Clark NP15 Forklift Service Repair Manual

1. SERVICE MANUAL SM535 NP 1520-12D WARNING Read and observe all warnings on the unit before operating it. Do not operate this equipment unless all factory installed guard and shields are properly secured in place. Copyrighted Material Intended for CLARK dealers only Do not sell or distribute SM535 00-00

2. INTRODUCTION PRELIMINARY SERVICE This manual is intended for the service mechanic who is seeking information about maintenance and service. It contains a section on troubleshooting which will enable a qualified mechanic to locate and solve problems which may occur. Examine this Clark Electric Truck carefully determine whether or not it has been damaged in shipment. Any damage should be immediately reported to the transportation company. to This machine should also be checked out by a QUALIFIED MECHANIC. delivery checklist is sent with each machine. The sheet is to be returned to the Clark Co., to validate warranty and to assure that the user has received a quality Clark product ready to do its jobs. (There is an example on the next page of the predelivery checklist.) This manual does not contain operation instructions or parts information. For operation instructions or parts information, refer to Clark Co. Product Support Department. An arrival and pre- An index for this manual is located on the following page. The manual is arranged according to major sections. The first part of the page number indicates the section it belongs in, and the second number identifies the page number. The higher the number of the section, the farther in the manual it is located. The sectional breakdown is as follows: All operators should be trained before operating this or any materials handling truck. This training should include a study of acceptable operating practices and actual supervised driving experience. The operator should be familiar with all operating instructions before attempting machine. Section 05 Frame Section 10 Controls Section 15 Transmission Section 20 Electrfcal System Section 30 Hydraulic System Section 35 Tires Section 40 Shielding Section 41 Jacking and Hoisting Section 45 Mast Section 50 Specification Table and Charts Section 99 Troubleshooting to operate the Check the transmission oil level and hydraulic unit oil level before operation. Check to determine that the battery is adequately charged properly installed and connected. The deadman brake pedal should be checked before each operation. THE MACHINE SHOULD NOT BE OPERATED PEDAL DOES NOT SHUT OFF ELECTRICAL POWER TO THE DRIVE MOTOR AND SET THE BRAKES. The schedule for checking the battery charge and condition is necessary for satisfactory operation of any battery powered truck. IF RELEASE OF THE Although information in this -manual is based on industry sources and is as complete as it was possible to make it at time of publication, possibility exists that some make later have changes, which could not be included here. Such information would appear in next edition of this manual and in updated pages. the “WARNING” This is used to call your attention to items or operations that could be dangerous to you or other persons using this equipment. messages carefully. It is essential that you read the instructions and safety regulations before you attempt to assemble or use this unit. Please read these Copyrighted Material Intended for CLARK dealers only Do not sell or distribute SM535 00-02

3. INDEX Frame General Description Auxiliary Door Battery Retainer Battery Rollers Load Wheel Caster Assembly Instruments and Dash Controls General Description Emergency Disconnect Auxiliary Controls Hand Lift/Speed Steering Brake Troubleshooting Transmission General Description Transmission Drive Motor Removal & Installation Drive Wheel Removal & Installation Transmission Removal Transmission Disassembly Transmission Inspection Transmission Assembly Transmission Installation Troubleshooting Electrical System General Description Battery Battery Troubleshooting Contactor General Electric Cableform EV-1 Panel Control Component Symbol Explanation Checking Components . Prestolite Motor Service Inst.. Motor Troubleshooting Master Control Switch Master Control Switch Troubleshooting Hydraulic System General Description Lift Pump Auxiliary Pump Torque Generator Lift Valve Auxiliary Valve Solenoid Valve Deep Reach Solenoid Valve 2 Stage Cylinder 3 Stage Freelift Cylinder 3 Stage Staging Cylinder Single Reach, Reach Cylinder Single Reach, Tilt Cylinder Deep Reach, Reach Cylinder Deep Reach, Tilt Cylinder Sideshifter Cylinder Flow Divider Troubleshooting 05:oo 05:Ol 05:02 05:03 05:04 05:05 05:06 lo:oo 1O:Ol 10:02 10:03 10:04 10:05 lo:06 10:99 15:oo 15:Ol 15:02 Tires General Description Caster Assembly Load Wheel Assembly Troubleshooting Shielding General Description Shielding Padding Jacking and Hoisting General Description Elevating the Truck Mast System General Description Two Stage Mast Three Stage Mast Single Reach Removal Double Reach Removal Side Shifter Removal Fork Removal/Repair Lift Chain Troubleshooting Specification General Description Data Plate Bolt Torque Data Spec. Charts for 24 V. Units Spec. Charts for 36 V. Units Periodic Maintenance Lubrication Charts External Specifications Single Reach Units External Specifications Deep Reach Units Shimming Information Serial Number Location Electrical Schematic Electrical Schematic Symbols Hydraulic Schematic Hydraulic Schematic Symbols Decal Location Special Tools Troubleshooting General Description Cylinder Auxiliary Pump Lift Pump Steering Transmission Brakes Lift Lower Reach Extend Reach Retract Sideshift Left Sideshift Right Tilt Back Tilt Forward ‘35:oo 35:Ol 35:02 35:03 35:99 40:oo 4O:Ol 40:02 40:03 41:oo 41:Ol 41:02 45:oo 45:Ol 45:02 45:03 45:04 45:05 45:06 45:07 45:08 45:09 50:oo 5O:Ol 50:02 50:03 50:04 so:05 50:06 50:07 Control Tables and Charts 15:99 20:oo 2O:Ol 20:02 Charts 20:03 for 50:08 for 20:04 50:09 5O:lO 5O:ll SO:12 50:13 50:14 50:15 50:16 50:17 99:oo 99:Ol 99:02 99:03 99:04 99:05 99:06 99:07 99:0 8 99:09 99:lO 99:ll 99:12 99:13 99:14 99:15 - 20:05 20:06 30:oo 3O:Ol 30:02 30:03 30:04 30:05 30~06 30:07 30:08 30:09 3O:lO 3O:ll 30:12 30:13 30:14 30:15 30:16 30:17 30:99 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute SM535 00-03

4. Never bypass limit switchs to gain speed. death from unstable truck operation. READ AND OBSERVE ALL warnings BEFORE operating Keep ALL guards, shields and decals in place and properly secured. Rest the forks in the down postion when NOT in use. Travel slowly over rough terrain and NEVER make sharp turns with load on forks. Check battery in a safe place away FROM open flames and potential ALWAYS park machine on a level ground or park across the incline. DO NOT ATTEMPT to clean, adjust, lubricate moving. DO NOT “HOT ROD” when starting, stopping, Operation of the machine at full speed should only be attempted familiarization with all operations. ALWAYS exercise caution and good judgment while running this machine. NEVER leave the fork raised when not attended. ALWAYS observe pedestrian% right-of-way. Do not operate this truck unless you are trained and authorized. understand operator’s manual before operating lift truck. have replacement manuals. Do not operate damaged or faulty truck. trained and authorized. Look where you drive. Watch out for people, obstructions and drop-offs. Truck will tip over if not properly operated. slow down before turning. Do not operate on slopes. Protect against falling objects. Overhead guard must be in place. Do not load truck over capacity on nameplate. carefully. Do not move unstable loads. Before getting off truck, lower forks or attachments key. Brake applies automatically. Do not clean electrical components with solvent or steam. NEVER travel, lift, or lower with the reach mechanism extended except to place or remove a load from storage. ALWAYS travel with load resting on forks not the outrigger legs. This can result in severe injury or this machine. sparks. or service the machine when parts are turning, or reversing machine direction. after complete . Read and Prime-Mover dealer’s Do not attempt repairs unless you are (especially overhead), Lower forks or attachments and Move long, high or wide loads all the way and turn off Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

5. When a powered industrial truck is to be left unattended: OPERATING INSTRUCTIONS RULES AND Stop truck. 1. OPERATOR QUALIFICATIONS 2. Lower the forks. Only trained and authorized operators shall be permitted to operate a. powered industrial truck. Operators of powered industrial trucks shall be qualified as to visual, auditory, physical, and mental ability to operate the equipment. 3. Place directional controls in neutral. 4. Apply the parking brake. 5. Turn off power. OPERATOR TRAINING 6. Turn off the control circuit. An effective operator training center around user company’s policies, operating conditions and trucks. presented completely to all new operators and not condensed for those claiming previous experience. program should 7. Block the wheels if truck is on slight incline. The program should be Maintain a safe distance from the edge of docks and platforms when operating powered industrial trucks. Do not use powered industrial trucks, while on any elevated dock or platform, to move freight cars. G. OPERATOR RESPONSIBILITY Powered industrial truck operators shall abide by the following rules and practices. H. Elevating personnel; This unit was not designed personnel. Refer to ANSI B56.1 1975 section 513 and 427 for elevating requirements. for elevating GENERAL RULES AND PRACTICES personnel A. Safeguard the pedestrians at all times. Do not drive a truck up to anyone standing in front of a bench or other fixed object. I. Care shall be’taken that overhead installations such as lights, pipes, sprinkler systems, etc. are not contacted. B. Do not allow anyone to stand or pass under the elevated portion of any truck, whether loaded or empty. J. A load bracket extension shall be used when necessary to guard against the load, or part of it, from falling toward the operator. C. Unauthorized permitted to ride. passengers shall not be K. Do not use this truck in explosion hazardous locations. and fire D. Do not put any part of the body between the uprights of the mast or outside the running lines of the truck. L. Report all accidents building structures, and equipment. involving personnel, E. When the operator is dismounted and within 25 feet (7.60 m) of the truck which remains in his view, the load engaging means shall be fully lowered, controls neutralized and brakes set to prevent movement. F. A powered industrial truck is unattended when the operator is 25 feet (7.60 m) or more from the truck which remains in view, or whenever the operator leaves the truck and it is not inhis view. Copyrighted Material Intended for CLARK dealers only Do not sell or distribute SM535 00-05

6. 3. Use extra caution grades. Never turn on any grade, ramp, or incline; Always travel straight down. when operating on up and A. Observe authorized plant speed limits. traffic conditions, keep to the right. Maintain a safe distance, based on speed of travel, from the truck ahead and keep the truck under control at all times. all traffic regulations including Under normal G. Under all travel conditions the truck shall be operated at a speed that will permit it to be brought to a stop in a safe manner. H. Travel with forks or load low. Do not elevate the load except during picking or stacking. B. Yield ambulances, emergency situations. the right of way to pedestrians, fire trucks or other vehicles in I. Make starts, stops, turns or direction reversals in a smoother manner so as not to shift load and/or overturn truck. C. Do not pass another truck traveling in the same direction at intersections, blind spots or other dangerous locations. J. Do not indulge in stunt driving or horseplay. D. Slow down and sound the audible warning device(s) at cross aisles and other locations where vision is obstructed. carried obstructs fomard view, the operator shall travel with the load trailing. K. Slow down for wet and slippery floors. If the load being L. Before driving over a dockboard or bridgeplate, be sure that it is properly carefully and slowly across the dockboard or bridgeplate and never exceed capacity. secured. Drive its rated E. Keep a clear view of the path of travel and observe for traffic clearances. personnel and safe M. Do not drive trucks onto any elevated unless specifically authorized to do so. Approach elevators slowly, and then enter squarely after 5he elevator car is properly leveled. Once on the elevator, neutralize the controls, shut off power and set brakes. other personnel leave the elevator before a truck is allowed to enter or leave. F. These trucks are designed operation. If it is necessary to operate them on a slight grade, ramp, or incline be sure to do so slowly and cautiously. totally familiar with the controls, the braking action of the trucks, plugging techniques, etc. It is also recommended operated at some what less than full capacity on grades, ramps and inclines to assure full breaking traction on the rear drive wheel. for level floor Operators should be It is advisable that all that the truck be N. Trucks shall enter elevator or other confined areas with load end forward. 0. Avoid running roadway surface. over loose objects on the 1. Loaded motorized hand trucks should be operated on all downgrade, ascending or descending. grades with load P. While negotiating turns, reduce speed, turning steering handle in a smooth sweeping motion. Except when maneuvering at a very low speed, turn the handle at a moderate even rate. 2. On all grades the load and load engaging means shall be tilted back, if applicable, and raised only as far as necessary to clear the road surface. Copyrighted Material Intended for CLARK dealers only Do not sell or distribute SM535 00-06

7. OPERATOR OF THE TRUCK A. A. Handle only stable and properly loads. When handling off-center loads which cannot be centered, operate with extra caution. arranged Before operating the truck, check its condition, giving special attention to the: 1. Tires B. Handle only loads within the capacity of the truck as rated on the nameplate. 2. Warning Devices C. Handle long and wide loads exceeding the dimension used to establish truck capacity with extra caution. Stability and maneuverability may be adversely affected. 3. Lights 4. Battery 5. Controller D. When attachments are used, extra care shall be taken in securing, manipulating, positioning and transporting the load. equipped with attachments as partially loaded trucks when not handling a load. 6. Lift and tilt engaging means, chains cable and limit switches. systems including load Operate trucks 7. Brakes E. The handling of suspended loads, by means of a crane arm (“boom”) or other device, can introduce dynamic forces affecting the stability of a truck that are not considered in the stability criteria. Sudden starts, stops and turns can cause the load to swing and create a hazard. 8. Steering Mechanism If the truck is found to be in need of repair or in any way unsafe, or contributes to an unsafe condition, the matter immediately to the designated authority, and the truck shall not be operated until it has been restored to proper operating condition. shall be reported The following precautions shall be taken when handling suspended loads: Do not exceed the truck manufacturer’s load rating of the trucks as equipped for handling suspended loads. if, during operation, the truck becomes unsafe in anyway, the matter shall immediately to the designated authority, and the truck shall not be operated until it has been restored to proper operating condition. 1. be reported 2. The load shall only be lifted vertically and never dragged horizontally. B. Do not make repairs or adjustments specifically authorized to do so. unless 3. The load shall be transported bottom of the load as low as possible. with the C. Do not use open flames electrolyte level in batteries. when checking 4. Maneuvering the truck with load elevated shall be done slowly and cautiously and only to the extent necessary lowering to the transport position. D. to permit Operate position after assuring that the operation will not endanger the operator persons. Do not operate a truck in hazardous areas. Make sure that the forks and/or load have clearance to lower and do not “hang-up”. the machine from the operators or any other Copyrighted Material Intended for CLARK dealers only Do not sell or distribute SM535 00-07

8. Arrival and Pre-Delivery Check List Your new Prime-Mover Electric Truck was carefully inspected prior to shipment from the fac- tory and should be in good working condition upon arrival. However, the following items can be checked in just a few minutes and will assure that the unit is operating satisfactorily. If ad- justments need be made, consult the Parts and Service Manual shipped with every unit. 1. UPON DELIVERY BY FREIGHT COMPANY 0 Check the unit for visible or concealed damage caused c’ damage immediately to the delivering carrier. 2. PRIOR TO DELIVERY.TO ULTIMATE USER: Operate the unit in all speeds and in both directic wires, connections, etc. have not been looseneti Check the brake interlock switch to make sur Operate the brake to make certain it is fun Operate all hydraulic controls (lift, lower. hydraulic system operates properly. Bf perly. Check transmission and hydraulic Inspect the hydraulic hoses and from dents or buckles. Check for oil leaks at cylinc’ nections should be tight. Grease all fittings. (SW Review “OPERAT@ 4” section of the parts manual with user. 3. The following checks .ade on all units using SCR control systems before battery is pl* 0 Check batte dr positive to positive, negative to negative connec- tions. DO ‘- LRY IN TRUCK. 0 Check’ ,I + or- sides of battery’ plug (on truck) to truck frame. Shou’ 3r more. NO, .itery is unplugged, key switch is on and brake pedal is d. Also operate the master control switch (with battery lb. led) forward and reverse and the lift/tilt controls to check for grou.lds on control circuits. (Always use proper size and voltage bat- tery. Never “jump” or “tap” batterys to operate SCR controlled machines or operate truck with dissimilar connectors.) 0 Plug in battery and check for smooth control on SCR to high speed in both forward and reverse. ransit. Report any the switches, .y. de, etc.) to be sure .&off switches operate pro- % .ertain they are unbroken and free ,mp and transmission. All hydraulic con- V b 77 Q This is to certify all the above points have been checked before this unit was placed in ser- vice and is now qualified for warranty registration. (Warranty card must be returned to register unit for we.rranty.) Distributor Date BY Serial No. Model No. Fofm No. 90191 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute SM585 00-08

9. PARTS ORDERING INSTRUCTIONS FIELD MODIFICATIONS The regulations mandatory that alternation of industrial trucks be done only as approved in advance and in writing by the manufacturer. These regulations counterweighing, changes in masts when such changes affect capacity modification. It is mandatory that nameplates and instructions be changed accordingly. ( 1910.178 (a) (4). imposed by OSHA make it HOW TO ORDER When you order, supply the part number, quantity and model and serial numbers of your machine. Supplying this information efficient handling of your order. reference number is not needed and including it can only add confusion. apply to will assure prompt, The pictorial and any other safety Since your dealer carries many parts i stock and maintains up-to-date prices on all parts, he will be able to process your order immediately. some reason, the part is not in stock, he will order it from the factory. In either event, he maintains a current file of Service References, which give all available parts ordering or technical information. Clark will approve such change requests as we can properly evaluate and rerate as to capacity. Normally a change will be evaluated upon receipt of a written request with full paticulars including truck and mast serial numbers, proposed changes, new heights of lift, etc. If, for If the change is approved, authorization will be sent as will new nameplates or other labeling where appropriate. The new nameplates installed over the earlier nameplate. WHERE TO ORDER should be Always order parts form the dealer who sold you your Clark truck. If it is necessary for the dealer to order parts from the factory, he is able to get prompt service for you. accordance with shipping instructions given on the order. The modifier should send confirmation change to the factory along with pictures of the revised truck. of the Parts are shipped in INSTRUCTIONS FOR RETURNING PARTS Under no circumstances will parts be accepted at the factory for credit without prior approval. Clark Co. cannot accept responsibility returned without authorization. The for parts - If you have some parts which must be returned, contact your dealer. If he believes parts should be returned, he will arrange for authorization to return the parts. .%w Numb Copyrighted Material Intended for CLARK dealers only Do not sell or distribute SM535 00-09

10. Remove the drive motor from mounting plate. Four (4) cap screws hold the drive motor. There are shim washers between the mounting plate and drive motor. Mark their number and location for easier reassembly. 4. DRIVE WHEEL REMOVAL AND INSTALLATION The drive wheel may be removed without removing the transmission from machine. To remove and/or replace the drive wheel, the following steps should be taken: NOTE: Do not remove the brake cable from the brake linkage. Disconnect the battery. 1. NOTE: Do not disassemble drive motor (wires should remain on drive motor) or brake assembly on top of the drive motor unless repairs are needed. the Hoist the machine approximately one (1) foot off the floor and Mock. 2. Remove the eight (8) nuts holding the drive wheel hub on transmission drive shaft. 3. Remove the steering chain by opening the master link. 5. 4. Remove drive tire from wheel hub, tap drive tire off the wheel hub shoulder. Removal of the six (6) remaining cap screws will release the transmission from the mounting plate. Remove the transmission underneath the truck. 6. Check the wheel hub for wear and replace if needed. 5. form ASSEMBLY 1. Press drive tire on wheel hub, check that the drive tire fits completely over shoulder of wheel hub. WARNING The transmission ds at this time, Woht is 354 2. Install drive wheel on drive shaft aligning the drive wheel with studs. Remove the drive wheel form the transmission. Eight (8) nutshold the wheel on the drive axle. 7. 3. Install torquing to 90 ftllbs. nuts and pull down evenly before Thoroughly clean the outside of transmission before disassembly preferred). 8. (steam cleaning is 4. Lower machine to floor, connect battery and test operation. TRANSMISSION INSTALLATION Transmission removal from the truck. 1. Disconnect the battery. 2. Hoist and block the truck off the floor (see elevating the truck instructions.) 3. Remove transmission fluid. the drain plug to remove the Copyrighted Material Intended for CLARK dealers only Do not sell or distribute SM535 15 - 05

11. After draining gear case lubrication and thoroughly cleaning outside, proceed with disassembly transmission as follows: of 1. Remove the steering chain sprocket halves. Four (4) screwshold them in place, two (2) cap screws and two (2) fit bolts. Shim(s) 3. Inspect pivot bearing and seal on yoke for wear, replace if needed. bottom of 2. Remove internal snap ring which retains yoke and bearing. NOTE: The bearing is shimmed .against internal perfect fit. snap ring for a NOTE: It is necessary to remove collar assembly to allow yoke to be removed. (See step # 7) 4. Remove cap screws retaining gear set cover and pry gear set cover off gear case. NOTE: fluid will be trapped behind this cover. cap Screw Transmission lubrication Remove shim, bearing and seal and parts for wear and replace, if needed. inspect nand COVW Copyrighted Material Intended for CLARK dealers only Do not sell or distribute SM535

12. After cover has been removed, inspect nut, washer, and pin in transmission replace if needed. for wear, ing Bearing Cone \ Bearing Cone 6. The bearing on the pivot pin can be removed by threading the nut on pin. Tighten nut in vice with bearing up and press or drive bearing down against vice. NOTE: removed from pin if found to be damaged of failed. Bearing should only be Remove sealing ring over bearing on pivot. Pin Nilos Ring Bearing Cone 7. Remove the six (6) socket screws from collar and remove collar from transmission by pulling up. head cap _ 5. To remove pivot pin loosen nut so it is even with the end of pin threads. striking of pin with out damage to threads. This will allow Once the pin is loosened, washer from pin and pin from transmission. remove nut and Copyrighted Material Intended for CLARK dealers only Do not sell or distribute 4/ / SM535 15 - 07

13. The nut half of this tool is to be placed in the jaws of a vice and securely clamped. locknut will fot with its slots in the tool to keep from rotating then, the shaft tool is slid in the splines of the pinion shaft. A 1 l/2” socket is then slid over the hex nut. A breaker bar is attached and removal can begin. The 8. Press lockwasher tap from locknut to remove nut. Inspect the bearing races in the collar for wear. If only one of the races are worn, replace both races, bearings and snap rongs for they are a matched set and should only be replaced as a set. 9. Collar 10. Remove Nilos ring from pinion an check pinion teeth for excessive wear and tooth pattern. _ Lockwasher The pinion and its NOTE: matching gear are a matched set and should be only replaced as that. There is a specially designed tool for use in disassembly and assembly of collar assembly that may be obtained from the Clark Company. Copyrighted Material Intended for CLARK dealers only Do not sell or distribute SM535 15 - 08

14. 12. Place transmission with drive wheel side down and with the gear case cover up. 17. Remove snap ring from under the pinion. This will allow the removal of the piston and seal(0 ring). The piston can be disassembled removing the seal (0 ring). with new when assembling. by NOTE: Failure to do this will result in the gears and needle bearings falling out when cover is removed. Replace 0 ring roller Snap 13. Remove the four (4) cap screws securing the bearing holder and four (4) cap screws securing the beating holder cover, remove the bearing holder cover also. NOTE: Shims maybe removed at this time. Bearing Holder Cap Screw Cap Screw Copyrighted Material Intended for CLARK dealers only Do not sell or distribute SM535 15 - 09

15. 14. Remove lockwashers used to secure gear case cover on gear case. the roll pin, cap screws, and \ Gear Case Cover Gear / (W”“’ 16. Remove all 0 rings from shafts and discard. On assembly, replace all 0 rings with new. The gear case cover maybe removed tapping with a soft metal (lead) hammer around the cover to loosen. The cover may then be removed straight up from the gear case. by NOTE: retained on gear case cover and should be tapped out of cover before removing cover. The gear shafts may be Copyrighted Material Intended for CLARK dealers only Do not sell or distribute SM535 15-10

16. 17. Dowel pin may be removed from gear case at this time if needed. 18. Remove bearing race from shaft of large gear set and remove gear by pulling straight up or out of gear case. The shaft maybe removed from gear case by pulling straight up and using a rocking motion. Remove 0 ring from shaft and discard and on assembly replace 0 ring with new. 0 Ring Washer, needle roller bearings, and spacer may need to be removed from the gear case. Copyrighted Material Intended for CLARK dealers only Do not sell or distribute SM535 15 - 11

17. 19. Remove race (.094), thrust bearing, and race 1.031) from shaft of small gear set and remove gear by pushing the bearing holder away from the gear by pulling straight up and out of gear case. Bearing Holder / Gear \ Race (.031) 21. Remove bearing holder assembly by sliding assembly down and out the back of the gear case. NOTE: The gear case maybe laid on its side for ease of bearing holder removal. Remove race (.031), thrust bearing, and race (.094) will need to be removed from the gear case. Ra 20. Needle roller bearings and spacers will need to be removed from gears if not already removed from gear case. This is done so needle roller bearings and spacers cleaning and inspection of gears. will not be lost in Copyrighted Material Intended for CLARK dealers only Do not sell or distribute SM535 15 - 12

18. 22. Push the lockwasher down. tap in slot of locknut Remove locknut (this can be done using the special tool from Clark) lockwasher, washer, and bearing holder. removed the top bearing core will go with it and should be removed for cleaning and inspection. Once the bearing is asher Bearing inspected for wear and damage, replaced if found. Remove shims from shaft and now remove shaft from vice and rotate so nut is on top and clamp in vice as shown in illustration. holder bearing races should be Bearing Race -. fib3 Place bearing holder hexnut in jaws of vise and clamp. NOTE: prevent damage to parts. Use a soft jawed vice to Remove nut, washer, gear, and key from shaft. Copyrighted Material Intended for CLARK dealers only Do not sell or distribute SM535 15-13

19. 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.

20. Gear Bearing Cone Copyrighted Material Intended for CLARK dealers only Do not sell or distribute SM535 45 - 14

21. 23. Turn gear case over so the open gear side is down, and you can see the hub. Toraue nut Drive 24. Loosen nut on ‘hub so it is flush with end of threads on drive axle. This is done so damage does not occur when end of drive axle is struck with a soft metal hammer to remove hub from drive axle. Remove nut, washer, hub (hub should slide off end of drive axle) and seal from drive axle. Turn gear case over and remove drive axle. The bearing, spacer, and shims will need to be removed from drive axle. NOTE: Wheel bolts can be pushed out at this time. Copyrighted Material Intended for CLARK dealers only Do not sell or distribute SM535 15 - 15

22. The bearing core on drive axle can be removed from drive axle and inspected for wear and damage. Bearing Cone 25. Inspect drive axle races in gear case for wear or damage, replace if needed. Shim(s) The races may be driven out of gear case from the other side of the race. Outer Race Drive Copyrighted Material Intended for CLARK dealers only Do not sell or distribute SM535 15 -