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CLARK FORKLIFT SM 622 CDP 100164 SERVICE MANUAL
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CLARK FORKLIFT SM 622 CDP 100164 SERVICE MANUAL – PDF DOWNLOAD
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CLARK FORKLIFT SM 622 CDP 100164 SERVICE MANUAL – PDF DOWNLOAD
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CLARK FORKLIFT SM 622 CDP 100164 SERVICE MANUAL – PDF DOWNLOAD
- Proper maintenance and care are essential if your Clark truck is to be always ready for use. These preventative maintenance procedures provide a basic guide which should be followed when servicing your Clark truck.
- A lubrication guide and recommended preventative maintenance program is included in this section and for further information regarding adjustment procedures, specifications, etc., please refer to the index in the front of this manual. IMPORTANT Your Clark dealer has both the facilities, parts, and adequately trained personnel enabling them to carry out all necessary service procedures, including complete inspections, maintenance and lubrication programs, all aimed at ensuring your Clark Lift truck will perform safety and efficiently and most importantly, maximizing its availability for your day to day work schedules.
- RECOMMENDED MAINTENANCE PROCEDURE Particular attention should be paid to the conditions under which your CDP 100/164 forklift truck is used as those conditions play a significant role in determining how long the interval between each maintenance task should be.
- It is quite clear that a truck used in sandy, dusty, dirty locations will require more frequent maintenance than one being used in a clean warehouse situation. The maintenance schedules and recommendations made in this book apply for use under normal operating conditions.
- The following classifies the different types of operating conditions.. Class 1 – Normal conditions of use Basically transfer and loading of goods and materials for eight hours per day in buildings or in the open air.
Table Of Contents:
CLARK FORKLIFT SM 622 CDP 100164 SERVICE MANUAL – PDF DOWNLOAD
SM 622 CDP 100/164......................................................................................... 1 Contents................................................................................................... 2 Major Component Location................................................................................... 3 PERIODIC SERVICE........................................................................................... 4 Section 1. INTRODUCTION................................................................................ 5 Section 2. Lift Truck Maintenance...................................................................... 8 ACCUMULATORS....................................................................................... 21 Air Brakes......................................................................................... 18 Air Brakes Adjustment.............................................................................. 20 Air Pressure Gauge................................................................................. 17 Batteries.......................................................................................... 19 Carriage and Upright Load Rollers.................................................................. 23 Carriage Side Thrust Rollers....................................................................... 23 Checks with the engine running..................................................................... 18 Cleaning........................................................................................... 22 Container Handling Attachments..................................................................... 22 Critical Fastener Torque Checks.................................................................... 22 Daily Check Lift................................................................................... 9 Differential Oil and Breather Check................................................................ 21 Engine Accessories................................................................................. 19 Engine Air Cleaner................................................................................. 19 Engine Cooling System.............................................................................. 19 Engine Oil......................................................................................... 20 Engine Oil and Filter Change....................................................................... 20 Fluid and Filters.................................................................................. 19 Forks.............................................................................................. 16 Fork Tynes......................................................................................... 22 Functional Tests................................................................................... 17 HOW TO PERFORM PLANNED MAINTENANCE................................................................. 16 Hour Meter......................................................................................... 17 Hydraulic System................................................................................... 21 Hydraulic Tank..................................................................................... 21 Hydraulic Tank Breather Maintenance and Inspection................................................. 21 Key/Start Switch................................................................................... 17 Lift Chains........................................................................................ 22 Lift Chain Maintenance............................................................................. 22 Lift Chain Adjustment Check........................................................................ 22 Lift Chain Inspection and Measurement.............................................................. 23 Lift Mechanisms and Controls....................................................................... 18 NAMEPLATES & DECALS................................................................................ 16 Operating Conditions............................................................................... 9 Preventative Maintenance Schedule.................................................................. 12 PLANNED MAINTENANCE REPORT......................................................................... 14 Planned Maintenance................................................................................ 9 Planned Maintenance Program........................................................................ 16 PM Program......................................................................................... 16 Radiator........................................................................................... 20 Scaffolds and Work Platforms....................................................................... 23 Steering System.................................................................................... 18 Shift Control...................................................................................... 19 Transmission Fluid Check........................................................................... 21 Transmission Light................................................................................. 17 Truck Chassis Inspection and Lubrication........................................................... 22 Upright and Tilt Cylinder Lubrication.............................................................. 22 Upright/Carriage Maintenance....................................................................... 23 Water Temperature Gauge............................................................................ 17 Wet Disc Brakes.................................................................................... 21 Wet Disc Brakes.................................................................................... 18 Wheels and Tires................................................................................... 17 250 Hour Service Check list........................................................................ 11 GROUP SA SAFE MAINTENANCE.................................................................................. 24 Section 1. Safety...................................................................................... 25 Section 2. Lifting, Jacking, and Blocking.............................................................. 27 Safe Parking....................................................................................... 28 Lifting, Blocking, and Jacking Points.............................................................. 28 Section 3. Towing...................................................................................... 29 GROUP 00 CUMMINS DIESEL ENGINE............................................................................. 30 SECTION 1. TROUBLESHOOTING............................................................................. 31 Section 2. Engine Removal and Replacement.............................................................. 42 ENGINE REMOVAL..................................................................................... 43 Section 3 Cumrnins Engine Specifications............................................................... 46 GROUP 01 COOLING SYSTEM.................................................................................... 47 Troubleshooting........................................................................................ 48 SECTION 2 TESTING AND MAINTENANCE...................................................................... 49 SECTION 3 RADIATOR REPAIR.............................................................................. 52 GROUP 03 AIR INDUCTION SYSTEM.............................................................................. 53 SECTION 1 AIR INTAKE and AIR CLEANER................................................................... 54 GROUP 06 TRANSMISSION...................................................................................... 55 SECTION 1 SPECIFICATIONS & SERVICE DATA................................................................ 56 SECTION 2 Troubleshooting.............................................................................. 59 SECTION 3 TRANSMISSION COOLING......................................................................... 61 SECTION 4 TRANSMISSION FILTER INSTALLATION............................................................. 62 SECTION 5 28000 SERIES TRANSMISSION.................................................................... 63 TOWING OR PUSH STARTING............................................................................ 65 FOREWORD........................................................................................... 66 TABLE OF CONTENTS.................................................................................. 67 TRANSMISSION ASSEMBLY.............................................................................. 68 HOW THE UNITS OPERATE.............................................................................. 69 Sectional Views.................................................................................... 70 FIGURE A....................................................................................... 70 FIGURE B....................................................................................... 71 HR 28000 CONVERTER GROUP....................................................................... 72 FIGURE C....................................................................................... 73 HR 28000 CONVERTER AND TRANSMISSION CASE GROUP................................................. 74 FIGURE D....................................................................................... 75 28000 THREE-SPEED CASE AND CLUTCH GROUP........................................................ 76 FIGURE E....................................................................................... 77 LOW CLUTCH GROUP............................................................................... 78 REVERSE AND 3rd CLUTCH GROUP................................................................... 78 FORWARD AND 2nd CLUTCH GROUP................................................................... 78 FIGURE F....................................................................................... 79 PRESSURE REGULATOR VALVE, CHARGING PUMP & OIL FILTER GROUP..................................... 80 FIGURE G....................................................................................... 81 CONTROL VALVE ASSEMBLY......................................................................... 82 MECHANICAL PARKING BRAKE....................................................................... 83 FIGURE H....................................................................................... 83 FIGURE I....................................................................................... 84 FIGURE J....................................................................................... 85 MAINTENANCE AND SERVICE............................................................................ 86 CLUTCH DISASSEMBLY............................................................................. 94 LOW CLUTCH DISASSEMBLY......................................................................... 94 FORWARD &2ND CLUTCH DISASSEMBLY................................................................ 96 CLEANING AND INSPECTION............................................................................ 97 CLEANING....................................................................................... 97 INSPECTION..................................................................................... 98 REASSEMBLY..................................................................................... 98 LOW CLUTCH REASSEMBLY..............................................................................100 SERVICING MACHINE AFTER TRANSMISSION OVERHAUL......................................................111 SPECIFICATIONS AND SERVICE DATA-...................................................................112 LUBRICATION........................................................................................112 TROUBLE SHOOTING GUIDE.............................................................................113 3 SPEED TRANSMISSION...............................................................................114 28000 SERIES - 3 SPEED CLUTCH & GEAR ARRANGEMENT...................................................115 MODULATED FWD. & REV. CLUTCHES.................................................................116 SHIELDED BEARING INSTALLATION......................................................................117 16 SCREW RING GEAR INSTALLATION PROCEDURE..........................................................119 32 SCREW RING GEAR INSTALLATION PROCEDURE..........................................................121 SPEED SENSOR BUSHING INSTALLATION..................................................................123 PROPER INSTALLATION OF TEFLON PISTON RING AND PISTON RING EXPANDER SPRINGS.........................124 DRIVE PLATE INSTALLATION...........................................................................125 TRANSMISSION TO ENGINE INSTALLATION PROCEDURE......................................................126 28000/32000 SERIES TRANSMISSION AND C-270/C-320 CONVERTER DRIVE PLATE INSTALLATION INSTRUCTIONS....127 TRANSMISSION TO ENGINE INSTALLATION PROCEDURE......................................................128 DRIVE GEAR REPLACEMENT PROCEDURE...................................................................129 NON-ASBESTOS THIRTYTWO (32) BOLT TORQUE CONVERTER DRIVE RING GEAR..................................131 TORQUE CONVERTER DRIVE GEAR INSTALLATION...........................................................133 DIMEMSIONAL VALUES.............................................................................135 INSPECTION OF IMPELLER COVER GEAR TEETH........................................................136 ENGINE FLYWHEEL AND FLYWHEEL HOUSING INSPECTION PROCEDURE......................................137 FLYWHEEL HOUSING RUNOUT........................................................................137 FLYWHEEL HOUSING BORE..........................................................................138 CHARTFOFtDlALlNDlCATOR.........................................................................139 FLYWHEEL RUNOUT................................................................................140 Eccentricity - Drive Gear to Nose Pilot........................................................141 GROUP 13 ELECTRONIC CONTROLS...............................................................................142 SECTION 1 PROTECTIVE SYSTEMS...........................................................................143 SECTION 2 EGS USER MANUAL AND TROUBLESHOOTING GUIDE....................................................144 PRODUCT DEFINITION.................................................................................145 FUNCTION DESCRIPTION...............................................................................145 USER INTERFACE.....................................................................................145 SHIFT LEVER OPERATION..........................................................................145 GRIP TYPE OPERATION........................................................................145 STANDARD TYPE OPERATION....................................................................145 STANDARD FEATURES..............................................................................146 AUTOMATIC POWERUP IN NEUTRAL...............................................................146 NEUTRAL START PROTECTION...................................................................146 SHIFT REPEAT...............................................................................146 EXTERNAL INPUTS................................................................................146 DISPLAY FUNCTION...............................................................................146 DISPLAYED INFORMATION......................................................................146 SELECTED POSITION......................................................................146 APPLICATION SPECIFIC INFORMATION.......................................................146 DIAGNOSTIC INFORMATION.................................................................146 DISPLAY LAYOUT.............................................................................147 DISPLAY METHOD.............................................................................147 OVERRIDE SYSTEM....................................................................................147 EGS LED’S FUNCTION.................................................................................148 GENERAL DISPLAY INFORMATION....................................................................148 N LED..........................................................................................148 T LED..........................................................................................148 LED 1 THROUGH 6................................................................................148 LED 7..........................................................................................148 LED 8..........................................................................................148 POWER UP CONDITION.............................................................................148 TO GET DRIVE...................................................................................148 SELFTEST FUNCTIONS.................................................................................148 SELFTEST OPERATION.............................................................................148 OPERATION OF THE “N” AND “T” LEDs..............................................................149 OVERVIEW...................................................................................149 DETAILED OPERATION.........................................................................149 INPUT TEST.................................................................................149 SPEED SENSOR TEST..........................................................................149 LAMPTEST...................................................................................149 SPEED DISPLAY..............................................................................149 OUTPUT TEST................................................................................149 SECTION 3 How to Use Battery Jumper Cables.............................................................150 GROUP 14-ELECTRICAL........................................................................................152 Section 1 General Troubleshooting......................................................................153 Section 2 Starter and Battery Troubleshooting..........................................................154 General Information................................................................................154 Minimum Tools Required.............................................................................154 Starting System Inspection.........................................................................155 Electrical Checks..................................................................................156 Slow or Sluggish Cranking......................................................................156 Nothing Happens When Start Attempt Is Made.....................................................157 Volt Drop Tests....................................................................................159 Section 3 Alternator Troubleshooting...................................................................162 Alternator Maintenance Precautions.................................................................162 Troubleshooting Procedures.........................................................................163 Abnormal Operation (Negative Reading) of the Ammeter...........................................164 Symptoms, Causes, and Remedies.....................................................................164 SECTION 4 Alternator Overhaul..........................................................................165 FEATURES...........................................................................................167 CONTENTS...........................................................................................168 INTRODUCTION.......................................................................................168 FEATURES...........................................................................................169 OPERATING PRINCIPLES...............................................................................170 TROUBLESHOOTING....................................................................................171 ALL CHARGING SYSTEMS...........................................................................171 SYSTEMS WITH INDICATOR LIGHT...................................................................171 SYSTEMS WITHOUT INDICATOR LIGHT................................................................172 NO OUTPUT......................................................................................173 RATED OUTPUT CHECK.............................................................................173 GENERATOR UNIT REPAIR..............................................................................175 DISASSEMBLY AND BENCH CHECKS...................................................................175 GENERATOR..................................................................................175 SRE HOUSING AND COMPONENTS.................................................................175 Electrical Check of Stator.............................................................176 Electrical Check of Diode Trio.........................................................176 Electrical Check of Rectifier Bridge...................................................176 DE FRAME AND COMPONENTS....................................................................177 Electrical Check of Rotor..............................................................178 GENERATOR ASSEMBLY.............................................................................178 ASSEMBLY OF DE FRAME AND COMPONENTS........................................................178 ASSEMBLY OF SRE HOUSING AND COMPONENTS.....................................................178 Installing Rectifier Bridge............................................................179 Installing Relay Terminal..............................................................179 Installing BAT Terminal and Capacitor..................................................179 Installing Regulator...................................................................180 Assembly of Brush Holder...............................................................180 Installing Brush Holder and Diode Trio.................................................180 Regulator Connector, l-Wire System.....................................................180 Regulator Connector, 3-wire System.....................................................181 Fastener Tightening Order..............................................................181 Installing Stator......................................................................181 FINAL UNIT ASSEMBLY........................................................................182 Cleaning Slip Rings....................................................................182 Removal of Brush Pin...................................................................182 GENERATOR BENCH TEST...........................................................................183 GENERATOR MOUNTING.................................................................................185 SERVICE PARTS......................................................................................187 Generator Specifications...........................................................................188 SECTION 5 Starter Troubleshooting......................................................................189 CRANKING MOTORS....................................................................................190 MAINTENANCE........................................................................................190 ADJUSTABLE NOSE HOUSING............................................................................190 OPERATION..........................................................................................190 Cross-sectional view,..............................................................................191 TROUBLESHOOTING THE CRANKING CIRCUIT...............................................................192 DISASSEMBLY........................................................................................193 CLEANING...........................................................................................193 ARMATURE SERVICING.................................................................................194 FIELD COIL CHECKS..................................................................................195 FIELD COIL REMOVAL.................................................................................195 SOLENOID CHECKS....................................................................................195 THREE-TERMINAL SOLENOID............................................................................195 FOUR-TERMINAL SOLENOID.............................................................................196 REASSEMBLY.........................................................................................196 LUBRICATION........................................................................................196 PINION CLEARANCE...................................................................................196 PINION CLEARANCE...................................................................................197 SECTION 6 Wiring Diagrams SM622 Section Title Page Nov ‘98.............................................198 SECTION 7 ELECTRICAL TOOLS.............................................................................203 GROUP 20-DRIVE AXLE........................................................................................205 SECTION 1 Troubleshooting.............................................................................206 SECTION 2 DRIVE AXLE Overhaul..........................................................................208 Index..............................................................................................210 AXLE DESIGN........................................................................................211 WHEEL HUBS.........................................................................................212 Removal:.......................................................................................212 Dismantling:...................................................................................213 Assembly:......................................................................................214 Wheel hub bearing adjustment:..................................................................214 Half shaft inspection and installation:........................................................214 Assembly of planetary carrier..................................................................214 Installation of planetary carrier..............................................................215 DRIVE GEAR.........................................................................................216 DIFFERENTIAL LOCK..................................................................................216 DIFFERENTIAL.......................................................................................217 PINION UNIT........................................................................................218 Dismantling....................................................................................218 Assembly.......................................................................................219 DIFFERENTIAL.......................................................................................221 DRIVE GEAR.........................................................................................222 REPLACEMENT OF PINION I CROWN WHEEL ASSEMSLY.......................................................223 INSTALLATION OF THE DRIVE GEAR.....................................................................225 SPECIAL TOOLS......................................................................................226 TIGHTENING TORQUES.................................................................................226 LUBRICATION........................................................................................226 AXLE CHARACTERISTICS AND DATA......................................................................226 GROUP 21 PROP SHAFT........................................................................................227 Section 1 Troubleshooting..............................................................................228 Section 2 Prop Shaft Removal and Repair................................................................229 GROUP 22 TIRE AND WHEEL SAFETY.............................................................................231 Pneumatic Wheels and Tires.............................................................................232 Pneumatic Tire Maintenance Precaution..................................................................233 General Tire Maintenance, Inspection, and Repair.......................................................234 Wheel Dismounting and Remounting.......................................................................235 Wheel Disassembly and Tire Removal.....................................................................235 Tire Replacement and Wheel Reassembly..................................................................237 Tire-to-Wheel Mounting.............................................................................238 Filling Tires with Air.............................................................................239 Installing to Truck................................................................................239 GROUP 23 PARKING BRAKES....................................................................................240 GROUP 24 SERVICE BRAKES....................................................................................242 Contents...............................................................................................244 Cross-section of WDB brake assembly....................................................................245 Brake Maintenance......................................................................................246 Brake Dismantling......................................................................................246 Wheel Hub Seal Replacement.............................................................................246 Install the Wheel Hub/Brake Adapter as Follows:........................................................247 Hub Inner Seal Installation Details....................................................................248 Sleeve Ring Installation...............................................................................248 Brake Dismantling......................................................................................250 Brake Cover/Piston Inspections.........................................................................251 Brake Drum Dismantling.................................................................................251 Brake Plate Installation...............................................................................252 Brake Unit Installation................................................................................253 Brake Back Plate, Piston and Piston Seal Replacement Details...........................................255 Outer Hub Seal Replacement.............................................................................256 Seal Installation......................................................................................256 Brake Plate Centering Tools in Position................................................................258 Special Tools..........................................................................................259 GROUP 25 STEERING..........................................................................................260 Steering Section 1. S.T.A.C. and Accumulator Charge Valve..............................................260 Steering Valve.....................................................................................261 GENERAL............................................................................................262 SAFETY.............................................................................................262 FUNCTION TESTING...................................................................................262 DISMANTLING........................................................................................263 INSPECTION.........................................................................................263 RE-ASSEMBLY........................................................................................263 RE-TEST............................................................................................263 Group 26. Steer Axle.......................................................................................264 General Description....................................................................................264 Steer Axle Stop Adjustment.............................................................................264 MAINTENANCE PROCEDURES.................................................................................264 Removal............................................................................................264 Installation.......................................................................................264 STEERING CYLINDER......................................................................................265 Removal............................................................................................265 Inspection.........................................................................................265 Assembly...........................................................................................265 Installation.......................................................................................265 Wheel Bearing and Pivof Bearing Adjustment.............................................................265 GROUP30 HYDRAULICS.........................................................................................266 Section 1 Hydraulic Schematic..........................................................................267 Section 2 Control Valve................................................................................268 REPLACING, ADDING OR REMOVING SECTION..............................................................269 REPLACING SPOOL SEALS..............................................................................270 REPLACING, ADDING OR REMOVING WORK SECTION ASSEMBLIES..............................................271 REPLACING SPOOL SEALS..............................................................................272 Section 3 TANDEM COOLING PUMPS.........................................................................273 single gear pump introduction......................................................................275 Index..............................................................................................276 Tools required.....................................................................................276 Preparation for disassembly........................................................................278 Disassembly........................................................................................280 Service inspection.................................................................................284 Reassembly.........................................................................................288 Break-in of repaired pumps.........................................................................295 Hydraulic system maintenance.......................................................................295 TROUBLESHOOTING....................................................................................296 GROUP 32 TILT CYLINDER.....................................................................................297 Section 1 Tilt Cylinder Service Procedures.............................................................298 Disassembly........................................................................................300 Cleaning & Inspection..............................................................................302 Reassembly.........................................................................................303 Seal Installation Tool.............................................................................304 Section 2 Tilt Cylinder Drift Test.....................................................................307 Section 3 Tilt Cylinder Adjustment.....................................................................309 GROUP34 UPRIGHT............................................................................................310 Section 1 GENERAL DESCRIPTION..........................................................................311 SAFETY PRECAUTIONS,................................................................................311 Section 2 CARRIAGE AND UPRIGHT ROLLERS.................................................................312 INTRODUCTION.......................................................................................312 LOAD ROLLER ASSEMBLY...............................................................................312 CARRAIGE THRUST ROLLERS............................................................................312 Section 3. Upright Chain Inspection, Adjustment........................................................313 Periodic Inspections...............................................................................314 Chain Length Adjustments...........................................................................316 Chain Removal and Replacement......................................................................320 Chain Lubrication..................................................................................321 Other Chain Service Notes..........................................................................321 Group 40, Specifications...................................................................................322 Section 1. General Specifications......................................................................322 Weights and Performance Specifications.............................................................323 Capacities*....................................................................................323 Truck weights..................................................................................323 Maximum Grade..................................................................................323 Parking Brake Test.............................................................................324 Drawbar Pull Maximum...........................................................................324 Travel Speeds..................................................................................324 Turning Radius.................................................................................324 Drift - Lift and Tilt Cylinders................................................................325 Lift arid Lower Speeds. Utxiaht................................................................325 Group Specifications...........................................................................325
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- This is the SAME exact manual used by your dealers to fix your vehicle.
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