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Clark SM 649 Service Manual
Clark SM 649 Service Manual
Service
Manual
SM.649
CMP50/60/70
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
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Main Table of Contents
Contents
Contents are listed by Group number and name followed by Section number and name:
20 DRIVE AXLE
1. Specifications and Description
2. Drive Axle Overhaul
GROUP SA
GROUP SA
SAFE MAINTENANCE
Section 1. Safety
16. Batteries, motors, controllers, limit switches, protec- General Industrial Standards, OSHA 2206: OSHA Safety
tive devices, electrical conductors, and connections and Health Standards (29 CFR 1910), Subpart N-Materials
must be inspected and maintained in conformance Handling and Storage, Section 1910.178 Powered Indus-
with good practice. Special attention must be paid to trial Trucks. For sale by: Superintendent of Documents,
the condition of electrical insulation. U.S. Government Printing Office, Washington, DC 20402.
Section 2.
A WARNING
Lifting or jacking any large piece of equipment such as your fork truck presents
obvious hazards. It must be done with great care and forethought. Consult the
truck weight tabulations in Group 40, “Specifications” to ensure that your
lifting equipment is of adequate capacity.
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SM 649, July ‘99 Intended for CLARK dealers onlyLifting, Jacking, and Blocking . SA-2-l
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Main Table of Contents
AWARNING
Do not attempt to lift the truck by the over-
head guard or the counterweight. Severe
injury may result and the truck can be
damaged.
6. Insert blocking under the frame behind the drive 3. To raise the front of the truck using the upright, spread
wheels or slip wheel cradles under the drive wheels. If two chains on the outer rail tiebar of the upright.
using blocking, check for safe clearance between drive
wheels and floor and blocks.
NOTE
A
When forks are raised as in illustration
above, use shop rags, paper, or bright tape WARNING
on fork tips to signal the danger of trip- Chain and hoist used to lift truck should be
ping. checked to make sure they are of safe lift-
ing capacity. See the truck data plate for
7. Check for stable condition of the truck. Be sure that the information.
blocks are located securely under the truck frame
before operating the drive or working on truck. 4. Slowly lift truck and lower drive wheels onto the
cradles or place blocking under frame prop points.
8. Lower the drive wheels to the floor and remove the
blocks by reversing the above procedure.
A CAUTION
When lifting the front of the truck watch
truck for signs of lateral instability. It may
tip sideways. You may have to support or
guide the side of the truck or overhead
guard to prevent tipping.
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SM 649, July ‘99 Lifting, Jacking, and Blocking l SA-2-3
Intended for CLARK dealers only
Do not sell or distribute
Main Table of Contents
Group SA, Safe Maintenance CWRK
Blocking the Upright In Raised Position
This procedure is used to safely provide clearance for
access from the front of truck to components on or near the
drive axle. Illustrations show upright with forks removed
however. fork removal is not necessary
Outer
1. Park truck safely as described in “Safe Parking.” Rail
2. Put blocks in front of and behind drive wheels.
3. Put wooden support blocks conveniently near upright
rails before raising the upright. Use two 100 x 100 mm
(4 x4 in) hardwood blocks or equal, of about 300 x 300
mm (12 in) and 600 x 600 mm (24 in) length.
NOTE
For standard uprights, block may need Short
length cut to suit. For triple stage uprights, Block
the carriage may be blocked up, as shown.
A WARNING
An incorrectly installed counterweight can
move or fall unexpectedly. Never lift or
block a truck using the counterweight. Fail-
ure to follow procedures outlined in this
manual can result in injury or death.
6. Hold the shorter block against the outer rail and lower
the upright until inner rail rests on the block.
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SA-2-4 l Lifting, Jacking, and Blocking SM 649, July ‘99
Intended for CLARK dealers only
Do not sell or distribute
Main Table of Contents
2. Put a floor jack under the steer axle mounting frame 6. When maintenance work is completed, lower the rear
member, centered between the two wheels. of truck to the floor by reversing the above procedure
and lowering each side of the truck 50 mm (2 in) at a
A WARNING
Never lift the truck by the counterweight.
time:
l Put jack under frame and raise truck.
l Carefully remove blocks and lower truck.
l Remove jack and blocks from drive wheels.
A CAUTION
Before performing any maintenance, check
the truck for stability on the blocks.
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SM 649, July ‘99 Intended for CLARK dealers onlyLifting, Jacking, and Blocking l SA-2-5
Do not sell or distribute
Main Table of Contents
Group SA, Safe Maintenance ClmK
3. Put the jack under side frame near the center of the
truck. A CAUTION
Before performing any maintenance work,
check the truck for stable condition on the
blocking.
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SA-2-6 l Lifting, Jacking, and Blocking
Intended for CLARK dealers only SM 649, July ‘99
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Main Table of Contents
CIRRIC Group SA, Safe Maintenenance
Section 3.
Towing
If your truck is disabled but can be moved freely on its own 4. Check that the counterweight bolts on both trucks are
wheels without further damage. use the following proce- in place and properly torqued to 340-380 Nom (250-
dures to tow the truck safely to a repair area. 280 ft-lb). These bolts are made of special, high-tensile
steel and are not commercially available. When neces-
A WARNING
It is important for your safety and to the
sary, replace these bolts only with a genuine Clark
replacement part.
care of your lift truck to use the proper 5. Use an approved, solid metal tow bar with towing
equipment and carefully follow these rec- couplers that connect to the towing pins in the counter-
ommendations for safe towing. weights.
Do not tow a lift truck if there is a problem NOTE
with the brakes or tires, or if the steering DOT-approved towing equipment is avail-
cannot be operated. able from your Clark dealer.
Do not tow the disabled truck up or down
ramps or steep inclines. 6. Release the parking brake on the towed vehicle. Place
directional control lever in neutral.
Do not attempt to tow the disabled truck if
traction or weather conditions are poor. Tow the disabled truck backwards. An operator must
be on the disabled truck.
Be sure to apply the parking brake or block the drive
wheels on the disabled truck while working around it. A CAUTION
When possible, raise the carriage (forks) on the dis- The power steering will not operate on the
abled truck 300 mm (12 in) from the floor or ground. disabled truck when the engine is not run-
Secure the carriage on the upright with a chain. ning. The steering handwheel will be diffi-
cult to turn.
Use a truck for towing that is of equal or larger capacity
than the disabled truck. Carry a partial load on the tow Tow the truck slowly. Careful towing is necessary to
truck for improved traction. prevent injury to personnel or damage to the disabled
truck. The truck should be towed at a speed of less than
8 kph (5 mph, or a moderate walking speed) with a
driver in place and steering the disabled truck.
IMPORTANT
Do not lift the disabled truck or any wheels A WARNING
Always engage the parking brake when
off the floor while the truck is being towed.
parking a lift truck. The truck can roll and
9. Park the disabled truck in authorized areas only. Fully cause injury or death to personnel near it.
lower the forks on the floor, leave the directional
control in neutral, turn the ignition switch to OFF, and
engage the parking brake. Remove the ignition key
and, when necessary, block the wheels to prevent the
truck from rolling.
GROUP PS
PERIODIC SERVICE
Section 1.
Maintenance Schedules
IMPORTANT
MAINTENANCE INTERVALS. If the lift
truck is used in severe or extreme operat-
ing 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 ap-
plied as actual conditions dictate.
0CO Antifreeze
0 Lubricant 0G Grease 0HO Hydraulic oil
Mast mounting
RH, LHQpoints)
Transmission oil
- Hydraulic oil
- Air cleaner
- Hydraulic breather
Wheel bearing
Fuel
RH, LH(2points)
\\ EverylOhoursordaily ._
\ \ \ \ Every2OOhoursormonthiy
Every 500 hours or every
Every 1000 hours or every
Every 2000 hours or yearly
I
clearance
Parking brake lever and
operation
Lii chain tension
Carnage bearing
Mast bearing
Mast operation 0 0
Tilt and lift cylinder fitting 0 0
Tilt and lift cylinder operation 0 0
Hydraulic pump operation 0 0
12. Lubrication
Transmission oil
Gear oil (diierential and axle end:
0
0
I
1
I.
I
I
0
0
I
I I
!
*l) Lift chain 0 0
3) Mast mounting bushing and pin 0
1
4) Joints 0
5) Tilt cylinder mounting pin and i
bearing 0
-I
6) Side roller (Carriage) 0 0 1
7) Steering axle bearing and arm 0 0
3. Clsanlng
1) Torque converter intake filter 0
2) Hydraulic oil tank interior 0
4. Replacement
*l) 1Transmission oil z
I I
I
I
I
! I
0 I
Section 2.
The Planned Maintenance Program
This Section defines a set of basic service procedures, known as the “Planned
Maintenance Program,” and describes a systematic approach for performing them.