact Chart Move Pinion AWAY from Gear in this direction rofile Pinion Ring Gear Spiral Bevel and Hypoid Tooth Bearing Contact Patterns see following page for adjustments Convex Side Contact Pattern 1 Check Ring and Pinion Tooth Contact ? Paint ring gear teeth with thin coating of a mixture of red lead and linseed oil. Rotate pinion shaft to cause one full revolution of ring gear. Check tooth pattern on ring gear and pinion to determine if proper pinion- to-ring gear tooth engagement exists. Bearing Pattern on pinion and both sides ? Preferred of gear tooth while under a light load. ? Toe contact on both sides of gear tooth. To move contact toward the heel, increase backlash within lim- its by moving the gear away from pinion. Contact Pattern 2 Gear Set Noisy 1 Pinion Pattern 1 SM 596, Aug ‘95 ? Drive Axle 20-l-12

  21. CMRK Group 20, Drive Axle ? Heel contact on both sides of gear tooth. To move contact toward the toe, decrease backlash within lim- its by moving the gear toward pinion. Contact Pattern 3 Ring Gear Pattern Gear Set Noisy Could result in early gear failure. Move Gear TOWARD the Pinion. ? Low contact on Gear and High contact on Pinion Correct by moving pinion away from gear. (Increase mounting distance). Contact Pattern 4 Move Pinion AWAY from Gear. Gear + ( + ? High contact on Gear and Low contact on Pinion. Correct by moving pinion in toward gear. (Decrease mounting distance.) Contact Pattern 5 Move Pinion INWARD Drive Axle ? 20-l-13 SM 596, Aug ‘95

  22. ClRRK Group 20, Drive Axle NOTE 17. Slide bearing cone (item 20.553) onto output gear shaft. Apply General Purpose Threadlocker to nut (item20.565). Install nut and torque to 68 N*m (50.2 lb-ft) with special tool. Apply General Purpose Threadlockerto locking screw (item 95.782).Locknut (item 20.565) with screw. Torque screw to 13 N*m (9.6 lb-ft). Do not install O-ring (item 20.212) at this time. . Rotate the pinion several times in a clockwise or counterclockwise direction and check against the tooth bearing contact chart on previous pages. Pinion gear backlash should be 0.198-0.102 0.0040 in). mm (0.0078- 18. Apply a thin layer of PermetexTM #2 to machined surface of axle end housing flanges. Mate the two axle end housings together and drive in roll pins (item 90.663). Apply General Purpose Threadlocker (Clark #1802300) to cap screws (item 20.227 and 20.228) and fasten axle end housings together. Torque capscrews to 67 Nom (49.5 lb-ft). Adjust pinion by changing the number of flange shims (item 20.201). The bevel gear is adjusted by grinding the gear spacer (item 20.666) to the thickness required. Use a surface grinder to remove material from the gear spacer. 10. Install drive motors. Refer to Group 16, Section 2. 11. When gear mesh adjustment is correct, remove two cap screws and flange and pinion assembly. Coat O- ring (item 20.212) with transmission fluid and install. ApplyGeneralPurposeThreadlocker(Clark#l8023OO) to all flangecap screws (item20.239) andinstall flange and pinion assembly. Torque cap screws to 67 Nom (49.5 lb-ft). 19. Drive Axle Installation Make sure truck is blocked in a secure manner and that there is clearance to move axle in place fromunderside of truck without disturbing blocking. 1. 12. Lock the bevel gear nut (item 20.835) by crimping the nut into the groove in the end of pinion shaft (item 20.636). A WARNING Use only approved hoist, chains and straps to lift the drive axle and motors. Be sure hoist and accessories have correct capacity to safely support the load. 13. Install inner bearing cup (item 20.579), backing ring (20.668), and snap ring (item 20.647) into axle end housing (item 20.388 or 20.387). 14. Install outer bearing cup and cone (item 20.542) into output shaft housing (item 20.539 or 20.540). Apply a thin coating of grease between the lips of oil seal (item 20.544). Apply a thin layer of PermetexTM#K2 to the outside diameter of oil seal and install. Put hoist straps on drive motors and hook straps to chain hoist. 2. Position axle under truck with chain hoist. 3. Align drive axle slots with axle mounting alignment pins, see next illustration. 4. 15. Insert output shaft (item 20.586) through housing (item 20.539 or 20.540). Do not damage oil seal (item 20.544) with splines of output shaft. Slide output gear (item 20.522) onto shaft. Apply General Purpose Threadlocker to nut (item 20.520) and install. Torque nut with special tool to 200 N*m (147.5 lb-ft). Use fabricated tool on page 20-l-7 to keep output shaft from turning. CAUTION n ! To avoid injury, install all the axle mounting bolts in the order indicated. Secure axle assembly to frame by first installing front two fasteners on each side of frame. 5. 16. Apply a thin layer of PermetexTM #2 to machined surface of housing cover (item 20.539 or 20.540). Apply General Purpose Threadlocker to cap screws (item 20.546) and install housing cover to axle end housing (item 20.388 or 20.387). Torque cap screws to 67 Nom (49.5 lb-ft). 6. Installreartwofastenersoneachsideofframe.Tighten all nuts snug, then torque nuts to 408469 N*m (301-339 lb-ft). ? Drive Axle SM 596, Aug ‘95 20-l-14

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