SERVICE MANUAL

OSX 15

Capacity : 1360 kg

Part No. 8089348

Book No. SM 844
Aug. 2010

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Intended for CLARK dealers only
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 CONTENTS

CONTENTS

Group 00. General Information Group 06. Electrical System

Group 01. Periodic Service Group 07. Motor Controls
Group 02. Structure and Major Parts Group 08. Motor - Drive and Pump
Group 03. Drive Axle Group 09. Hydraulic System
Group 04. Brake Group 10. Mast Cylinder
Group 05. Drive and Steering System Group 11. Attachment and Platform

Group 06. Electrical System

Group 11. Attachment
and Platform

Group 05. Steering System

Group 10. Mast Cylinder

Group 07. Motor Controls

Group 08. Motor - Drive Group 08. Motor - Pump

Group 09. Hydraulic System

Group 03 / 05. Drive Axle

and System Group 04. Brake

SM 844 CONTENTS-1

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 GROUP 00

GROUP 00

GENERAL INFORMATION

General Product Information................... Section 1

Technical Data ............................................Section 2

SM 844 00-0

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 Group 00, General Information

Section 1

General Product Information

Truck Presentation
The truck is a battery powered order picker truck. The truck is
intended solely to be operated indoors carrying pallets or similar
load carriers. The truck is equipped with a steering wheel with all
the controls for operating within easy access. The truck has a vari-
ous maximum lifting capacities (review data plate on the truck to
note the maximum lifting capacity).
The truck is equipped with a 24V(or 36V) electrical system and the
speed is regulated by means of a traction power amplifier (TPA)
[transistor controller] to provide gentle control of acceleration and
speed while operating. The forks are raised by means of an electric
powered hydraulic pump unit. The lift and lower forks thumb knob
is on the end of the control handle. Rotating the thumb knob up will
lift the forks and rotating the thumb knob down will lower the
forks. The truck can be specially equipped to work in cold condi-
tions. Lift and
Lower
Steering
Truck Side Views Wheel
The terms right-hand and left-hand used indicate the right and left
side of the truck as viewed from the operator’s line of sight for 㶝
㶝
proper operation of truck. Use this view when ordering parts to
assure proper selection of parts.
Left Side
Conrtrol Handle
(travel speed /
direction)

Rearward Foreward

Right Side

Intended Truck Application

The truck is solely designed and manufactured to handle piece picked goods and not full pallets or loads. Truck should be
fitted with the appropriate accessories relevant to the application.

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Prohibited Truck Application

Caution
The truck is designed for handling goods indoors. It is not permitted to use the truck for other purposes including the fol-
lowing:
• As a towing tractor for trailers.
• To tow other trucks.
• To transport/lift passengers.
• To drive on gravel or grass.

Truck Data
The following table provides information regarding technical data which is of value with daily use of the truck. Lifting
capacity, lifting height, and weight of the truck can be found on the truck’s data plate.
Metric dimensions and capacities are show in parenthesis. They have been converted from their original measurements and
rounded for convenience.

Truck data OSX15

Lifting capacity rated load 3000 lbs (1360 kg) at 24 inch (610 mm) load center to 240 inch (6096 mm)
Lift height, inches (mm) 3 stage - 195-366 inch (4953-9296 mm)
Service weight without battery Approximate 5062 lbs (2296kg) with 210 inch (5334 mm) mast
Service weight including battery See Sales Truck Specification Sheet for the most up-dated information.

Dimensions
The following diagram shows external dimensions for the truck in its standard design.

9 Max. Lift Height 210 inch (5334 mm)

(610~711mm)

1013mm 12 Overall Dimensions 78 inch (1981 mm)

24~28”

13
Platform Width
13 Width 40 inch (1016 mm)
14 Height, Upright Lowered 95 inch (2413 mm)
19
16 Height, Overhead Guard 89.4 inch (2270 mm)
17 Step Height 8.2 inch (208 mm)
18 Head Clearance 79.3 inch (2015 mm)
19 Turning Radius 68.7 inch (1746 mm)
36 Wheelbase 57 inch (1448 mm)
37 Ground Clearance 2 inch (51 mm)
9
18
14
16

1210

37 3” 17
36 (76mm)
12

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Main Components
1. Driver controls:
The steering wheel, instrument panel, and switches (key, emergency stop, and light/fan cluster) are on the console
cover. The travel speed and direction, hydraulic function, and horn are controlled through the control handle.
2. Steering wheel:
Steers the truck in the direction of travel.
3. Dash display:
All information to seen about condition of the truck.
4. Key switch:
Shuts off electrical power to control system.
5. Emergency power off (EPO) switch:
Stops control functions.
6. Lamp switch
This functions to turn on various lamp.
7. Brake pedal:
The brake is applied in the up position.
8. Pallet clamp:
Applies clamping to retain pallets to operator platform.
9. Lower switch:
The operator platform and forks will lower when switch is rotated or until lower stops are reached.
10. Raise switch:
The operator platform and forks will raise when switch is rotated or until lift stops are reached.
11. Horn:
The horn sounds to warn others of your position.
12. Travel speed / direction selection:
To select direction rotate in the direction to travel. The further you rotate in that direction the faster you travel.
13. Mast:
The mast is clear view model.
14. Hydraulic unit:
Pump motor and pump are an integrated unit.
15. Drive unit with brake:
Drive motor, gears, drive wheel, and electric brake combine the drive unit.
16. Cover and shields:
Easily removed and hinged to provide good access for servicing.
17. Electronics
All the electronics are collected in a protected compartment.
18. Battery:
24V(or 36V) battery with different capacities and weights.
19. Load wheel:
Load wheel lube location.
20. Tether line, safety belt, and body harness:

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 Group 00, General Information

20

14

1
13

2 3 4 5 6

16

10 12
17

9
11 8
7

19 18

15

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 Group 00, General Information

Inch (SAE) and Metric Fasteners

Introduction
Threaded fasteners such as bolts, nuts, cap screws, and studs are made to specifications that describe the mechanical
strength and hardness of the fastener. A fastener used in a design application is selected in accordance with its specifica-
tions. Parts used on this truck are purchased from many countries. Many fasteners are similar but cannot be used as direct
replacements.
Service technicians must use replacement fasteners that have the same specifications. Fasteners made to each specification
have identification marks for that specification. This specification is commonly called “grade” for SAE standards and
“property” for metric standards. This section describes the identification of some common fasteners.
Fastener Torque Values
Property, Class 8.8 Property, Class 10.9 Property, Class 12.9
Size and Pitch
N•m in-lbs N•m in-lbs N•m in-lbs
M5 x 0.8 5-6 44-53 7-8 62-71 8-10 71-88
M6 x 1 8-10 71-88 12-14 106-124 14-16 124-142
M8 x 1.25 20-25 177-221 30-35 265-309 ------------ ------------
N•m ft-lbs N•m ft-lbs N•m ft-lbs
M8 x 1.25 ------------ ------------ 29-35 22-26 34-40 26-30
M10 x 1.5 40-45 30-33 60-65 44-48 70-75 52-55
M12 x 1.75 70-80 30-33 100-110 74-81 115-130 85-96
M14 x 2 110-125 52-59 155-180 114-133 180-210 133-155
M16 x 2 170-190 125-140 240-270 177-199 280-320 207-236
M20 x 2.5 340-380 251-280 450-500 332-369 550-600 406-443
M24 x 3 580-650 428-479 800-900 590-664 900-1050 664-774
M30 x 3.5 1150-1300 848-959 1600-1800 1180-1328 1850-2100 1364-1549
M36 x 4 2000-2250 1479-1660 2800-3150 2065-2323 3250-3700 2397-2729

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Section 2

Technical Data

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 Group 00, General Information

(610~711mm)
1013mm

24~28”
13
Platform Width

19

9
18
14
16

1210

37 3” 17
36 (76mm)
12

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 Group 00, General Information

1 Manufacturer CLARK CLARK

General Information

2 Model Manufacturer's Designation OSX15 OSX15

3 Load Capacity lbs(kg) 3000 (1360) 3000 (1360)
4 Load Center Fork Face to Load CG in(mm) 24 (600) 24 (600)
5 Power Type Electric 24 volt 36 volt
6 Operator Type Stand Stand
7 Tire Type Front & Rear Polyurethane Polyurethane
8 Wheels (x=driven) Front / Rear 1x / 4 1x / 4
9 Maximum Lift Height, Unload in(mm) 210(5334) 210(5334)
Upright1
10 Freelift in(mm) 11(279) 11(279)
1.50x4x42 1.50x4x42
11 Fork Std. Fork Size (T x W x L) in(mm)
(40x100x1070) (40x100x1070)
2
12 Length to Fork Face (TSU) in(mm) 78.2 (1986) 78.2 (1986)
Basic Dimensions

13 Width 4 in(mm) 40 (1016) 40 (1016)

14 Overall Dimensions Height, Upright Lowered in(mm) 95 (2413) 95 (2413)
15 Height, Upright Extended in(mm) 294 (7468) 294 (7468)
16 Height, Overhead Guard in(mm) 89.4 (2270) 89.4 (2270)
17 Step Height Ground to Top of Floor Plate in(mm) 8.2 (208) 8.2 (208)
18 Head Clearance Top of Floor Plate to Bottom of OHG in(mm) 79.3 (2015) 79.3 (2015)
19 Turning Radius in(mm) 68.9 (1751) 68.9 (1751)
20 Right Angle Stack Aisle Add Load Length and Clearance 2 in(mm) 76.7 (1948) 76.7 (1948)
21 Battery Roller Height Ground to Top of Rollers in(mm) 7.4 (188) 7.4 (188)
22 Stability Accroding to ANSI Yes Yes
23 Travel Speed, Max, With Load mph(kph) 7.5 (12.0) 7.5 (12.0)
Performance

Speeds
24 Travel Speed, Max, Without Load mph(kph) 7.5 (12.0) 7.5 (12.0)
25 Lift Speeds, Loaded Triple Stage Upright fpm(mps) 53 (0.27) 63 (0.32)
26 Lift Speeds, Unloaded Triple Stage Upright fpm(mps) 66 (0.34) 92 (0.47)
27 Lower Speeds, Loaded Triple Stage Upright fpm(mps) 84 (0.43) 81 (0.41)
28 Lower Speeds, Unloaded Triple Stage Upright fpm(mps) 79 (0.40) 77 (0.39)
29 Service Weight, TSU W/Min Battery Weight lbs(kg) 6548 (2970) 6613 (3000)
Weights3

30 With Load, Front lbs(kg) 1940 (880) 2028 (920)

31 With Load, Rear lbs(kg) 7628 (3460) 7606 (3450)
Axle loading
32 W/O Load, Front lbs(kg) 3726 (1690) 3792 (1720)
3
333 W
W/O
/O Load, Rear lb
lbs(k
(kg) 2822
2822 (1280)
(1280) 2822
2822 (1280)
(1280)
34 Number, Front/Rear 1/4 1/4
12 x 5 12 x 5
Size, Front in(mm)
Tires (305x127) (305x127)
35
6 x 3.625 6 x 3.625
Size, Rear in(mm)
Chassis

(152 x 92) (152 x 92)

36 Wheelbase in(mm) 57 (1448) 57 (1448)
37 Ground Clearance At Center of Wheelbase, Loaded in(mm) 2 (51) 2 (51)
38 Service Brake Type Foot/EM Foot/EM
39 Parking Brake Type Electro-Magnetic Electro-Magnetic
40 Steering Type Power Power
Type Lead-Acid Lead-Acid
41 Battery Max Capacity (6 hr. Rate) kWh
Weight, Min lbs(kg) 1520 (689) 1600 (726)
Drive Line

Drive Motor, Diameter in(mm) 7.87 (200) 7.87 (200)

Hydraulic Motor, Diameter in(mm) 6.69 (170) 6.69 (170)
42 Motors, Controls Drive Motor Control AC AC
Speed Control MOSFET MOSFET
Hydraulic Motor Control AC AC
43 Hydraulic Pressure
44 Sound Level EN 12053 dB(A) 55.2 56.6
Notes : 1 See upright table for other available uprights.
2 Dimensions are for TSU uprights
3 Specifications are given with preferred triple stage upright
4 Overall width increases with upright height, see chart
5 Actual lift speed prior upright staging. Measured on standard MFH upright after break-in period.

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 GROUP 01

GROUP 01

PERIODIC SERVICE

Introduction, Maintenance ....................... Section 1

Service Schedule .........................................Section 2

Lubrication Chart ......................................Section 3

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Section 1

Introduction, Maintenance

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Jacking Truck Off The Floor Truck Frame

To perform maintenance that requires the truck to be lifted 1. Place the jack at the designated jacking point to one
from the floor, observe the proper safety precautions as side of the truck frame.
follows: 2. Jack one side of the truck frame so the drive wheel is
1. Lower forks completely. Remove any load. off the floor approximately 1 inch (25.4 mm). Block
that side of the truck in place.
2. Place all controls in neutral.
3. Jack up the other side of the truck frame level with the
3. Block wheels to reduce risk of truck movement.
first side.
4. Disconnect battery connector from the truck.
4. Block that side of the truck in place.
5. Place the jack under the designated jacking points.
5. With the truck frame securely blocked with the drive
tire off the floor, functional tests may be performed to
! WARNING verify truck operation.
Use extreme care whenever the truck is
jacked up for any reason. Never block the Example
truck between the mast column and floor. Use
a suitable hoist to stabilize the mast. Keep
hands and feet clear from beneath the truck
while jacking. Use safety stands or solid
blocks to support the truck. Do not rely on the
safety stands or blocks alone to support the
truck.

Operator Platform
1. Using the lift button, raise the operator platform to
obtain sufficient clearance.
2. Place a stand or block between the platform and a
baseleg and carefully lower the platform onto the Tractor Jacking Points
safety stand.
3. Turn key switch OFF and depress emergency power
off (EPO) switch. Disconnect battery connector from Baseleg
truck. 1. Place the jack at the designated jacking point.
2. Jack the baseleg until sufficient clearance to replace
Example the load wheel.

Block Example

Baseleg

Operator Platform
Blocking Point Baseleg Jacking Points

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 Group 01, Periodic Service

Lubricants − Grease fittings provided on axle and other pivot

points
− Plated pins, shafts and linkage where required
Standard − All electrical connections coated with Dow
The recommended ambient temperature is above 40° F (5° Corning No. 4 compound during assembly
C) for a truck in its standard design under continuous oper- − Lift chains coated with Libriplate chain pro-
ation. Truck operation should apply to the following guide- tectant
lines: − Components coated with LPS Cold Galvanize
where appropriate
• Parked outside storage area when not in use − Components (adjustable features, bearing races,
• Charging and maintenance work to be done outside etc.) coated with Antiseize where appropriate
storage • Sealed components used in all non-heated
• locations
Cold Storage • Heavy-duty mechanical switches used where
To reduce moisture contamination in the electrical system, appropriate
a truck equipped with cold storage conditioning packages • Thermostat controlled heaters used to reduce mois-
have electrical compound applied to all electrical connec- ture buildup in electrical component areas
tions during assembly. For a cold storage truck with con- • Heaters located around the electronic card, the
tinuous operation, the recommended ambient temperature drive and controller, the steering tachometer, and
is to 14° F (-10° C). Truck operation should apply to the hydraulic control potentiometers
following guidelines: • Windshield replaced with a screen
• Truck completely dry prior to commencing the con- • Hydraulic fluid in lift system changed to 1802154
tinuous stay in the cold storage • Standard grease replaced with Mystik JT-6 lubri-
• Parked inside the cold storage for operator cating grease
• breaks
• Charging and maintenance work done outside the Freezer
cold storage
To reduce moisture contamination in the electrical system,
• Truck completely dry before returning to continu- a truck equipped with freezer storage conditioning pack-
ous cold storage operation ages have electrical compound applied to all electrical con-
nections during assembly. For a freezer storage truck with
For a cold storage truck with intermittent operation, the
continuous operation, freezer temperature must remain
recommended ambient temperature is to -4° F (-20° C).
above -20° F (- 29° C). Truck operation should apply to the
Truck operation should apply to the following guidelines:
following guidelines:
• Surface condensation occurs, “wet” truck should
• Truck must be parked inside the freezer for operator
neither remain idle in the cold storage for no longer
breaks
than 10 minutes nor operate inside the cold storage
for extended periods • Truck stays in the freezer during battery charging or
change-out (If truck is removed from freezer for
• Condensation must not be allowed to freeze on the
maintenance work or battery charging, it must be
truck at any time
completely dry before reentering the continuous
• Park outside the cold storage for operator breaks shift in the freezer.)
• Charging and maintenance work to be done outside
the cold storage Items included in the freezer storage package are as fol-
lows:
Items included in the cold storage package are as follows:
• All cold storage items
• In an environment where a damp, wet, or corrosive • Transmission fluid in the lift system will be
condition exists the following guidelines apply: changed to Valvoline Heavy Duty Synthetic
− All hardware coated with LPS Rust Inhibitor 80W90
during and/or after assembly
− Sealed components (switches, push/pull cables,
sensors, etc.) where appropriate

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 Group 01, Periodic Service

Section 2

Service Schedule

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Planned Maintenance Schedule

ITEM WORK REQUIRED
Interval in Hours 8 30 120 240 360 720 1440
Interval in Days/Weeks/Months 1d 1w 1m 2m 3m 6m 12m
1 Chassis
1.1 Check truck data plate and decals for legibility X
1.2 Check for crack formation and damage X
1.3 Retighten truck body bolts (to chassis) X
1.4 Check cover screws X
2 Motors
2.1 Check for arcing due to poor connections X
2.2 Check tightness on all connections X
2.3 Clean motor of dirt and dust X
2.4 Check torque of motor bolts X
2.5 Check for abnormal noise in motor bearings X
Blow carbon, copper, and plastic particle accumulations
2.6 X
from the motor using compressed air
2.7 Check brush wear X
3 Drive Gear
Check for proper fluid level in the drive unit. If fluid level
3.1 X
is low, check for leaks
3.2 Apply grease to drive unit fittings X
4 Brake
4.1 Clean dust and debris X
4.2 Check brake operation X
4.3 Check proper operation of switches by the deadman pedal X
4.4 Visually inspect friction plate for wear X
5 Wheels
5.1 Remove all string, wrapping and debris X
5.2 Check all wheels for wear X
5.3 Grease load wheel bearings X
6 Steering Wheel
6.1 Check fasteners X
6.2 Check ease of steering X
7 Electrical Control System
7.1 Check key switch X
7.2 Check brake micro switch X
7.3 Check control wiring harness for proper routing X
Examine negative cable and wires from battery to the cir-
7.4 X
cuit cards.
7.5 Check red emergency stop switch for operation X
7.6 Check travel direction/speed control for operation

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ITEM WORK REQUIRED

Interval in Hours 8 30 120 240 360 720 1440
Interval in Days/Weeks/Months 1d 1w 1m 2m 3m 6m 12m
7.7 Check horn button for operation X
7.8 Check lift/lower control for operation X
7.9 Check for connections in harness connectors X
8 Battery
Check electrolyte level (0.5-0.625 inch (12-15 mm) above
8.1 X
cell plates)
8.2 Check all connections: battery, battery and charger plugs X
8.3 Check all cell and link covers intact X
8.4 Check battery specific gravity X
8.5 Check overall condition of battery X
8.6 Check battery rollers and stops X
9 Instrument Panel
9.1 Check battery level and hourmeter for correct operation X
10 Controller (Traction, Pump, EPS)
10.1 Cleaning and check mounting to chassis X
10.2 Check tightness on all connections X
10.3 Inspect contact tips for burnt or pitted surfaces X
10.4 Check contactor tips for free movements X
10.5 Check all cable insulation for damage X
10.6 Clean and inspector controller X
11 Hydraulic System
11.1 Check hoses and connections for leakage X
11.2 Check hoses for wear and damage X
11.3 Check oil tank for cracks, leaks and mounting X
11.4 Check correct oil level X
11.5 Change hydraulic oil X
11.6 Check for oil leakage X
12 Mast
12.1 Check for damage and cracks X
12.2 Retighten mast mounting bolts X
12.3 Check clearance of the rollers X
12.4 Check lateral play of inner section
12.5 Clean and lube lift chains X
12.6 Clean and lube mast columns X
13 Lifting Device
13.1 Check clearance of platform X
13.2 Check platform for damage and cracks X

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 Group 01, Periodic Service

OSX15 Main Items

12

13

7
9
6

13

5
10

2
11

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 Group 01, Periodic Service

Planned Maintenance Procedures Hourmeter

Check the hourmeter for correct operation. The hourmeter
This section describes how to perform the services listed in displays the time the deadman pedal has been depressed.
the Schedule of Planned Maintenance Operations. As with
the “Schedule”, this section is subdivided into service Hydraulic System
intervals. Inspect the entire truck for leaks, especially around the
hydraulic pump assembly and the lift cylinders. Any sign
Services Performed Daily or Every 8 Operat- of oil on the floor under the truck is an indication that the
truck may be leaking hydraulic oil or transmission fluid.
ing Hours
Report any problems to the appropriate personnel. DO
The daily inspection is to be made by the operator prior to NOT operate the truck until it has been inspected and
each operating shift. It is the operator's responsibility to repaired by a trained, qualified, and authorized technician.
report any problems with the truck to the appropriate per-
sonnel. The truck should not be operated until it has been Frame/Sheet Metal
inspected and repaired by a trained, qualified, and autho- Inspect the truck for loose, damaged or missing parts. All
rized technician. The operator is ultimately responsible for shields must be in place and functional. Report any prob-
the safe operation of the truck. lems to the appropriate personnel. DO NOT operate the
truck until it has been inspected and repaired by a trained,
Battery Level (BL) qualified, and authorized technician.
Check the BL for correct operation.The BL will always
show the mode with the highest priority that is active. For Wheels/Tires
example, an info display message will override a BL mes- Inspect wheels and tires for wear and damage. Trash that is
sage. The BL measures the level of the battery. The BL wrapped around wheels and axles will cause premature tire
indicator has ten LEDs). When the battery is fully charged, wear and bearing damage. The floors should be kept clear
all the LEDs will be illuminated. As the battery discharges, of trash to reduce damage to the wheels and tires.
the illuminated LEDs will move downward showing the
correct discharge level of the battery. When the battery is Functions/Operations
discharged, the red LEDs on the far below of the BL will Test truck for the proper operation of all functions includ-
flash alternately to warn the operator that the battery needs ing the travel controls, steering, lift and lower functions,
recharging. The BL has an integrated cut-out function that brakes, and Emergency Power OFF (EPO) button. Safety
cuts out the truck’s lift function when a predetermined devices must be operational and warning decals present
charge level has been reached. This reduces the risk of and legible. Report any problems to the appropriate per-
overloading the battery and increases the operating econ- sonnel. DO NOT operate the truck until it has been
omy of the truck. inspected and repaired by a trained, qualified, and autho-
rized technician.
! CAUTION
Safety Belt, Tether, and Body Harness
If optional devices are connected to the key Inspect safety belt, tether, and body harness for damage or
switch, the result will be a lower battery level excessive wear.
reading. The connection of optional devices to
the key switch is not recommended. An acces-
sory harness is available from as an option.

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 Group 01, Periodic Service

Services Performed Monthly or Every 120 Hydraulic Reservoir

Operating Hours Check the fluid level in the hydraulic reservoir.

The monthly planned maintenance service should be per- Frame Lube

formed by a trained, qualified, and authorized technician. The pressure type grease fittings (zerk fittings) should be
lubricated with grease. The total number of grease fittings
Inspection depends on the truck options when built. A truck with a
All of the services and inspections listed for the daily cold storage or corrosive environment application package
inspection should be performed at this time. The inspection will have more grease fittings than a standard truck. Look
procedure should be more thorough. Minor deficiencies for flush-type grease fittings on the load wheel axles. Reg-
should be corrected. ular fittings may be found on the transmission mounting
bearing and the mast chain sheave shafts.
Transmission
Inspect for oil leakage. Pivot Points
There are pivot points and other items that need to be lubri-
Battery
cated but do not have grease fittings. Lubricate these non-
Contact your battery dealer for specific instructions on
greasable wear points with a drip oil can using 10 weight
care and maintenance of the battery. An average battery
machine oil.
will have a specific gravity of 1.170 at the 80% discharged
level. However, there are many different batteries on the
market. The battery supplier can accurately determine the
fully charged and 80% charged levels. Contact the bat-
tery supplier for this information.

Electrical Connections
Check that all electrical connections are clean and tight.
Plugin connectors should be unplugged and plugged back
in to clean terminals. If the truck is equipped with any of
the cold storage, or corrosive environment application
packages, the di-electric compound in the plug-in connec-
tors should be renewed.

Contactor Tips (NOT Sealed)

Inspect contactor tips for arcing, pitting, or burning. Minor
pitting of the tips is not a problem. However, if tips are pit-
ted through the tip to the copper bar, tips should be
replaced. DO NOT file tips. Replace tips in complete sets.
Some contactors have concealed tips or are fully sealed so
that tips cannot be replaced.

Drive Motor
Blow out the drive motor fan and vents. Check for signs of
oil on the drive motor fan and air vents. Check for damage
to the fan or air vents.

! WARNING
When using compressed air, wear effective
chip-guarding and personal protective equip-
ment. Compressed air used for cleaning
MUST be reduced to less than 30 psi (207
kPa).

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 Group 01, Periodic Service

Services Performed Semi-Annually or Every Lift and Platform Chains

720 Operating Hours Inspect lift and platform chains. A chain gauge should be
used to check stretch of the links. To adjust inner columns,
The annual planned maintenance service will take a longer loosen jam nut and tighten chains equally until the top of
period of time to complete than does the monthly service. the columns are level in the fully lowered position.
This would be a good time to arrange other repairs that Retighten jam nut and torque. Platform chains should be
have been noted on the monthly service. adjusted in the fully lowered position with the forks level.
Adjust chains until the tip of the forks to the floor at the
Inspection edge of the platform measures 2.50 inches (64 mm).
All of the services and inspections listed for the daily and
monthly inspection should be thoroughly performed at this
time. All deficiencies should be corrected.
Services Performed Annually or Every 1440
Transmission Operating Hours
The transmission fluid should be drained once a year. The
drain port is located on the lower portion of the side cover Battery
opposite the drive tire. Remove the bolt to drain the trans- At approximately 1500 hours, contact an authorized bat-
mission fluid. Flush the transmission case with a cleaning tery dealer to determine the overall condition of the bat-
solution. Pour clean solution into the fill port accessed tery. Determine if the battery needs to be washed down.
from the battery compartment. With drive tire off the floor, This should be done by properly equipped and trained per-
allow solution to run out of drain port while transmission sonnel.
is running. Stop flushing when the solution runs clean.
Allow the solution to drain well before replacing the drain Brake
plug bolt. Replace the drain plug bolt. Refill the transmis- Visually inspect friction plate for wear on the electric
sion with the proper clean oil before operating the truck. brake.
Hydraulic System Hydraulic Fluid
Change hydraulic fluid.
! WARNING
Before siphoning oil from reservoir, make
certain siphon is clean.

The hydraulic system should be drained, flushed and

refilled. To drain reservoir, remove reservoir filter assem-
bly. Siphon oil from reservoir and purge oil out of hydrau-
lic system. Fill reservoir with proper clean oil. Operate the
raise and lower function several times to purge air from
system. Check oil level. Put rated truck capacity load on
the forks and adjust pressure relief valve, if necessary, so
that truck will lift a rated load.

Brakes
Follow procedures for brake removal before inspecting.
Remove the brake assembly and inspect the friction disc
for wear. The friction disc should be replaced once thick-
ness is 0.236 inch (6 mm) or less. The armature and mag-
netic coil should be adjusted if truck will not meet stopping
and holding specifications. The air gap should not exceed
0.015 inch (0.38 mm) and should remain within 0.005 inch
(0.127 mm) throughout the circumference.

SM 844 01-2-7

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 Group 01, Periodic Service

Section 3

Lubrication Chart

SM 844 01-3-1

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 Group 01, Periodic Service

Pos. Interval/Running hours

Service point Lubricant
No. 720 h 1440 h 4320 h
1 Wheel bearings L A
2 Upright Beam L E
3 Lifting chains L D
4 Hydraulic system C O B
5 Brake C
6 Steering bearings L
7 Gear ring L A
8 Drive Motor shaft, spline L G
9 Rocker plate L F
L=Lubrication C=Check O=Oil change

6
8
7

9
1

Truck Lubrication Points

SM 844 01-3-2

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 Group 01, Periodic Service

Oil and Grease Specifications

Approved Oils and Grease

Specification
Standard and
Cold Storage
Corrosion
Location

Continuous Opera- Application area Filling

Lubricant Continuous Opera-
tion To 14°F [-10°C] quantities
tion Above
Intermittent Operation
40°F [5°C]
To -4°F [-20°C]

A Grease CLARK spec. MS-6 or MS107-C Bearings and

bushings
AZOLLAZS32 EQUMS46 III Hydraulic
B Hydraulic oil system 29 L
(S-OIL) (S-OIL)
Standard: 80w90 / CS Option : 75w90
C Drive axle oil * Must meet the reguirements of API service Gears 2.2 L
GL-5 (Do not use oil that only meets GL-4)
D Motor oil In accordance with CLARK #886396 Chains
E Grease In accordance with CLARK #3762516 Mast rails
F Grease Dow corning G-N Assembly paste Rocker plate
Kluberflex BEM34-132 or Dow corning Drive motor shaft,
G Grease Molykote G-N plus paste spline

Grease Location Points

SM 844 01-3-3

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 GROUP 02

GROUP 02

STRUCTURE AND MAJOR PARTS

Chassis ........................................................ Section 1

Battery Compartment ................................Section 2

Operator Controls ......................................Section 3

SM 844 02-0

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 Group 02, Structure and Major parts

Section 1

Chassis

OzpT[`Y`WP

1 Knob 11 Link_Top Cover

2 Hinge Assy 12 Floor Mat
3 Clevis-Pin 13 Handle
4 Washer-Plain 14 Cover
5 Pin_Split 15 Side Gate MTG Assy
6 Capscrew-Flanged 16 Dash Panel
7 Flanged_Head_Cap_Screw 17 OSX Top Cover
8 Washer-Plain 18 Cover Control Lever
9 Side Cover 19 Multi Pocket
10 Front Cover

SM 844 02-1-1

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 Group 02, Structure and Major parts

Theory of Operation
The chassis is the body section of the truck that contains
the battery, motors, drive unit, hydraulic unit and electric
control panel. It has several panels and covers that are
removable. During operation of the truck, all panels and
covers must be secured to the chassis. The front cover
opens with easy release of the knob to make all areas of the
compartment easily accessible for inspection.

Maintenance
See “Planned Maintenance Schedule” on page 01-2-2

Troubleshooting
Inspect chassis every six months for crack formation and
damage. Bent or damaged body panels should be replaced.

Repair and Rebuild

When covers and/or panels become damaged and do not fit
or close properly, replace with new as necessary. Exten-
sive damage to chassis or truck in any weldment must be
reported to the company. Do not attempt to weld the chas-
sis, mast, or overhead guard without permission from the
company .

Front Cover
Removal
1. Park truck on a level surface and block.
2. Turn key switch OFF and depress emergency power
off (EPO) switch. Disconnect battery connector from
truck.
3. Release knob (1) on both sides. Tilt top cover (17) up
and slide tabs out of the chassis.
4. Open the front cover (10) from the top.

Installation
1. Position the bottom of the front cover(10) inside the
frame and then fasten the knob.
2. Position top cover (17) and push down.
3. Reconnect battery connector to truck. Energize EPO
switch and turn key switch ON.

SM 844 02-1-2

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 Group 02, Structure and Major parts

Operator Platform

OzpT[`ZWXP

SM 844 02-1-3

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 Group 02, Structure and Major parts

Theory of Operation Dash Panel

NOTE! Call-outs in the following procedures refer
The operator platform attaches to the mast chains and oper-
to illustration on 02-1-1.
ates within the mast columns. An operator overhead guard
is integral to the operator platform. The pallet clamp
Removal
applies clamping to retain pallets to the operator platform.
The deadman pedal is located on the floor of the platform. 1. Park truck on a level surface and block wheels, if nec-
essary, to prevent truck from rolling.

! DANGER
Securely block mast columns to reduce risk of
lowering when working on or near mast. If
Overhead
Guard
not blocked, unexpected movement could
occur resulting in personal injury or death.

2. Lower platform.
3. Turn key switch OFF and depress emergency power
Deadman
Pedal
off (EPO) switch. Disconnect battery connector from
truck.
4. Remove screws holding panel to platform.
5. Tip the panel cover from the bottom and remove.

Installation
Pallet
1. Position panel on the platform and secure with
Clamp
screws.
2. Reconnect battery connector to truck. Energize EPO
switch and turn key switch ON.
Maintenance
Floor Mat
See “Planned Maintenance Schedule” 01-2-2.
Removal
Troubleshooting Park truck on a level surface and block wheels, if neces-
sary, to prevent truck from rolling.
Inspect operator platform every month for crack formation
and damage. A bent or damaged platform or overhead ! DANGER
guard must be replaced.
Securely block mast columns to reduce risk of
lowering when working on or near mast. If
Repair and Rebuild not blocked, unexpected movement could
occur resulting in personal injury or death.
When the console cover becomes damaged and does not fit
or close properly, replace with new as necessary. The floor 3. Lower platform.
mat should be replaced when it becomes damaged and no
longer provides proper traction and cushioning. A bent or 4. Turn key switch OFF and depress EPO switch. Dis-
damaged platform extension (optional) must be replaced. connect battery connector from truck.
The overhead guard must not be repaired or welded. If the 5. Pry floor mat loose and remove from platform.
overhead guard is damaged and requires repair, the plat-
form assembly must be replaced. Installation
1. Position floor mat on the platform.
2. Reconnect battery connector to truck. Energize EPO
switch and turn key switch ON.

SM 844 02-1-4

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 Group 02, Structure and Major parts

Section 2

Battery Compartment

OzpT\WWX[P

1 Frame Weld Assy 6 SBR Roller Assy

2 Battery Stoper Plate 7 Hexhead_Screw
3 Battery Stoper Plate 8 Hexhead_Screw
4 Battery Stoper 9 Capscrew Flanged
5 Plate Bumper Cover

SM 844 02-2-1

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 Group 02, Structure and Major parts

Theory of Operation the tongue on the operator compartment end of the

battery stop plate.
The truck is equipped with battery rollers and battery stop 2. Continue lifting until the battery stop plate (2) is clear
plates for ease of battery removal and replacement. of the truck, then set aside.

Maintenance Installation
1. Position the battery stop plate (2) with tongued edges
! WARNING
on the bottom and facing the operator compartment.
2. The edge toward the operator compartment should be
Battery electrolyte is a solution of sulfuric
tilted in so that the tongue engages with the slot in the
acid and water. Battery acid causes burns.
back of the battery compartment.
Should any electrolyte come in contact with
clothing or skin, flush the area immediately 3. Carefully lower the battery stop plate into position.
with cold water. Should the solution get on Move the plate forward and backward until proper
your face or in eyes, flush the area with cold engagement is noted.
water and receive medical attention immedi-
ately. Battery

! CAUTION
Removal
1. Park truck in an approved battery changing area.
Before working on the battery, review Bat-
tery Safety. Batteries may weigh more than 2. Turn key switch OFF and depress Emergency Power
24volt : 1520 pounds (689 kg), 36volt : 1600 OFF (EPO) switch. Disconnect battery connector
pounds (726 kg). Use extreme care during from truck.
replacement. Use a suitable battery replace- 3. Position battery changing device against side of truck
ment device or hoist for lifting. at battery compartment according to device manufac-
turer’s instructions.
Inspect the battery stop plates for bending or cracks, mak- 4. Remove stop plate on side of removal device.
ing sure they work properly. Inspect the battery rollers to
5. Roll battery using removal device.
ensure they can turn freely. Clean battery rollers of all elec-
trolyte with a solution of 1 lb (0.45 kg) of baking soda Installation
added to 0.5 gallon (1.9 liters) of hot water. See “Planned
1. Position device with fully charged battery against
Maintenance Schedule” on page 01-2-2.
truck.
2. Roll battery in truck.
Troubleshooting 3. Reinstall stop plate.
Check battery rollers and battery stops every six months. 4. Remove battery changing device.
5. Reconnect battery connector to truck. Energize EPO
Repair and Rebuild switch and turn key switch ON.

The battery rollers and battery stops can not be repaired or

rebuilt. Replace battery rollers and battery stops with new Battery Rollers
as necessary.
Removal
NOTE! Call-outs in the following procedures
1. Park truck on a level surface and block.
refer to illustration on page 02-2-1.
2. Turn key switch OFF and depress EPO switch. Dis-
connect battery connector from truck.
Battery Stop Plate
3. Remove batteries from truck.
Removal 4. While lifting the battery stop plate (2) upward, tilt the
edge toward the mast slightly forward to disengage
1. While lifting the battery stop plate (2) upward, tilt the
edge toward the mast slightly forward to disengage

SM 844 02-2-2

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 Group 02, Structure and Major parts

the tongue on the operator compartment end of the

battery stop plate.
5. Continue lifting until the battery stop plate (2) is clear
of the truck, then set aside.
6. Remove battery rollers assembly (6).

Installation
1. Install battery rollers assembly (6).
2. Slide battery plate in position.
3. Install batteries in truck
4. Reconnect battery connector to truck. Energize EPO
switch and turn key switch ON. Test truck for proper
operation before returning to service.

SM 844 02-2-3

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 Group 02, Structure and Major parts

Section 3

Operator Controls

Theory of Operation Maintenance

The operator controls are located either on the console For maintenance see “Planned Maintenance Schedule”
cover or on the control handle. The steering wheel, instru- on page 01-2-2
ment panel display, and switches (key, emergency stop,
and light/ fan cluster) are on the console cover. The travel
speed and direction, hydraulic function, and horn are con-
Repair and Rebuild
trolled through the control handle. The control handle is The control handle, steer wheel, deadman pedal, pallet
the operator’s means of controlling travel, lift/lower, and clamp, or tether may wear due to normal usage. These
horn functions. The deadman pedal is located on the floor items can not be repaired or rebuilt and must be replaced
of the platform. The pallet clamp applies clamping to with new as necessary.
retain pallets to the operator platform. The tether line,
safety belt, and body harness secures the operator in place
during truck operation. Multi-Function Control Handle
The multi-function control handle is located on the console
to the right of the steering wheel of the operator platform.
Travel direction and speed as well as hydraulic functions
and the horn are controlled through this handle. Operating
instructions are given in the Operator’s Manual.

Removal
1. Turn key switch OFF and depress Emergency Power
OFF (EPO) switch. Disconnect battery connector
from truck.
2. Remove dash panel (page 02-1-4).
3. Disconnect wiring harness
4. Remove screw and ground screw from control handle
assembly. Remove control handle assembly.
Control
Steering Handle Installation
Wheel 1. Install control handle assembly and secure with
ground screw and screw.
2. Install dash panel.
3. Calibrate the control handle.
Deadman
Pedal 4. Reconnect battery connector to truck. Energize EPO
switch and turn key switch ON. Test truck for proper
operation before returning to service.

Pallet
Clamp

SM 844 02-3-1

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 Group 02, Structure and Major parts

Steer Wheel

Steering Wheel
Detail

Steering
Wheel

Removal
1. Turn key switch OFF and depress EPO switch. Dis-
connect battery connector from truck.
2. Remove dash panel (page 02-1-4).
3. Remove steer wheel (see page 05-4-2).

Installation
1. Install steer wheel (see page 05-4-2).
2. Install dash panel.
3. Reconnect battery connector to truck. Energize EPO
switch and turn key switch ON. Test truck for proper
operation before returning to service.

SM 844 02-3-2

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 Group 02, Structure and Major parts

Deadman Pedal

Deadman
Pedal

27 Du Bush-Flange, Duf 1825-26

28 Spring-Deamdan Switch
29 Pedal-Deadman Switch
30 Cotter-Pin
31 Support-Cottor Pin
32 Proximity Sensor

SM 844 02-3-3

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 Group 02, Structure and Major parts

Pallet Clamp

(SI-50040)

1 Bearing-Shaft 15 Brkt Assy-Clamp

2 Spring-Brake 16 Cable Assy-Clamp
3 Pad-Parking Pedal 17 Cable Assy-Short
4 Nut-Flanged Hex 18 Cover-Lh
5 Pin-Cotter 19 Cover-Rh
6 Capscrew-Flanged 20 Link-Cable
7 Ring-Cotter-Rue 21 Spring
8 Pedal-Pallet Latch 22 Roller Assy
9 Shaft-Latch 23 Nut-Hex
10 Hex-Socket-Cap-Screw 24 Capscrew-Hex
11 Capscrew-Flanged 25 Cover
12 Clevis-Rin 26 Pin-Clevis
13 Jaw Assy-Lh 27 Ring-Retaining C-Type
14 Jaw Assy-Rh 28 Ring-Retaining

SM 844 02-3-4

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 Group 02, Structure and Major parts

Decals removing the decal. Replacement of warning decals are

free from the company.
Remove and replace any decals that are damaged. Replace
Using the required cleaning solution, thoroughly clean the
any missing decals. Remove a damaged decal by using a
surface of the truck before applying a new decal. Allow the
sharp edge to peel the decal from the surface. Use caution
surface to completely dry, be sure that there is no residue.
not to scratch or damage the paint on the truck when
Touch up the paint in the area of the decal, as required.

7
11

1
2 8

;3;6898

12
10 3

SM 844 02-3-5

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 GROUP 03

GROUP 03

DRIVE AXLE

Maintenance and Installation Instructions

..................................................................... Section 1

Repair ..........................................................Section 2

SM 844 03-0

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 Group 03, Drive Axle

Section 1

Maintenance and Installation Instructions

GK20

SM 844 03-1-1

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 Group 03, Drive Axle

Safety Instructions
• The use as directed requires the strict observance with the manufacturer’s specifications for installation, dis- and
reassembly, initial operation and maintenance.
• Every person concerned with installation, disassembly and reassembly, initial operation and maintenance of the
transmission in the user plant must have read and understood the whole instructions and in particular the safety
instructions.
• Any working method which endangers the safety of the transmission is prohibited.
• Modifications and changes without the proper permission are affecting the safety of the transmission and are not
allowed.
• Only original spare parts from ZF or spare parts approved by ZF are allowed to be used. It is explicitly pointed out
to the fact that spare parts and accessories, which were not supplied by ZF are not checked and approved by us
either. We do not accept any liability or admit any warranty for damages caused by the use of spare parts and acces-
sories which are no original parts from ZF.
• The described work is only allowed to be made by authorized, skilled and instructed staff.
• The proper repair of these ZF-products requires adequately trained specialists. The repairer is responsible for the
training!
• Keep away aggressive cleaners from your skin, do not drink it or inhale its vapours! Always wear safety gloves and
goggles. If by mistake cleaner was swallowed, call medical aid immediately! Strictly observe manufacturer instruc-
tions.
• Do not drain cleaners or transmission oil into the sewerage system or into the soil.
• Prior to start working on the installed or mounted transmission, the wheels must be blocked.
• Prior to any work on the installed transmission (e.g. oil change) or its mounted-on parts the voltage source feeding
the motor must always be disconnected resp. switched off.
• The local regulations for safety and prevention of accidents must be observed!

SM 844 03-1-2

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 Group 03, Drive Axle

Install

EPS Motor

Item NO. Description

1 Washer-Plain
2 Bolt
3 Pinion-EPS
4 Drive-Unit

SM 844 03-1-3

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 Group 03, Drive Axle

Screw

Centering ring

Screw

Bearing Steering limiter

Screw
Steering pinion
Screw
Stop

Breather valve
Cap
Steering gear Hex nut

Super gear

Taper roller Bearing

Shim ring
Sealing ring
Spacer tube
Retaining ring
Shim ring
Ball bearing
Taper roller Bearing

Input pin Bevel gear set

Cap
Ball bearing Cover

Housing Pin
Screw
Shim ring

Ring

Bolt Sealing ring Plug Taper roller O-ring Screw

Bearing
Shaft protection Gear Shaft Taper roller Plug Pin Retaining ring Shim ring Cover
Bearing

SM 844 03-1-4

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 Group 03, Drive Axle

Components and Accessories of a GK Transmission

01 one-piece transmission housing
02 Venthole for electric motor ventilation
03 Optional steering: Gear ring with steering pinion (is shown) or steering chain as alternative
04 Mounting holes (optional)
05 One-piece pivoted bogie bearing (optional)
06 Wheel shaft with centering and locating face for drive wheel
07 Fully integrated drive pinion with motor connection profile
08 Housing cover
09 Oil filler plug and oil level check
10 Oil drain plug

Other customer-specific accessories are possible!

05 03

03
01

02

09

06
10

07

04

04

08

SM 844 03-1-5

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 Group 03, Drive Axle

Transmission Identification
The transmission type is cast in the transmission housing on the bearing cover side.

Transmission type of
the product range GK

The model identification plate is fixed to the transmission housing side.

Technical data of the transmission is indicated on the model identification plate.

Transmission type Serial Number

GK 20 200001
4699 801 017 14,50

ZF Parts List No. Total ratio

SM 844 03-1-6

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 Group 03, Drive Axle

Installation

General Instructions

Torque limits in Nm for screws to ZF Standard 148

Torque limits, if not especially indicated, can be taken from the following list:

Metric ISO-Standard thread DIN 13, Sheet 13 Metric ISO-Fine thread DIN 13, Sheet 13
Size 8.8 10.9 12.9 Size 8.8 10.9 12.9
M4 2.8 4.1 4.8 M 8x1 24 36 43
M5 5.5 8.1 9.54 M 9x1 36 53 62
M6 9.5 14 16.5 M 10x1 52 76 89
M7 15 23 28 M 10x1.25 49 72 84
M8 23 34 40 M 12x1.25 87 125 150
M 10 46 68 79 M 12x1.5 83 120 145
M 12 79 115 135 M 14x1.5 135 200 235
M 14 125 185 215 M 16x1.5 205 300 360
M 16 195 280 330 M 18x1.5 310 440 520
M 18 280 390 460 M 18x2 290 420 490
M 20 390 560 650 M 20x1.5 430 620 720
M 22 530 750 880 M 22x1.5 580 820 960
M 24 670 960 110 M 24x1.5 760 110 1250
M 27 1000 1400 1650 M 24x2 730 1050 1200
M 30 1350 1900 2250 M 27x1.5 1100 1600 1850
M 33 1850 2600 3000 M 27x2 1050 1500 1800
M 36 2350 3300 3900 M 30x1.5 1550 2200 2550
M 39 3000 4300 5100 M 30x2 1500 2100 2500
M 33x1.5 2050 2900 3400
M 33x2 2000 2800 3300
M 36x1.5 2700 3800 4450
M 36x3 2500 3500 4100
M 39x1.5 3450 4900 5700
M 39x3 3200 4600 5300

Friction value: μ tot. 0.12 for screws and nuts without after-treatment, as well as phosphatized nuts.
Tightened by hand!

SM 844 03-1-7

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 Group 03, Drive Axle

Condition as supplied
! CAUTION
The basic transmission is supplied as follows:
Do not drain cleaners into the soil. Overflown
• Ready assembled cleaner is to be disposed of adequately. Do not
• Without oil filling (customer-specific agreement abrade with emery or scrape off! Avoid that
possible) cleaners get in contact with rubber parts, the
electrical connections of the accessories or the
• Painted with prime coating (ZF Standard 902) and motor ventilation!
coating varnish (RAL 9005), colour: jet black
• The wheel shaft sealing, the centering- and locating
face for the drive wheel on the wheel shaft, the ! DANGER
wheel bolt threads, the connecting faces and bore- Keep away cleaning agent from your skin, do
holes for motor and vehicle connection are pro- not drink it or inhale its vapours! Wear safety
vided with a short term corrosion protection. gloves and goggles! In case of skin contact
• Metallic bright sections (like e.g. fits or guides) are rinse immediately with a lot of water! If by
also provided with a short term corrosion protec- mistake the cleaning agent was swallowed,
tion. call medical aid immediately! Observe the
• With internal preservation for short-term storage in regulations for the prevention of accidents!
a dry ambience.

Storage
The supplied GK-transmissions are provided with an inter-
nal preservation, ensuring a corrosion protection for
approx. 1 year at an adequate storage in closed and dry
rooms.
If a transmission is to be stored for a longer time, the trans-
mission has to be filled with the specified transmission oil
(see Chapter “Initial Operation / Maintenance” “Oil
Grade”).
At an input speed of 1000 to 1500 min-¹ the transmission
is to be driven for approx. 2 minutes, so that all transmis-
sion internal parts are wetted with oil. If this is ensured, the
oil can be drained off again.
We recommend repeating this procedure yearly!

Transport
The unit is only allowed to be lifted with soft ropes or belts,
never with steel ropes or chains. During transportation care
must be taken to avoid shocks.

Removal of the corrosion protection

Only with a suitable cleaner the corrosion protection is to
be removed from the connecting points before installation
into the vehicle. Never use benzene, solvents or other com-
bustible substances for cleaning. Only use non-toxic, non-
combustible and commercially permissible cleaning
agents.

SM 844 03-1-8

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 Group 03, Drive Axle

Attachment of the Electric Motor Turn the hole pattern of the pivoted bogie bearing to be
accurately aligned with that of the electric motor. Fasten
If the unit is supplied with an already attached electric the electric motor by means of six (6) cap screws M8 and
motor this chapter is not applicable. locking pieces with the pivoted bogie bearing. Pay atten-
The centering- and locating faces for connection of the tion to the minimum screw-in depth (4).
electric motor must be perfectly clean and undamaged.
Check face run-out of the motor connecting face to the ! CAUTION
motor shaft. The maximum run-out must not exceed 0.05 Please observe the specified mounting dimen-
mm. sions of the corresponding installation draw-
ing!
! DANGER
An excessive face runout will have a negative
effect on the noise behaviour and results in ! CAUTION
premature wear of the spur gear stage. For connecting cautiously rotate the wheel
shaft of the transmission or the input shaft of
Assembly instructions for the splined shaft- the electric motor (depending on the mount-
hub connection ing position) until the input shaft engages into
the splined hub connection of the drive pin-
An assembly paste has to be used as assembling aid and
ion. When locating the electric motor take
later long-term lubricant for the splined shafthub connec-
tion. care that the splined shaft-hub connection (5)
of the drive pinion and the electric motor
shaft will not be damaged.
Attachment of the electric motor to the trans-
mission
Apply a thin and even coat of the special lubrication grease
! DANGER
BEM 34-132 onto the splined shaft-hub connection. Damages cause louder running noises and
Assemble the electric motor (1) into the centering seat of premature failure of the splined shaft-hub
the pivot bogie bearing (2) and join it cautiously with the connection!
splined hub connection of the drive pinion (3).

Example for the electric motor attachment without centering ring connection directly to the pivoted bogie bearing.

01

04

02

03
05

SM 844 03-1-9

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 Group 03, Drive Axle

Pivoted Connection-Steering

Mounting of the gear ring with pivoted bogie bearing GK 20

1. The centering and supporting face for the gear ring
has to be clean.
2. Pay attention that no foreign substances or cleaning 03
agents get through the threaded holes (01) of the
mounting construction (hole pattern of the housing) 04
inside the transmission.
3. Place the gear ring (02) and rotate it, so that the bolt-
holes in the gear ring are aligned with the threaded 02
holes of the mounting construction.
4. By means of a plastic tip hammer install the gear ring.
5. Put on the pivoted bogie bearing (03) with the correct
side and rotate it so that the boltholes in the pivoted
bogie bearing are aligned with the hole pattern of the
gear ring and the housing.
01
6. Fasten the pivoted bogie bearing and the gear ring on
the mounting construction by means hexagon screws
M8x40 (04).

01

Attention
In order to avoid inadmissible leakage problems on the screws, it is mandatory to observe the following
procedure for thread sealing:

• Always seal the screws (01) located in the oil sump of the transmission! For this purpose these are to be wetted with
LOCTITE 243 around the thread contact face and only then to be attached.
• In order to avoid inadmissible variations among the screw clamping forces, always pretension the screws carefully
crosswise to the specified value. Tightening torque: 34 Nm
• After a possible disassembly the LOCTITE residues in the threaded holes must be removed. It is necessary to use
new screws.

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Lubrication and maintenance of the pivoted connection

First lubrication of the teeth is to be made immediately after mounting. Spray grease is to be sprayed or to be applied evenly
onto the teeth. For this purpose and any later relubrication only use acid-free, nonresinous, waterproof and non-ageing
greases!

! DANGER
Without lubrication and relubrication respectively there will be a direct metallic contact of the teeth
resulting in damages.

Relubrication intervals
The relubrication intervals depend essentially of:
• the existing operating conditions
• the environmental influences like e.g. dirt, water, etc.
• the mounting type of the pivoted connection

! CAUTION
Prior to every relubrication procedure it is necessary to clean the teeth, in particular the tooth root.

Exact relubrication intervals can only be determined by tests under application conditions. If no comparable results are
available, Table 01 serves as orientation.
Operating condition Relubrication interval
dry and clean rooms after 250 h
heavier dirt accumulation, after 100 to 150 h
outdoor operation
extreme dirt accumulation continuously
<Approximate values for the relubrication interval>

The indicated values are based on the following conditions:

• Operating temperature <70°C
• Circumferential speed <0,5m/s
• Low to medium load

If longer relubrication intervals are determined by tests, the relubrication interval can be determined by the ageing resis-
tance of the lubricant, if necessary.

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Transmission Attachment to the Mounting Construction in the Vehicle

For economy reasons the cross sections of the pivoted bogie bearings are kept very small in comparison with the diameter.
This requires a rigid and torsion-resistant mounting construction for these bearings. Additionally the supporting face for
the pivoted bogie bearings and mounting of the same must also provide the maximum evenness or flatness.
The supporting face in the vehicle requires a mechanical machining. Inadmissible distortions or deformations during fas-
tening of the screws occur due to uneven locating on the frame plate or unevenness in the locating area of the pivoted bogie
bearing.

! DANGER
The pivoted bogie bearing must support evenly on the whole surface of the mounting construction. If this
requirement is not fulfilled the service life of the pivoted bogie bearing reduces. Additionally, the reliabil-
ity in service is put at risk.

! CAUTION
Shape alternatives of the locating face require a written approval by ZF, which however will only be given
after a preceding installation investigation.

M 12

0.15

Screw-in depth
min 15 mm

! CAUTION
Please observe the specified vehicle mounting dimensions indicated in the corresponding installation
drawing of the unit!

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Initial Operation / Maintenance Oil Change

! DANGER Drain the transmission oil at GK 20

If the units are not delivered with filled oil, fill
in the transmission oil before the initial oper- ! CAUTION
ation! Do not drain transmission oil into the soil or
the sewerage system. Pay attention to the type
Oil grade for transmission types GK 20 and quantity of debris.
Approved are only oils which fulfill the below specifica-
tions: ! DANGER
• Classification to API-GL5 High oil temperatures are to be expected after
− Standard : SAE 80W90 continuous operation of the transmission.
− Option : SAE 75W90 Wear temperature-resistant gloves!
• Do not use oil that only meets GL-4
• Position the vehicle on even ground and lock the
wheels for safety purposes.
Oil capacity
• Carefully clean the area around the oil filler and oil
Total transmission oil quantity GK 20: 2.2 liters drain plug.
The oil quantities are approximate values and serve as • Place a suitable big oil collecting vessel under the
guide only. oil drain plug.
• Loosen the oil filler plug (01) with a 6mm Allen
Maintenance intervals Transmission wrench. Remove the oil filler plug and the sealing
ring (02).
After approx. 25 operating hours:
• Loosen the oil drain plug (03) with a 6mm Allen
• Visual inspection for possible oil leakage on the
wrench. Remove the oil drain plug and the sealing
transmission; oil level check
ring (02).
• Have the transmission oil drained into the vessel
completely.
After 1500 operating hours or at yearly intervals:
(whatever occurs first)
• Visual inspection for damages, leakages and possi-
ble oil loss on the transmission – oil level check

! CAUTION
02
No further transmission oil changes are
required. Repaired transmissions are to be
treated like new transmissions. 01
Modifications of these specifications require
the written approval by ZF. 02

03

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! Technical Data of the GK – Product

CAUTION
For transmissions an oil drain time of approx.
Range
5 min. must not be exceeded.
GK – product range GK 20
Max. wheel load kg 2000
Fill in the transmission oil at GK 20
Max. wheel size Ø mm 310
• Clean magnet on the oil drain plug (03) and always Max. wheel size mm 125
reattach it with a new sealing ring (02). (Please
refer to the drawing on page 03-1-13) Max. wheel torque Nm 980
Tightening torque: 22 Nm Max. speed min-1 4500
• Fill in the transmission oil. For oil quantities and Ratio 10.2 – 25.4
viscosity classes see Chapter „Initial Operation / Envelope mm 168
Maintenance“ Paragraph „Oil Grade“ & „Oil Temperature range °C - 30 to + 40
Capacity“
Weight, without oil,
• For filling use a suction and pressure injector ( 05). kg 46
E-motor, drive wheel
This allows an easy and rapid filling of the trans-
mission with oil.
• The correct oil level and the correct oil quantity is Subject to technical modifications.
achieved when the oil level is at the lower edge of
the oil filler plug, at least when oil penetrates at the
oil filler plug.
• Attach the oil filler plug (01) with a new sealing
ring (02).
• Tightening torque: 22 Nm

05

! CAUTION
After 25 operating hours check the oil level
once again. Refill oil, if necessary!

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Maintenance Scheme
Maintenance only once after regularly after
intervals after operating
0h 25h 200h 300h 600h 1500h
hours
varying, depending
what occurs first at intervals Mounting 7 days 1 month 3months 6months 12months

Maintenance work
Attention:
after 50 km it is absolutely necessary to
retighten the wheel nuts of the installed ●
drive wheel with the specified tightening
torque of 140 Nm!
Retighten the fixing bolts of the pivoted
connection with the specified tightening ●
torque 34 Nm!
Oilchange ●
Greasing of the teeth on the pivoted con-
nection ●

Visual inspections
Visual inspection for oil leakage ● ● ●
General condition of the pivoted connec-
tion (for extreme conditions, see Chapter
“Lubrication and maintenance intervals ●
of the pivoted connection”
General condition of the transmission
(e.g. damages; cracks in the housing, ●
noises, etc.)
General condition of the drive wheel (e.g.
deformation, damage, etc.) ●
General condition of the motor (e.g.
grease in the motor, tempering colours, ●
fan inspection, etc.)

Special application conditions

stored transmissions Conservation to be renewed every 6 months
Transmissions with less operating hours acc. to maintenance scheme
Transmissions with extreme operating Intervals to be reduced by half
conditions

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Section 2

Repair

General Data for Disassembly and Reassembly

Instructions
• Pay attention to cleanliness and expert like manner for all work to be carried out. Transmissions removed from the
vehicle have therefore to be cleaned prior to opening. Both utmost care and cleanliness are essential conditions for
a correct disassembly and reassembly of the transmission as well as for the installation of each spare part. A fault
during installation can result in an early wear and chips or other foreign particles in the transmission can cause fatal
damages.
• Prior to assembly all parts must be cleaned and inspected for wear and other defects.
• If it is found that removed parts are damaged or worn, do not reinstall but replace them by new ones.
• If not separately indicated, the housing and cover faces forming an oiltight connection are to be provided with the
corresponding sealing compound during assembly.
• Special devices and special tools are necessary besides the standard tools. Their use is unavoidable for a technically
adequate dis- and reassembly! The application of devices, special tools and other fixtures are to be adapted to cir-
cumstances of the respective users.
• Commercial tools and fixtures belonging to the basic equipment are assumed to be available.
• If not otherwise indicated all pressing operations are made by means of the hand lever press.
• All screws and threads in this transmission have metric dimensions. Only spanners and socket spanners with metric
sizes are allowed to be used.
• For reassembly all of the indicated setting values, test data and tightening torques must be observed.
• Observe the described sequence of the working steps.
• All pictures serve the illustration and are not obliging for this execution.

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Replacement of Wheel Bolts

Necessary Tools
Standard Tools

Tool 1 Tool 2 Tool 3 Tool 4 Tool 5

Center punch Hammer Drill ø 3.0 Drill ø 7.1 Tap Wrench

Special Tools

Tool 6 Tool 7 Tool 8 Tool 9 Tool 10

Screw extractor Tap Thread plug gauge Torque spanner Fixture 62313-03
M11-M14

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Replacement of Broken Wheel Bolts

• Initial situation

• Punch mark with hammer and center punch (TOOL 2 and 1).

• Bore with drill (TOOL 3).

• Bore with drill (TOOL 4).

• Place the screw extractor (TOOL 6).

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• Place trap wrench (TOOL 5) onto screw extractor (TOOL 6) together

with a suitable locking tool (shown is a crow bar).

• Unscrew the wheel bolt.

• Chase thread with the tap (TOOL 7).

• Check thread with thread plug gauge (TOOL 8) – ”GO side“

• Check thread with thread plug gauge (TOOL 8) – “NO-GO side“

• If the NO-GO side fits, the wheel shaft is to be replaced completely.
(See Page 03-2-21. Removal of Wheel Shaft and Crown Gear)

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• Put fixture 62313-03 (TOOL 10) with new wheel bolt into the thread
and lock it with a suitable tool. (shown is a crow bar).

<Figure 1>

• Tighten wheel bolt with torque spanner (TOOL 9).

Torque: 80 Nm.

<Figure 2>

Replacement of Wheel Bolts

• Lock the transmission like <Figure1>
• by means of pliers unscrew the wheel bolt to be replaced CCW and get it disposed of.
• install the new wheel bolt as explained in <Figure1> and<Figure 2>.

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Replacement of Shaft Seal – Wheel Shaft (Field Version)

Disassembly
• Put the fixture “63428” onto a suitable and robust support and
place the transmission as shown in the Figure on the right.

• Loosen and remove the 8 cap screws (1) on the transmission cover.
Then pull off the cover cautiously.
GK 20: M10x30-8.8

IMPORTANT
Parts will be needed again for reassembly!

• The taper roller bearing (2) which is now visible in the transmis-
sion interior on the wheel shaft has to be removed with the puller.

IMPORTANT
Parts will be needed again for reassembly!

• Remove the circlip wheel shaft – crown gear (3) by means of the
flat-head pliers.

IMPORTANT
Parts will be needed again for reassembly!

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• Connect hydraulic hose (4) of the hydraulic cylinder 62222 (5),

mentioned as cylinder 1 in the following, with the wheel shaft and
tighten it (6).

• Connect the dis- and assembly fixture (7) with the press-out cylin-
der 63428 for the wheel shaft, mentioned as cylinder 2 in the fol-
lowing, and tightened it with the transmission (8) completely.

! WARNING
For work at high oil pressures there is the danger of eye and skin injuries, if oil would come out under high
pressure. Always wear goggles and safety gloves during this work!

• Actuate cylinder 1 (9) until approx. 30MPa/4300PSI is reached.

Under this pressure the bevel gear is expanded sufficiently. This
pressure is to be kept constant by pumping subsequently until the
wheel shaft has been loosened completely.

• Actuate cylinder 2 until the wheel shaft has been loosened from
the bevel gear completely.

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• Take the wheel shaft out of the transmission.

• Unscrew the hydraulic hose of cylinder 1 from the wheel shaft.

Wipe off the excessive oil.

IMPORTANT
Wheel shaft will be needed again for reassembly!

• Unscrew the dis- and assembly fixture form the transmission.

ATTENTION
Pay attention not to damage the crown gear at the following removal. Damages might cause louder noises
later.
The crown gear is needed again for reassembly later.

• Take the crown gear out of the transmission cautiously.

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• Removal of further components:

on GK 20: Taper roller bearings and shims
Parts will be needed again for reassembly!

ATTENTION
Do not damage the transmission housing!

• By means of the impact-resistant screwdriver beat out the shaft

seal.

Thus the disassembly is ended.

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Reassembly

! CAUTION
Wear safety gloves for working with adhesives and observe the LOCTITE instructions.

• Apply Loctite 574 onto the outside of new shaft seal evenly.

• Mount the shaft seal with striking mandrel and hammer cau-
tiously.
GK 20 : Striking mandrel 63291

• Apply grease SHELL ALVANIA R3 onto the shaft seal.

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• Clean the parts removed at disassembly:

on GK 20: Taper roller bearings and shims

• Reinstall acc. to the same sequence:

on GK 20: Taper roller bearings and shims

ATTENTION
Install the crown gear cautiously. It is absolutely necessary to avoid tooth flank damages. An incorrect
installation will cause louder running noises later!

• Clean and degrease the crown gear.

• Assemble the crown gear into the transmission cautiously.

• Center the shims and spacer ring with the crown gear by hand.

• Apply a thin layer of glycerin onto the crown gear.

SM 844 03-2-11

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ATTENTION
Do not damage the shims!

• Clean and degrease the wheel shaft.

• Mount the wheel shaft from the bottom through the transmission
housing, the shims, the spacer ring and the crown gear.

• Bolt the dis- and assembly fixture with the press-out cylinder for
the wheel shaft with the transmission.

• Insert the transmission into the press-in fixture 63429 and check
for tight fit.

ATTENTION
Too fast pressing-in might damage the transmission. Press-in
the wheel shaft slowly and evenly!

• Press in the wheel shaft actuating the press until stop.

SM 844 03-2-12

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• Remove the dis- and assembly fixture.

• Mount the circlip on the wheel shaft and crown gear with the flat-
head pliers.

• Mount the bearing inner ring by means of a hammer and mounting

fixture 63294 onto the wheel shaft.

SM 844 03-2-13

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• Clean contact surfaces on the transmission housing and the trans-

mission cover from Loctite residues carefully. Wet the O-ring
slightly with silicone grease 704 and insert it into the housing
cover.

• Apply a thin and even layer of Loctite 574 onto the contact sur-
faces of the transmission housing and transmission cover.

ATTENTION
Use an adjustable torque spanner to tighten the screws. Tighten the screws several times!

Tightening torques: GK 20: M10x30-8.8 46 Nm

• Fasten the transmission cover with 8 cap screws.

Thus the reassembly is ended.

ATTENTION
For reinstallation of the transmission into the vehicle observe the installation instructions in the operating
instructions of the transmission and the instructions of the vehicle manufacturer.

ATTENTION
Transmission and vehicle respectively may be used or operated at the earliest 24 hours after the reassem-
bly again!

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Complete Disassembly

General Instructions Disassembly

• Remove the transmission from the vehicle as described in ”ZF-Ergomat GK 20 Maintenance and Installation
Instructions“ for the transmission types GK 20. Remove the drive.
• Prior to dismantling the transmission is to be cleaned carefully.
• Parts which are only available as assemblies will not be dismantled further.
• It is recommendable to install a locating fixture as shown in pic-
ture. It serves to rotate the unit and offers easy working for disas-
sembly and reassembly.

Locating fixture 62507 for GK 20

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Necessary Special Tools for Disassembly and Reassembly

Reference number Description Is necessary for:

225296 Extracting fixture Removal of drive pinion
62519 Holding fixture Loosening of taper press fit
62507-1 Counter holder Determination of shim thickness
62523 Assembly fixture Installation of drive pinion
62478 Striking mandrel Roller bearings Drive pinion
62507 Locating fixture Transmission locating jack
62529 Striking mandrel-Insert Bearing outer ring Pinion shaft bottom
62625 Striking mandrel Roller bearing Housing
63428 Press-in/out fixture Wheel shaft and crown gear
62521 Striking mandrel Shaft seal Drive pinion
62522 Striking mandrel Breather Cover
63290 Press-in sleeve Grooved ball bearing Drive pinion
63293 Strik.mandrel without handle Thread protective shield
63291 Strik.mandrel without handle Shaft seal Wheel shaft
62542 Strik.mandrel without handle Bearing outer ring Crown gear
63294 Strik.mandrel without handle Bearing inner ring Wheel shaft
62748 Striking mandrel Bearing outer ring Cover
63296 Handle Striking mandrels
62819 Measuring stop Torsional backlash
62228 Gear lock Helical gear lock
62222 Pressure oil device Loosen press fit
223705,22 Press-in sleeve Bearing inner ring Pinion shaft
62747 Striking mandrel Bearing outer ring Pinion shaft top
62846 Striking mandrel Helical gear on pinion shaft
62825 Measuring fixture Housing dimension Wheel shaft
62827 Measuring fixture Housing dimension Crown gear
222863.2 Extracting fixture Pulling-off taper roller bearing outer ring
222863.2 Extracting fixture Pulling-off taper roller bearing outer ring
62532 Measuring fixture Bearing friction torque Wheel Shaft

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Removal of Drive Pinion

ATTENTION
Pay attention not to damage the surface (1) where the radial
sealing ring is located!

• With a screwdriver press the radial sealing ring (2) upwards from
the bore seat of the housing and remove it.
• Dispose of the radial sealing ring according to Page 03-2-62 "Dis-
posal".

• Unsnap and remove the retaining ring (3) from the housing bore
by means of flat-head pliers.

Extracting fixture 225296 is necessary to remove the drive pinion (4)

from the bore.
• Insert the extracting fixture into the bore of the drive pinion.

• Fasten the hexagon screw of the bearing puller hand-tight so that

a sufficient preload of the clamping jaws is given.
• By tightening the hexagon screw expand the clamping jaws of the
bearing puller (5) in the bore of the drive pinion.

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• Handle the extracting fixture "S" as shown on the right. Move the
handle on the bar upwards strongly several times until the drive
pinion is loosened from the bearing seat completely.

ATTENTION
Do not damage the gearing of the drive pinion at the next work
step! Damages might cause louder running noises and consequential damages

• By means of the extracting fixture pull the drive pinion (6) out of
the housing bore and remove it.

• Loosen the hexagon bolt (7) and remove the extracting fixture
from the drive pinion.

ATTENTION
Do not damage the gearing of the drive pinion! Damages might
cause louder running noises and consequential damages!

• Pull of the grooved ball bearing (Item 8) by means of a puller or a

parting tool over the bearing seat of the drive pinion and dispose it
of according to Page 03-2-62 "Disposal".

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Removal of Gear Ring and Pivoted Bogie Bearing

• Loosen the 12 hexagon screws (1) on the pivoted bogie bearing
(2), remove and dispose them of acc. to Page 03-2-62 "Disposal".

• With a dead-blow soft-face hammer slightly beat against the gear

ring (Item 3) from the bottom to loosen it from the connecting con-
struction. Take off and remove the pivoted bogie bearing and the
gear ring.

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Disassembly of Transmission Housing with Transmission Components

Removal of Sealing Cap

ATTENTION
The surface (1) where the sealing cap is located must not be dam-
aged. The sealing cap itself is destroyed and cannot be reused.

• Insert a screwdriver (2) into the sealing cap (3) beating cautiously
and press it off or by using the lever effect upwards and scrap it.
• The breather valve is not to be scrapped.

Removal of Side Cover

• Loosen and remove the 10 cap screws (4) on the side cover.

ATTENTION
Do not damage the housing surface at the next working step! Burrs and other damages on the sealing sur-
face which are caused during the removal have to be eliminated. Touch up damaged sealing surface on the
housing with an oil stone!

• Separate the side cover (5) from the sealing compound with a suit-
able screwdriver. Place the tool between housing and cover and
press it off slightly from the housing.
• Loosen the side cover from the housing by tapping onto the outer
contour and dispose it of acc. to Page 03-2-62 "Disposal".

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Removal of Wheel Shaft and Crown Gear

• Loosen and remove the 8 cap screws (1) in the housing cover.

ATTENTION
Do not damage the housing and cover surface! Burrs and other damages on the sealing surface which are
caused during the removal have to be eliminated. Touch up damaged sealing surface on the housing with
an oil stone!

Loosen the housing cover (2) by tapping against the outer edges and
remove it. Use the two recesses in the housing.

• With a three-armed puller (4) pull the taper roller bearing inner
ring (3) over the bearing seat of the wheel shaft and remove it.

• Unsnap and remove the retaining ring (5) by means of flat-head

pliers.

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Loosening of Taper Press Fit

ATTENTION
For work at high oil pressures to loosen the taper press fit there is the danger of eye and skin injuries, if
oil would come out under high pressure. Always wear goggles and safety gloves! Observe and follow the
instructions of the pressure oil device manufacturer.

A pressure oil device with a maximum pressure of up to 300 MPa is necessary for widening of the taper press fit. There
are two possibilities to press out the shaft wheel from the crown gear which are described in the following:

(S) Pressure oil device 62222

Pressing-off by means of press

• Locate the housing (Item 1) in the press-out fixture "S" on the

press as shown in the picture.

(S) Press-out fixture 63428

• The holding fixture "S" which is used as stop for the gliding off
wheel shaft is to be connected to the cover surface with the appro-
priate cap screws (2).
• Fasten the 4 supporting bolts (3) hand-tight until contact with the
crown gear.
(S) GK 20: Holding fixture 62519.

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• Connect the flexible high-pressure pipe (4) from the pressure oil
device into the connecting bore provided in the wheel shaft (5).
• Fixedly tighten the connecting nipple with an openjaw spanner.

ATTENTION
Pay attention for pressing-off that there is sufficient clearance in pressing-off direction avoiding that the
wheel shaft is bottoming. Do not jam the wheel shaft at the pressing-off procedure.

• Mount the stamp (6) from the holding fixture into the press.
• Adjust a pressing-off force from approx. 80 ... max. 120 KN on the
press.

• At the same time also use fixture 62222 to produce the necessary
pressure until the wheel shaft is pressed out from the crown gear.

• Remove and handle the wheel shaft in such a way that the flexible
high-pressure pipe can be unscrewed from the connecting bore of
the wheel shaft (9), removed and put aside.

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• Loosen the cap screws (Item 10), take off and remove the holding
fixture "S" from the housing.

Pressing-off by means of 2nd hand pump

Alternatively the wheel shaft can be pressed off with a second press-out
cylinder, e.g. in the mobile area. It is to be proceeded as follows:
• Connect the dis- and assembly fixture with the press-out cylinder
for the wheel shaft and bolt it with the transmission completely.
(S) Press-out cylinder 63428

• Actuate the pressure oil device (7) until approx. 30MPa/4300PSI

is reached. Under this pressure the bevel gear is expanded suffi-
ciently. This pressure is to be kept constant by pumping subse-
quently until the wheel shaft has been loosened completely.

• Actuate the second oil pressure device (8) until the pressure oil
cylinder has loosened the wheel shaft from the bevel gear com-
pletely.

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• Take the wheel shaft out of the transmission.

• Unscrew the hydraulic hose from cylinder 1 of the wheel shaft.

Wipe off excessive oil.

• Unscrew the dis- and assembly fixture from the transmission.

ATTENTION
When the gearing is damaged, running noises and consequential damages might occur, so that the bevel
gear set has to be replaced.

• Take the crown gear (11) cautiously out of the housing as shown.

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• Then remove the following parts from the housing (12):

− on GK 20: Shims and taper roller bearing

Removal of Bevel Pinion Shaft

• Put the gear lock "S" into the housing bearing bore of the drive
pinion and block the helical gear with it.

(S) Gear lock 62228

• Unlock the hexagon nut (1). Loosen, take off and remove the hexa-
gon nut.
• Take out and remove the gear lock.

ATTENTION
Pay attention not to damage the bevel pinion shaft when it is
expelled in the following procedure.

• By means of a dead-blow soft face hammer expel the bevel pinion

shaft (2) from the internal gearing and the bearings.

SM 844 03-2-26

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 Group 03, Drive Axle

• Pull out, remove and keep the helical gear (3) from the cover open-
ing of the housing.

• Take out and remove the taper roller bearing inner ring (4) from
the bearing bore:
− on GK 20: upwards

Only on GK 20:
Take off and remove the spacer bush (5) from the bevel pinion shaft.

On GK 20:
Pull off and remove the taper roller bearing inner ring (6) from the bevel
pinion shaft.

ATTENTION
If disassembly of the bearing inner ring is not possible with a special tool or puller, the bearing cage must
be destroyed and the inner ring must be removed by heating.

ATTENTION
When the gearing of the bevel pinion shaft is damaged, running noises and consequential damages might
occur, so that the bevel gear set has to be replaced.

SM 844 03-2-27

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Removal of Thread Protective Shield and Radial Sealing Ring

ATTENTION
Do not damage the housing and supporting face!

• By means of a hammer remove the thread protective shield (Item

1) from the glued joint on the housing.

ATTENTION
Do not damage the surface where the radial sealing ring is seated! At this working step the radial sealing
ring is destroyed completely.

• With a screwdriver and a hammer expel and remove the radial

sealing ring (Item 2) cautiously from the housing seat.

Disassembly of Bearings

Disassembly bearings drive pinion

• With an extracting fixture (S) pull out the grooved ball bearing (1)
from the bore of the housing seat and dispose it of acc. to Page 03-
2-62 "Disposal".
• The service of the extracting fixture (S) is analogous like in the
page 03-2-17 to 18 shown.

ATTENTION
Upon removal of the bearing outer rings put them to the respec-
tive bearing inner ring.

SM 844 03-2-28

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 Group 03, Drive Axle

Disassembly bearings bevel pinion shaft

• Expel the outer rings of the taper roller bearings (2) on both sides
from the housing seat cautiously.
• Shims which were damaged have to be replaced by new shims of
the same size.

Disassembly bearings wheel shaft

• Expel the outer ring of the taper roller bearing (3) by means of a
copper mandrel and a hammer from the housing cautiously.

• Pull out and remove the outer ring of the 2nd taper bevel bearing
(Item 4) with the bearing extracting fixture "S" from the bore of
the housing cover.
• The service of the extracting fixture (S) is analogous like in the
page 03-2-18 shown.
• Shims which were damaged have to be replaced by new shims of
the same size.

(S) GK 20: Extracting fixture 222863.2

Thus the disassembly is ended.

SM 844 03-2-29

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 Group 03, Drive Axle

Complete Reassembly

General Instructions for Reassembly

• Clean components by means of cleaning agent if necessary and remove the LOCTITE residues.
• Check all components for wear, damage and cracks, if necessary components have to be replaced.
• All connection faces and plan face clean and steadly smoothing.

Consumables
Suitable cold cleaners, e.g. LOCTITE.
Only use suitable agents, which are non toxic, non-combustible and permissible on the market. Never use benzene, solvents
or other combustible agents for cleaning purposes.
Description To be used for
LOCTITE No. 243 Screw lock up to Size M10 and bigger
LOCTITE No. 270 Screw lock for studs
LOCTITE No. 574 to glue the shaft seals into the housing & sealing of housing and cover
LOCTITE No. 5910 Surface sealing for side cover on the housing
Grease “Shell Alvania R3” to grease or wet the sealing lip of the shaft seal
Silicone grease 704 or transmission oil to grease or wet the O-rings
acc. to API GL-5 or MIL-L-2105C/D

Used Descriptions and Symbols

You will find again all descriptions used in the following sections and their calculations.
Description Symbol
Bearing width Taper roller bearing Dimension „B“
Housing dimension Dimension „G”
Housing bearing bore 1 L1
Housing bearing bore 2 L2
Housing bearing bore 3 L3
Zero position at measuring fixture I (Part I) with dial gauge Dimension “1”
Difference dimension Bevel pinion shaft calculation of L3 Dimension “2”
Zero position at measuring fixture II (Part I) with dial gauge Dimension “3”
Difference dimension Crown gear calculation of L3 Dimension “4”
Installation dimension Bevel pinion shaft Dimension “E”
Bearing difference dimension Dimension “D”
Constant on GK 20 K1
Free constant a
Shim dimension Dimension “P”
Shim thickness Dimension “X”

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Use of Removed Shims as Basis for Reassembly

The bevel gear set, consisting of bevel pinion shaft and crown gear, has fixed installation dimensions. However the trans-
mission housing and the taper roller bearings have to be measured.
• If the removed shims are used as basis it is not necessary to measure the transmission housing.
• If all of the removed components are to be reused, the original shim thickness has also to be used again.
• If the taper roller bearings with the bevel gear set are replaced, only the taper roller bearings have to be measured.

Determination of Bearing Width and Difference of a Taper Roller Bearing

Determination of Bearing Width General

• Zeroize depth gauge (1) by means of gauge blocks (2).

• Put the new bearing on both gauge blocks and roll it as shown.

SM 844 03-2-31

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 Group 03, Drive Axle

• Determine Dimension “B”.

Example: Dimension “B” = 22.09 mm

Determination of Bearing Difference for the Installation of Removed Shims

The difference dimension „D“ of the new bearings to the bearings to be replaced is compensated with the shim dimension.
Example:
New bearing Dimension “B” 22.09 mm
Original bearing -21.99 mm
Difference “D” 0.10 mm
The height of the existing shim set must by reduced by 0.1 mm.

SM 844 03-2-32

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 Group 03, Drive Axle

Determination of Basic Installation Dimensions

Determination of the Necessary Shim Thickness for the Exact Installation Dimension Setting of the Bevel Pin-
ion Shaft

The correct position of the bevel pinion shaft is

required for an optimum service life of the transmis-
sion.
Thickness of the shim (Item 1) and the correct setting
of the bevel pinion shaft respectively will be deter- L2
mined acc. to the following method: 1

X
1. Put measuring fixture I Part 1 into the housing
bearing bore L1 until contact is obtained. L1
2. Put measuring fixture I Part 2 into the housing
bearing bore L2 until contact is obtained and

B
fasten it hand-tight with measuring fixture I Part
G
1. L3
3. Put measuring fixture part 1 to zero. E
Part I

(S) GK 20 Measuring fixture I 62825 or 62231

At zero position of the dial gauge the following can be taken as basis:
GK 20 Dimension “1” = 111.50 mm

Determine Dimension “2” in housing bearing bore L3 and add it to the respective Dimension “1”.
Example:
Dimension “1” 111.50 mm
Dimension “2” 0.05 mm
Housing dimension “G” 111.55 mm

SM 844 03-2-33

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 Group 03, Drive Axle

By means of the equation

X=G-E-B
The required thickness of the shim (1) can be calculated. “E“ means the installation dimension of the bevel pinion shaft
Dimension “E”:
GK 20 89.00 mm

Calculation example for GK 20:

Dimension “G” - 111.55 mm
Dimension “B” - 22.09 mm
Dimension “E” - 89.00 mm
X=G-E-B
X = 111.55 - 89.00 - 22.09 = 0.46 mm
Add shims acc. to thickness X = 0.46 mm.

Determination of Necessary Shim Thickness for Optimum Setting of Torsional Backlash of the Crown Gear

Correct setting of the crown gear is necessary to obtain an optimum torsional backlash of the bevel gearing.
Bearing width “B” for the taper roller bearing on the crown gear can be measured according to Page 03-2-31 “Determi-
nation of Bearing Width and Difference of a Taper Roller Bearing”.

Thickness of the shim and the correct setting of the crown gear respec-
tively will be determined acc. to the following method:
1. Put the measuring fixture into the housing bearing bore L3 until con-
tact is obtained

(S) GK 20 Measuring fixture 62827

2. Put measuring fixture dial gauge to zero position.

At zero position of the dial gauge the following can be taken as basis:
GK 20 Dimension “3” = 68.50 mm

Determine Dimension “4” in housing bearing bore L3 and add it to the

respective Dimension “3”.
Example:
Dimension “3” 68.50 mm
Dimension “4” 0.03 mm
Housing dimension “G” 68.53 mm

SM 844 03-2-34

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 Group 03, Drive Axle

Schematic sketch GK 20

By means of the equation:

X = G – E – B – K1
the required thickness of the shim (Item 3) can be calcu-
lated, i.e. with E
B
Dimension “E” GK 20 = 46.00 mm L1
Example GK 20:
Dimension “G” 68.53 mm
Dimension “B” 22.09 mm
Dimension “E” 46.00 mm
Dimension “K1” 0.11 mm

X = G – E – B – K1
X = 68.53 – 46.00 – 22.09 – 0.11 = 0.37 mm
3
X M

L3

Center Bevel gear set

G

SM 844 03-2-35

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Installation of Bearing for Bevel Pinion Shaft and Exact Setting of the Bearing Preload

Preassembly of Bevel Pinion Shaft with Bearing

ATTENTION
Pay attention to the gearing when the bearing of the bevel pinion shaft is installed. In case of damage, noise
problems can be caused later.

• Use a hand-lever press for pressing the taper roller bearing inner
ring (Item 1) with the press-in sleeve “S” cautiously on the bevel
pinion shaft (Item 2) until contact is obtained.

(S) GK 20 Press-in sleeve 223705,22

Installation of Bearing Outer Ring into the Housing

• Prepare the shim thickness determined according to Page 03-2-33

“Determination of the Necessary Shim Thickness for the Exact
Installation Dimension Setting of the Bevel Pinion Shaft” by
means of the differently thick shims.
• Put the shim(s) (1) and the bearing outer ring (2) into the bearing
seat.

SM 844 03-2-36

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 Group 03, Drive Axle

• By means of striking mandrel "S" install the shim(s) and the bear-
ing outer ring into the bearing seat of the housing until contact is
obtained.

(S) GK 20 Striking mandrel 62529

ATTENTION
A repeated measurement of the bearing height is only allowed to result in a deviation of max. ±0.05 mm.
Otherwise the process of the shim calculation has to be repeated.

Calculation of Distance Dimension between Collar Bevel Pinion Shaft and Housing

• Install the preassembled bevel pinion shaft (1) from the bottom
into the housing.

• By means of the counter holder "S" preload the bearing outer ring
in the housing hand-tight.

(S) GK 20 Counter holder 62507-1

• Put the spacer bush (2) onto the bevel pinion shaft.

SM 844 03-2-37

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 Group 03, Drive Axle

For GK 20 GK 20
Determine distance dimension "D" from the spacer bush (2) to contact of
the bearing outer ring in the housing.
(Item 3 is the required shim thickness)
3

Determination of Bearing Slack of the Taper Roller Bearing

• Arrow gap = Bearing slack H

Measure the bearing slack "H" with a measuring fixture and gauge
blocks/measuring ledge in the following steps:
• Zeroizing of depth gauge (1) by means of gauge blocks (2).

SM 844 03-2-38

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 Group 03, Drive Axle

• Rolling-in of bearing.

• Measuring of bearing slack H.

• Example: Dimension “H” = 0.10 mm

Calculation of Shims Required for Upper Bevel Pinion Shaft Bearing

By means of the equation

X=D–H
the required thickness of the shim (Item 3 Figure 108 or 109) can be calculated, i.e. with
Dimension “D” on GK 20: Distance from spacer bush
Dimension “H” Bearing slack of taper roller bearing
Dimension “a” Constant = 0.04 mm

Example:
Distance dimension: Dimension D measured on the housing - 0.7 mm
Bearing slack: Dimension H measured on the bearing - 0.10 mm
X=D–H– a
X = 0.7 – 0.10 – 0.04= 0.56 mm
Add shims corresponding to thickness X = 0.56 mm.

SM 844 03-2-39

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 Group 03, Drive Axle

Installation of Upper Taper Roller Bearing of the Bevel Pinion Shaft

Prepare the shim thickness determined according to Page 03-2-39 “Cal-

culation of Shims Required for Upper Bevel Pinion Shaft Bearing” by
means of the differently thick shims and continue the installation as fol-
lows:

GK 20:

• Put shim(s) (1) and bearing outer ring (2) into the bearing seat.

• By means of striking mandrel "S" install the shim(s) and the bear-
ing outer ring into the bearing seat of the housing until contact is
obtained.

(S) GK 20: Striking mandrel 62747

ATTENTION
A repeated measurement of the bearing height is only allowed to result in a deviation of max. ±0.05 mm.
Otherwise the process of the shim calculation has to be repeated.

• Put the bearing inner ring (Item 3) into the outer ring of the taper
roller bearing.

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Installation of Grooved Ball Bearing for Drive Pinion (GK 20)

ATTENTION
Prior to installation of the helical gear the lower grooved ball bearing has to be installed into the housing
bearing bore.

• Install the grooved ball bearing (Item 1) with the striking mandrel
"S" into the bearing seat of the housing until contact is obtained.

(S) Striking mandrel 62625

Installation of Helical Gear with Bevel Pinion Shaft

! CAUTION
Wear safety gloves for working with adhesives and observe the LOCTITE instructions.

• Apply a thin and even layer of LOCTITE 270 onto the internal
gearing of the helical gear (1).

ATTENTION
When inserting the helical gear pay attention that the helical gear is not damaged. In case of damage noise
problems can occur later.

• Insert the helical gear (2) by the lateral opening of the housing,
align it centrally and put it onto the taper roller bearing.

SM 844 03-2-41

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 Group 03, Drive Axle

• Install the bevel pinion shaft (3, on GK 20 with spacer bush) from
the bottom into the housing and assemble is through the profiled
seat of the helical gear bore.

• Preload the bevel pinion shaft (3) with the counter holder "S"
hand-tight against the bearing outer rings in the housing.

(S) GK 20: Counter holder 62507-1

• By means of striking mandrel “S” install the helical gear until con-
tact is obtained. Hand-tighten the adjusting screw on the counter
holder repeatedly, so that all components like taper roller bearing,
spacer bush (on GK 20) and shims are located exactly!
• When all components are located tightly the counter holder can be
removed again.

(S) GK 20: Striking mandrel 62846

• Insert gear lock "S" into the housing bearing bore of the drive pin-
ion and block the helical gear.

(S) Gear lock 62228

SM 844 03-2-42

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 Group 03, Drive Axle

• Place the hexagon nut M16x1.5 (GK 20) onto the bevel pinion
shaft and tighten it with a torque spanner (4).

Tightening torque: GK 20: 100 Nm

ATTENTION
Do not yet peen the hexagon nut with the bevel pinion shaft! The hexagon nut must only be peened after
setting and checking of the bearing preload! Use the hexagon nut only once.

• Turn the bevel pinion shaft and the helical gear respectively by hand several times, that the taper rollers can align
in the bearing rings.
• Check the bearing preload by means of a drag torque spanner with dial gauge.
The bearing preload is adjusted correctly, when a bearing friction torque of
0.5 ... 1.0 Nm
is reached on the bevel pinion shaft.
If this value deviates the procedure must be repeated.

• Drive the collar of the hexagon nut (5) by means of a chisel (6,
edge of the chisel must be a radius of approx. 2.0 mm) into the
recesses of the bevel pinion shaft. Lock the hexagon nut by peen-
ing!

SM 844 03-2-43

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Installation of Crown Gear and Wheel Shaft into the Housing

Installation of Thread Protective Shield and Radial Sealing Ring

• Wet the thread protective shield (Item1) on the bore seat evenly
with LOCTITE 270 and install it until contact by means of the
striking mandrel "S".

(S) Striking mandrel 63293

• Apply a thin and even layer of LOCTITE 574 onto the outer diam-
eter of the radial sealing ring.
• By means of the striking mandrel "S" drive the radial sealing ring
(Item 2) into the housing seat until contact is obtained at the man-
drel.

(S) GK 20: Striking mandrel 63291

ATTENTION
Pay attention that the radial sealing ring is not jammed during installation. Jamming will cause leakage.

ATTENTION
Do not damage the sealing lip of the radial sealing ring.

• Wet the sealing lip of the radial sealing ring with grease (e.g. Shell
Alvania R3) slightly.

SM 844 03-2-44

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Installation of Taper Roller Bearing into the Housing

• By means of striking mandrel “S” drive the bearing outer ring into
the bearing seat of the housing until contact is obtained.

(S) GK 20 Striking mandrel 62542

• Insert the bearing inner ring (1) into the outer ring of the taper
roller bearing.
• Prepare the shim thickness (Thickness X) with the differently
thick shims as determined in Page 03-2-39 “Calculation of Shims
Required for Upper Bevel Pinion Shaft Bearing”.
• Insert shim(s) (2).

Determination of Control Dimension for Seat

• Place the wheel shaft (3) onto a plane and solid support. Mount the
crown gear (4) onto the taper seat of the wheel shaft by hand cau-
tiously and press it on slightly.
• Determine distance "A" from plane face P of the wheel shaft to
face S of the crown gear as shown in page 03-2-46 <Figure 3>.

Dimension “A” e.g. 30.85 mm

ATTENTION
Carry out this measuring procedure to 1/100 mm exactly.

ATTENTION
Pay attention not to damage the gearing of the crown gear, when the crown gear is mounted onto the wheel
shaft. In case of damage, noise problems can occur later.

SM 844 03-2-45

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 Group 03, Drive Axle

A
S

<Figure 3>

ATTENTION
Pay attention not to damage the gearing, when the crown gear is assembled.

• Assemble the crown gear (Item 4) into the housing carefully and
insert it into the gearing of the bevel pinion shaft at the same time.
Pay attention that the crown gear is aligned centrally to the shim
and the bush.

SM 844 03-2-46

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 Group 03, Drive Axle

Pressing-on of Wheel Shaft

ATTENTION
Taper press fit must be grease- and oilfree. Pay attention to an impeccable surface of the press fit. In case
of damage use a new wheel shaft.
All components must be aligned and centered for the press-on procedure.
For this installation procedure a press with a controllable press-on force is required.
Press-on force: 250 kN up to max. 300 kN.

• Assemble the wheel shaft (1) cautiously and install it until contact
is obtained.

• Screw on the press-on fixture (S).

(S) Press-on fixture 63428

ATTENTION
For pressing on the wheel shaft, only apply the press-on force to the wheel shaft.

• Press the wheel shaft onto the crown gear.

During this procedure the shim(s), the taper roller bearing inner ring are
pressed on until contact is obtained.

SM 844 03-2-47

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Determination of Seat

ATTENTION
The seat must be 10 to 15 mm.

• Measure Dimension A from plane face/wheel shaft to face/crown

gear once again (see Page 03-2-45 “Determination of Control
Dimension for Seat”).
Dimension “A” e.g. 44.34 mm

Example:
Dimension “A” after pressing-on 44.43 mm
Dimension “A” after pressing-on 30.85 mm
resulting difference = Seat 13.49mm

ATTENTION
If the seat determined is not between 10 and 15 mm a new wheel shaft and a new crown gear have to be
installed.

• Install the retaining ring (2).

SM 844 03-2-48

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Installation of Bearing for Wheel Shaft

Determination of Required Shim Thickness for Exact Bearing Preload of the Wheel Shaft

Thickness of the shim (4) to be added can be determined with the following method:

C
Meas. ledge
1
4

L
Block gauge Block gauge

1 Measuring ledge
2 Housing cover
Dim. “L” Distance from mounting face / housing cover equal to zero position on measuring instrument
Dim. “C” Measure distance from contact shim / housing cover.
Dim. “L” e.g. Zero position on measuring instrument = 0
Dim. “C” e.g. 0.85 mm

1 Measuring ledge F

A
2 Bevel pinion shaft
3 Wheel shaft Meas. ledge 1
4 Crown gear
5 Housing 3
Dim. “A” Distance from mounting face /
2
housing equal to zero position on
5
measuring instrument
Dim. “F” Measure distance from contact 4
bearing inner ring / wheel shaft.
Dim. “A” e.g. zero position on measuring
instrument = 0
Dim. “F” e.g. 23.01 mm

SM 844 03-2-49

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Calculation of Shim Required

Thickness of shim can be calculated with the dimensions determined.

Example for GK 20:

Cover dimension: Dim. C measured on housing cover - 0.85 mm
Housing dimension: Dim. F measured on housing - 23.01 mm
Bearing dimension: Dim. B measured on bearing under preloading force - 21.85 mm
X1 = F - (C + B)
X1 = 23.01 - (0.85 + 21.85) = 0.31 mm
Constant: a = 0.20 at X1 0.31
a = 0.25 at X1 0.30
X = X1 + a
X = 0.31 + 0.20 mm = 0.51

Add shims according to thickness X.

Installation of Bearing into Housing Cover and Wheel Shaft

• Prepare the shim thickness determined upper Page 03-2-50 “Cal-

culation of Shim Required” by means of the differently thick
shims.
• Put shim(s) (1) and bearing outer ring (2) into the bearing seat.

• By means of striking mandrel “S” drive shim(s) and bearing outer

ring (1) into the bearing seat of the housing cover until contact is
obtained.

(S) GK 20: Striking mandrel 62748

SM 844 03-2-50

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• Place counter holder "N" into the assembly fixture and preload it
hand-tight against the wheel shaft (cf. page 03-2-42).

(N) GK 20: Counter holder 62507-1

• Mount the taper roller bearing inner ring (2) by means of striking
mandrel "S" onto the bearing seat of the wheel shaft (3) until con-
tact is obtained.

(S) Striking mandrel 63294

Installation of Housing Cover

ATTENTION
Use a new O-Ring for the installation. Wet the O-Ring with transmission oil or grease slightly. Clean plane
face of the housing cover carefully and do not damage it.

• Put the O-Ring (4) into the groove of the housing cover.

• Plane face for housing cover on the housing is to be cleaned care-

fully and must be grease-free.
• Apply a thin and even layer of LOCTITE 574 onto the plane face.

SM 844 03-2-51

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• Place the housing cover cautiously and install it slightly tapping

with a dead-blow soft face hammer until contact is obtained.
• By means of cap screws M10x25 (Item 5) bolt the cover to the
housing. Tighten the cap screws crosswise evenly!

Tightening torque of the cap screws: 46 Nm.

Checking of Bearing Friction Torque on Wheel Shaft

Rolling
• For measuring of the bearing friction torque place tool “S” on the
wheel shaft congruent with the wheel bolts and by means of the
torque spanner turn the wheel shaft several times.

(S) GK 20: Measuring fixture 62532

Bearing preload is adjusted correctly when a bearing friction torque of

7.0 ... 14 Nm for GK 20
is obtained at the wheel shaft.
If this value is not reached the working steps from page 03-2-50. have to be repeated. The cover has to be removed again.
If the measured value is greater than the above mentioned value, the shim thickness of value “X” in “Page 03-2-50. Cal-
culation of Shim Required” has to be reduced.
If the measured value is smaller than the above mentioned, the shim thickness of value “X” in “Page 03-2-50. Calculation
of Shim Required” has to be increased.

SM 844 03-2-52

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Measuring of Torsional Backlash on Wheel Shaft

• For measuring of the torsional backlash lock the bevel pinion shaft
against distortion, e.g. with a wooden wedge (1).

• Measure the torsional backlash with measuring stop “S”.

(S) Measuring stop 62819

Admissible torsional backlash:

GK 20 0.10 - 0.15 mm
The torsional backlash can be adjusted by adding or removing of the
shim(s) (see Page 03-2-34. “Determination of the Necessary Shim Thick-
ness for Optimum Setting of the Torsional Backlash of Crown Gear“).
The wheel shaft has to be removed again.

Installation of Side Cover

• Prior to the installation of the side cover clean the sealing surface on the housing and remove the oil residues.
The sealing surface must not be damaged

! CAUTION
Wear safety gloves for working with adhesives and observe the LOCTITE instructions.

ATTENTION
The following step must be carried out within 10 minutes since the LOCTITE hardens.

SM 844 03-2-53

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• For sealing of the through holes as well as of the area around the
screw the following sealing application is required:
LOCTITE 243: Product application into the threaded blind holes
M6 as sealing function by excess product.

• Sealing of the cover:

LOCTITE 5910: Product application as uniform adhesive applica-
tion onto the sealing surface at the housing as sealing function.

• Put on the side cover (sheet cover) and fasten it hand-tight with 10
cap screws M6x10 (2) onto the housing.

ATTENTION
Do not yet tighten the cap screws with the corresponding tightening torque.

• Tighten the 10 cap screws evenly only in the tightening sequence shown in Picture.
Sequence of tightening:
Number 1 beginning ...... Number 10 end
Tightening torque of the cap screws: 9.5 Nm

9 5 1 3 7

8 4 2 6 10

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Preassembly and Installation of Drive Pinion

Installation of Ball Bearing

• For mounting of the bearing onto the drive pinion use assem-
bly fixture "S", as shown. Press

(S) GK 20: Assembly fixture 62523

3
• Put the drive pinion (Item 1) onto the guide mandrel (2) of the
assembly fixture and install it until contact is obtained.
• Put on the ball bearing (Item 4) and the pressing sleeve (3). By
means of a hand lever press, press on the ball bearing with the 2
pressing sleeve onto the drive pinion (1) until contact is
obtained.

(3) Pressing sleeve 63290

If there is no hand press available, the bearing can be installed as fol-

lows:
4
! CAUTION
Danger of burnings! Wear safety gloves.
1
• Heat the ball bearing to max. 90°C and install it onto the drive
pinion until contact is obtained.
• After cooling down install the bearing subsequently.

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Mounting of Sealing Cap

For sealing of the bore in the drive pinion a sealing cap (5) must be
mounted. This requires the following sealing application:
• LOCTITE 5910: Product application as adhesive application onto
the supporting face and around the bore in the drive pinion as seal-
ing function by excessive product.
• Insert the sealing cap.

• Press in the sealing cap with a press until contact is obtained.

Installation of Drive Pinion

ATTENTION
Pay attention when inserting the drive pinion not to damage the gearing of drive pinion and helical gear.
Damages might cause louder running noises and consequential damages!

• Install the preassembled drive pinion (1) into the housing bearing
bore cautiously. For joining turn the wheel shaft of the transmis-
sion cautiously until the drive pinion engages into the gearing of
the helical gear.

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• By means of the striking mandrel "S" install the drive pinion into
the bearing seat until contact is obtained.

(S) Striking mandrel 62478

• Snap the retaining ring (2) by means of flat-head pliers into the
groove of the housing bore and install it until contact is obtained.

• Wet the sealing lip of the radial sealing ring with grease (e.g. Shell
Alvania R3) slightly.
• Apply a thin and even layer of LOCTITE 574 onto the outer diam-
eter of the radial sealing ring.
• By means of striking mandrel "S" drive the radial sealing ring with
the closed surface upwards into the housing seat until contact at
the mandrel is obtained.

(S) Striking mandrel 62521

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Installation of Sealing Cap

• Press the breather valve (1) slightly by hand into the central bore
of the sealing cap (2) (Reference depth approx. 5mm).

• Insert the sealing cap with breather valve (Item 3) into the boring
seat of the housing bore in the bevel pinion shaft.
• By means of the striking mandrel "S" install the sealing cap sub-
sequently until contact is obtained.

(S) GK 20: Striking mandrel 62522

Attachment of Pivoted Connection Geared Steering

• Place the gear ring (2) and turn it so that the bolt holes match the
threaded holes of the connecting construction.
• Install the gear ring with a dead-blow soft face hammer until con-
tact is obtained.

• Put on the pivoted bogie bearing (Item 3) with the peripheral

recess upwards and turn it that the bolt holes in the pivoted bogie
bearing match with the gear ring and housing hole pattern.

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ATTENTION
Pay attention for installing of the drive pinion that the gearing of drive pinion and helical gear are not
damaged. Damages might cause louder running noises and consequential damages!

• Wet screws M8x40-10.9 (GK 20) (4) with LOCTITE 243.

By means of the screws fasten the pivoted bogie bearing and the gear ring
onto the connecting constructions.
• Tighten the screws evenly in the tightening sequence shown in
Figure 169.
Sequence of tightening:
Number 1 beginning....................... Number 12 end
Tightening torque of cap screws: 34 Nm

7 1

6
10

11
3

4
12

5
9

2 8

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General Instructions after Reassembly

• For reinstallation of the transmission into the vehicle observe the installation instructions in the operator's manual
of the transmission and the instructions of the vehicle manufacturer.
• Fill in oil according to the operating instructions.
• Transmission and vehicle respectively may be used or operated at the earliest 24 hours after the reassembly again!

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Failures, Possible Causes and Elimination

Noises
Kind of Noise Possible Cause Elimination
Check tooth flanks of the drive pinion and the
Gearing of helical gear stage damaged, inden-
helical gear for damage. In case of damage
tations
Loud, beating noise always replace both components
Fault on grooved ball bearing Input Remove and replace drive pinion bearing
Contaminations Remove and replace drive pinion bearing
Motor/transmission connection not ok Check motor installation
Loud, steady noise
Motor bearing defective Check motor bearing
Check bearing preload and backlash and read-
Dull, grinding noise Wrong bearing preload or incorrect backlash
just it, if necessary

Leakages
Location Possible Cause Elimination
Breather Excessive oil level Check oil level
Screws not tightened with the specified tight- Tighten screws with the specified tightening
Housing cover ening torque torque
O-Ring sealing defective Replace O-Ring
Screws not tightened with the specified tight- Tighten screws with the specified tightening
ening torque torque
Oil filler or oil drain plug
Dirt between sealing ring and housing Clean
Sealing ring worn Install new sealing ring
Radial sealing ring damaged or worn Install new radial sealing ring
Input shaft / wheel shaft Replace input shaft and wheel shaft respec-
Damaged race on input- and/or wheel shaft
tively
Tighten screws according to correct sequence
Screws not tightened according to sequence of
of tightening and with the tightening torque
tightening and the tightening torque
specified
Side cover No uniform adhesive application of LOCTITE Apply LOCTITE 5910 evenly and continu-
5910 ously
Observe LOCTITE specification and replace
Joining time not observed
the sealing
No uniform adhesive application of LOCTITE Apply LOCTITE 5910 evenly and continu-
Sealing disc on drive 5910 ously
pinion Observe LOCTITE specification and replace
Joining time not observed
the sealing

Other Fault Possibilities

Location Possible Cause Elimination
Only sluggish rotation of Cover disc has loosened and dirt got into the
Replace pivoted bogie bearing
the pivoted bogie bear- bearing
ing is possible or bearing Cage segments are damaged Replace pivoted bogie bearing
clearance is sensible Plastic deformation of the balls or the ball race Replace pivoted bogie bearing

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Disposal
Dispose of the replaced components, materials and substances adequately, environmentally friendly and in accordance
with the legal regulations for disposal for the respective material:
Component Consisting of Disposal acc. to the regulations:
Transmission oil Waste oil
Side cover Sheet
Radial sealing ring Sheet
Shims Sheet
Scrap metal
Wheel bolts Steel
Grooved ball bearing Steel
Screws Steel
O-Ring PE
Shaft seal PE PE plastic materials
Sealing cap PE

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 GROUP 04

GROUP 04

BRAKE

General Information ...................................... Section 1

Safety Instructions ..........................................Section 2

Technical Data.................................................Section 3

Mechanical Installation ..................................Section 4

Electrical Installation......................................Section 5

Commissioning and Operation ......................Section 6

Maintenance/Repair........................................Section 7

Troubleshooting and Fault Elimination........Section 8

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Section 1

General Information

Product key

Pr oduct k ey INTORQ 14 442 12 − 100

Legend for INTORQ 14.442.12 product key

A Product group Brakes
B Product type Two-step brake
C Size 12
D Design/version 100
Not coded: supply voltage, hub bore, options

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Abbreviations used
Abbreviation Unit Designation
P [kW] Power
Mrated [Nm] Rated brake torque
ML [Nm] Load torque
Mreq [Nm] Required brake torque
Ma [Nm] Deceleration torque
Δn0 [rpm] Relative initial speed of brake
JL [kgm2] Moment of inertia of all driven parts referred to the shaft to be braked
t1 [ms] Engagement time, T1 = T11 + T12
t2 [ms] Disengagement time (time from the beginning of the torque drop to
reaching 0.1 MK)
t11 [ms] Slipping time (time during which there is a relative motion between
input and output with brake engaged)
t11 [ms] Delay during engagement (time from switching off the supply voltage to
the beginning of the torque rise)
t12 [ms] Torque rise time
K Safety factor
Q12 [J] Calculated friction work per operation
Qperm [J] Max. permissible friction work per operation
Sh -1
[h ] Operating frequency, i.e. the number of periodical brakings
sair [mm] Rated air gap

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Scope of supply Drive systems

• The drive systems are combined individually
according to a modular design. The scope of deliv- Labelling
ery is indicated in the accompanying papers. Drive systems and components are unambiguously desig-
• After receipt of the delivery, check immediately nated by the indications on the nameplate.
whether it corresponds to the accompanying Manufacturer: INTORQ GmbH & Co KG, Wülmser Weg
papers. INTORQ does not grant any warranty for 5, D-31855 Aerzen
deficiencies claimed subsequently. Claim
• The spring-applied INTORQ brake is also deliv-
− visible transport damage immediately to the for-
ered in single modules and individually combined
warder.
to its modular design. The data - package labels,
− visible deficiencies / incompleteness immedi- nameplate, and type code in particular - apply to the
ately to INTORQ GmbH & Co.KG. complete stator.
• If single modules are delivered, the labelling is
Disposal missing.
The spring-applied brake consists of different types of
material. Legal regulations
• Recycle metals and plastics.
• Ensure professional disposal of assembled PCBs Liability
according to applicable environmental regulations. • The information, data and notes in these Operating
Instructions met the state of the art at the time of
printing. Claims referring to drive systems which
have already been supplied cannot be derived from
the information, illustrations and descriptions.
• We do not accept any liability for damage and oper-
ating interference caused by:
− inappropriate use
− unauthorised modifications to the drive system
− improper working on and with the drive system
− operating faults
− disregarding these Operating Instructions

Warranty
• Terms of warranty: see terms of sale and delivery of
INTORQ GmbH & Co. KG.
• Warranty claims must be made to INTORQ imme-
diately after detecting defects or faults.
• The warranty is void in all cases where liability
claims cannot be made.

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Section 2

Safety Instructions

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General safety information however necessary to check the functionality of all

mechanical components under the corresponding
• INTORQ components ... operating conditions.
− ... must only be applied as directed.
− ... must not be commissioned if they are notice-
ably damaged. Application as directed
− ... must not be technically modified. • INTORQ components ...
− ... must not be commissioned if they are incom- − ... are intended for use in machinery and sys-
pletely mounted. tems.
− ... must not be operated without the required − ... must only be used for the purposes ordered
covers. and confirmed.
− ... can hold live as well as moving or rotary parts − ... must only be operated under the ambient con-
during operation according to their degree of ditions prescribed in these Operating Instruc-
protection. Surfaces may be hot. tions.
• For INTORQ components ... − ... must not be operated beyond their corre-
− ... the documentation must always be kept at the sponding power limits.
installation site. Any other use shall be deemed inappropriate!
− ... only permitted accessories are allowed to be
used.
− ... only original spare parts of the manufacturer
Possible applications of the INTORQ
are allowed to be used. spring-applied brake
• All specifications of the corresponding enclosed • Humidity: no restrictions
documentation must be observed. • Ambient temperature:
This is vital for a safe and trouble-free operation as − -20°C to +40°C (standard)
well as for achieving the specified product features.
• At high humidity and low temperature:
• Only qualified, skilled personnel are permitted to − Take measures to protect armature plate and
work on and with INTORQ components. rotor from freezing.
According to IEC 60364 or CENELEC HD 384,
qualified, skilled personnel are persons ... • Protect electrical connections against contact.
− ... who are familiar with the installation, mount-
ing, commissioning, and operation of the prod-
uct.
− ... who have the qualifications necessary for
their occupation.
− ... who know and apply all regulations for the
prevention of accidents, directives, and laws
relevant on site.
• Risk of burns!
− Surfaces may be hot during operation! Provide
for protection against accidental contact.
• Risk of injury due to a rotating shaft!
− Wait until the motor is at standstill before you
start working on the motor.
• The friction lining and the friction surfaces must by
no means have contact to oil or grease since even
small amounts reduce the brake torque consider-
ably.
• The brake is designed for operation under the envi-
ronmental conditions that apply to IP54. Because of
the numerous possibilities of using the brake, it is

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Section 3

Technical Data

Product description General information

The spring-applied brake 14.442.12.100 is a single-disk
Versions brake with two friction surfaces. The braking torque is
generated by several compression springs (3.1 and 3.2) by
means of friction locking. This spring-applied brake fea-
tures two braking steps, the stator of braking step 1 (1) and
the stator of braking step 2 (2). Like this the user can gen-
erate two braking torques if the brake is connected accord-
ingly:
A Braking torque - by braking step 1
B Braking torque - by braking step 1 plus braking step 2
(total braking torque)
The spring-applied brake is designed for the conversion of
mechanical work and kinetic energy into heat. For operat-
ing speed, see page 04-3-3 Rated data. Due to the static
brake torque, the brake can hold loads without speed dif-
ference. Emergency braking is possible at high speed, see
page 04-3-3 Rated data. The more friction work, the higher
the wear.

(Fig. 1) Structure of a spring-applied brake 14.442 Braking

During the braking process in the partial load operational
Item Name range, the rotor (6) that can be displaced axially on the hub
(7) is pressed against the friction surface by the springs
1 Stator Braking step 1
(3.1) in the stator of braking step 1 (1) via the armature
2 Braking step 2 plate (4.1). The spring pressures generated by the compres-
3.1 Compression spring Braking step 1 sion springs in connection with the asbestos-free friction
3.2 Braking step 2 linings create a low-wear braking torque. If an increased
braking torque is required in the full load operational
4.1 Armature plate Braking step 1
range, the braking process is intensified by the stator of
4.2 Braking step 2 braking step 2 (2). The armature plate (4.2) is pressed
5.1 Setting ring gauge Braking step 1 against the armature plate (4.1) of braking step 1 by the
5.2 Braking step 2 compression spring (3.2), and the contact pressing force of
the armature plate (4.1) to the friction surfaces of the rotor
5.3 Cheese head screw Braking step 2
(6) is increased.
6 Rotor
The braking torque is transmitted between the hub (7) and
7 Hub the rotor (6) via gear teeth.
8 Sleeve bolts
9 Fixing screw set: DIN 912 cheese head screws

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Brake release
In the braked state, in the partial-load operational and in
the full-load operational range the air gap "s" is between
the stator of braking step 1 (1) and the armature plate of
braking step 1 (4.1) . For release the coils of the stators of
braking steps 1 and 2 are excited with the intended DC
voltage. The magnetic force that is generated pulls the
armature plates (4.1 / 4.2) against the spring pressure of the
stators of braking steps 1 and 2. Thus the rotor (6) is
released of the spring pressure and can rotate freely.
Due to the size and design of the stator of braking step 2, it
is not able to activate the internal armature plate (4.2) with-
out support of the stator of braking step 1 when it is sup-
plied with current and, like this, attain a braking process in
the partial-load operational range from the full-load opera-
tional range. The brake always has to be released by means
of both braking steps.

Brake torque reduction

Both steps contain compression springs (see items 3.1 and
3.2 in fig. 1) for generating the braking torques. Both steps
can be altered independently of each other via the setting
ring gauges (items 5.1 and 5.2 fig. 1) within certain limits.

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Rated data

Dimensions
Size Rated air gap Max. adjust- Rotor thickness Pitch circle Tightening Setting ring
“s” ment, permis- torque gauge max.
+0.1 mm sible wear perm. projec-
-0.05 mm tion 1)
[mm] [mm] min. [mm] max. [mm] d [mm] Thread [Nm] [mm]
12 0.3 2.0 8.0 10.0 132 3 x M6 9.5 8.5

Tab. 1) Dimensions of the spring-applied brake 14.442.12.100

1) See page 04-6-1

Operating frequency / friction work

100000

12

10000
Switching energy Q

1000
[J]

100

10
1 10 100 1000 10000
Operating frequency
Sh[h−1]

(Fig. 2) Switching energy as a function of the operating frequency

Stf
Stf
Sfperm Qperm QE 1 e Sf
Q
1 QE

The permissible operating frequency "Shperm" depends on the friction work "Q" (see Fig. 2). An operating frequency of
"Sh" results in the permissible friction work "Qperm".
With high speed and friction work, the wear increases strongly, because very high temperatures occur at the friction faces
for a short time.

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Emission

Electromagnetic compatibility
Note! The user must ensure compliance with
EMC Directive 2004/108/EC using
appropriate controls and switching
devices.
.If an INTORQ rectifier is used for the DC switching of an
INTORQ spring-applied brake and if the operating fre-
quency exceeds five switching operations per minute, the
use of a mains filter is required. If the INTORQ spring-
applied brake uses a rectifier of another manufacturer for
the switching, it may become necessary to connect a spark
suppressor in parallel with the AC voltage. Spark suppres-
sor according to coil voltage on request.

Heat
Since the brake converts kinetic energy as well as mechan-
ical and electrical energy into heat, the surface temperature
varies considerably, depending on the operating conditions
and possible heat dissipation. Under unfavourable condi-
tions, the surface temperature can reach 130℃.

Noises
The switching noises during engagement and disengage-
ment depend on the air gap "sair" and the brake size.
Depending on the natural oscillation after installation,
operating conditions and state of the friction faces, the
brake may squeak during braking.

Others
The abrasion of the friction parts produces dust.
In case of high load, the friction face will become so hot
that odours may occur.

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Section 4

Mechanical Installation

Important notes
Stop! Toothed hub and screws must not be lubricated with grease or oil!

Necessary tools
Type Torque wrench Insert for hexagon Wrench size of Hook wrench DIN Socket spanner for
socket screws open-jawed span- 1810 design A outer flange
ner [mm] mounting

Q
Measuring range Width [mm] Sleeve bolts Diameter [mm] Width [mm]
[Nm]
14.442.12 1 to 12 5 x 1/4" square 12 80 - 90 10 x 1/2" square

* For flange mounting insertion with journal guidance

Feeler gauge Caliper gauge Multimeter

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Mounting Installation

Important notes Installation of the hub onto the shaft

Minimum requirements of the end shield:
• Material S235 JR , C15 or EN-GJL-250
− If different materials are used, contact
INTORQ.
• Levelness < 0.06 mm
• Axial runout 0.10 mm,
• Roughness Rz 10 to Rz 16
• The threaded holes must have the minimum thread
depth (page 04-3-3).
• The end shield must be free of grease and oil.
• Minimum requirements of the motor shaft: (Fig. 3) Mounting the hub on the shaft
− The diameter of the shaft shoulder must not be
bigger than the tooth root diameter of the hub.
4 Hub 15 End shield
4.1 Circlip 15.1 Keyway
Preparation
1. Insert keyway (15.1) into the shaft.
1. Unpack spring-applied brake. 2. Press hub (4) onto the shaft.
2. Check for completeness. 3. Secure the hub against axial displacement, e.g. with a
3. Check nameplate data, especially rated voltage. circlip (4.1).
4. Fit threaded holes in end shield. Stop! In reverse operation, it is recommended
− Observe minimum depth! to additionally glue the hub to the shaft,
(e.g. using Delo-ML 5328)!
Stop!
• Observe the required minimum thread depth in the Brake assembly
motor flange to be able to readjust the brake:
− Thread depth > penetration depth of the fixing
screw for brand-new brake + maximum adjust-
ment path. (page 04-3-3, Tab. 1)
• If the required thread depth is not observed the fix-
ing screws may run into the thread root when
adjusting the brake. As a result, the required pre-
stressing force will no longer be built up and the
brake is no longer fixed securely!

(Fig. 4) Mounting without counter friction face

7 Hub 15 End shield

7.1 Circlip

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Assembly of the rotor

1 Stator 1 9 Sleeve bolts
2 Stator 2 11 Connector block
6 Complete rotor 15 End shield
8 Cheese head screw

6. Screw the complete stator (1) onto the end shield (15)
using the supplied screw set (8).
− Use torque key.
7. Remove and throw away the connector blocks (11).

Check air gap

(Fig. 5) Mounting of the rotor

6 Complete rotor 15 End shield

7 Hub

4. Push the rotor (6) onto the hub (7) and check whether
it can be moved by hand.

Assembly of the stator

5. Push the stator onto the shaft.
XU

(Fig. 7) Checking "s"

8. Check the air gap "s" near the screws (8) using a feeler
gauge and compare the values to the values in the
table (page 04-3-3).
If "s" is not within the tolerance, readjust the air gap (page
04-7-3).
YU

(Fig. 6) Mounting of the complete stator

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Section 5

Electrical Installation

Danger!
• Electrical connection must only be carried out by skilled personnel!
• Connections must only be made when the equipment is de-energised! Danger through unintended starts or electric
shocks.

Stop!
• It must be ensured that the supply voltage corresponds to the nameplate data.
• Voltages must be adapted to the local environment!

Note!
• The control of the brake is customised. If required, it should be agreed with INTORQ.

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Section 6

Commissioning and Operation

! Commissioning
DANGER
The live connections and the rotating rotor 1. Switch on drive system.
must not be touched. 2. Carry out a braking test, if necessary, reduce brake
The drive must not be running when checking torque.
the brake.
Setting the braking torque
Function checks before commission- Stop! The braking torques of the external and
internal braking step can be altered after
ing consultation with INTORQ
If required, the brake has to be rede-
Operational check signed.

Braking step 1
! DANGER
The brake must be free of residual torque.
The motor must not rotate.

! DANGER
Live connections must not be touched.

1. Remove two bridges from the motor terminals. Do

not switch off the DC brake supply. When connecting
the rectifier to the neutral point of the motor, the PE
conductor must also be connected to this point.
2. Connect the mains supply.
3. Measure the DC voltage at the brake.
− Compare the DC voltage measured with the
voltage specified on the nameplate. A ± 10 %
deviation is permissible.
4. Check air gap "s". It must be zero and the rotor must
rotate freely.
5. Switch off the power supply.
6. Bolt bridges to the motor terminals. Remove addi-
tional PEN conductor.
7. The preparations for commissioning are completed.
1 Stator 5.1 Setting ring gauge

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1. Turn the setting ring gauge (5.1) counter-clockwise During operation

with a pin wrench.
− Observe latchings. Positions between the ! DANGER
notches are impermissible.
− Observe maximally permissible projection The running rotor must not be touched.
"h1max" of the setting ring gauge (5.1) to the sta-
tor (1) (values for "h1max" see page 04-3-3). ! DANGER
Live connections must not be touched.
! DANGER
The reduction of the braking torque does not • Check the brake regularly during operation. Take
increase the maximally permissible air gap special care of:
"s". − unusual noises and temperatures
− loose fixing elements
− the condition of the electrical cables.
• The armature plate must be attracted and the rotor
must move without residual torque.
• Measure the DC voltage at the brake.
− Compare the DC voltage measured with the
voltage specified on the nameplate. A ±10 %
deviation is permissible.
• In the event of failures, refer to the troubleshooting
table in Section 8. If the fault cannot be eliminated,
please contact the aftersales service.

Possibility of emergency release

In the event of a breakdown (e.g. power failure) the brake
can be released mechanically via two cheese head screws
M5x35. By means of the cheese head screws the armature
plate (4.1) is pulled against the stator (2). Thus the braking
effect is cancelled.
Stop! During normal operation the cheese head
screws must not remain within the
brake!

2 Stator 5.2 Setting ring gauge

4.1 Armature plate 5.3 Cheese head screw
1. Loosen cheese head screw (5.3).
2. Turn setting ring gauge (5.2) counter-clockwise.
3. Tighten cheese head screw (5.3) again to prevent the
setting ring gauge from being turned out of position
unintentionally during operation.

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Section 7

Maintenance/Repair

Wear of spring-applied brakes

INTORQ spring-applied brakes are wear-resistant and designed for long maintenance intervals. The friction lining and the
mechanical brake components are subject to function-related wear. For safe and trouble-free operation, the brake must be
checked and readjusted at regular intervals, and, if necessary, be replaced.
The following table describes different causes of wear and their effects on the components of the spring-applied brake. For
calculating the service life of rotor and brake and determining the maintenance intervals to be observed, the relevant factors
of influence must be quantified. The most important factors are the friction work, initial speed of braking and the operating
frequency. If several of the causes of wear indicated for the friction lining occur in an application at the same time, the
influencing factors must be added for calculating the wear. The INTORQ Select dimensioning program can be used to cal-
culate the maintenance intervals.

Component Cause Effect Influencing factors

Braking during operation
Emergency stops
Overlapping wear during start and Friction work
stop of drive
Friction lining Active braking via the drive motor Wear of friction lining
with support of brake (quick stop)
Starting wear in case of motor mount-
Number of start/stop
ing position with vertical shaft, even
cycles
when the brake is not applied
Armature plate and Run-in of armature plate and
Rubbing of brake lining Friction work
counter friction face counter friction face
Relative movements and shocks Wear of splining (primarily on Number of start/stop
Splining of brake rotor
between brake rotor and brake shaft the rotor side) cycles
Load alternation and jerks in the back- Number of start/stop
Breaking of armature plate,
Armature plate support lash between armature plate, sleeve cycles, braking
sleeve bolts and guide bolt
bolts and guide bolt torque
Axial load cycle and shear stress of Number of switch-
Reduced spring force or fatigue
Springs springs through radial backlash on ing operations of
failure
reversal of armature plate brake

SM 844 04-7-1

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Do not sell or distribute
 Group 04, Brake

Inspections Stop! Stable properties of the organic friction

lining are only achieved in the case of
To ensure safe and trouble-free operation, spring-applied continuous use. The readiness for opera-
brakes must be checked and maintained at regular inter- tion of the brake has to be ensured with a
vals. Servicing can be made easier if good accessability of braking energy that is equivalent to one
the brakes is provided in the plant. This must be considered emergency stop per week. Unplanned
when installing the drives in the plant. emergency stops occurring at a sufficient
Primarily, the necessary maintenance intervals for indus- frequency have the same effect.
trial brakes result from the load during operation. When If the brakes are not maintained, failures, production losses
calculating the maintenance interval, all causes for wear or damage to the system may occur. Therefore, a mainte-
must be taken into account (see page 04-7-1). For brakes nance concept adapted to the particular operating condi-
with low loads such as holding brakes with emergency tions and brake loads must be defined for every
stop, we recommend a regular inspection at a fixed time application. For the INTORQ spring-applied brakes, the
interval. To reduce the cost, the inspection can be carried maintenance intervals and maintenance operations listed in
out along with other regular maintenance work in the plant the below table must be provided. The maintenance opera-
if necessary. tions must be carried out as described in the detailed
descriptions.

Maintenance intervals
• according to service life calculation
Service brakes • otherwise every six months
• after 4000 operating hours at the latest
• at least every 2 years
Holding brakes with emergency stop • after 1 million cycles at the latest
• plan shorter intervals for frequent emergency stops

Checking the component parts

• Check release function and control
• Measure the air gap (adjust if necessary)
See page 04-4-3
With mounted brake • Measure rotor thickness (replace rotor if necessary)
See page 04-7-3
• Thermal damage of armature plate or counter friction face (dark-
blue tarnishing)
• Check clearance of the rotor toothing (replace rotors with worn out See page 04-7-3
teeth)
• Play of torque plate on sleeve bolts, dowel pins and armature plate
After removing the brake • Check springs for damage
• Check armature plate and counter friction face or end shield
− Levelness < 0.06 mm
− Max. run-in depth = rated air gap of brake size

SM 844 04-7-2

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 Group 04, Brake

Maintenance Readjustment of air gap

Note!
Brakes with defective armature plates, cheese head screws,
springs or counter friction faces must always be replaced
completely.
Generally observe the following for inspections and main-
tenance works:
• Remove impurities through oil and grease using
brake cleaning agents, if necessary, replace brake
after identifying the cause of the contamination.
Dirt deposits in the air gap between stator and arma-
ture plate impair the function of the brake and must
be removed.
• After replacing the rotor, the original braking
torque will not be reached until the run-in operation
of the friction surfaces has been completed. After
(Fig. 8) Air gap adjustment
replacing the rotor, run-in armature plates and
counter friction faces have an increased initial rate
of wear.
1 Stator 1 8 Cheese head screw
2 Stator 2 9 Sleeve bolt
Checking the rotor thickness
4.1 Armature plate 15 End shield

! DANGER
! DANGER
The motor must not run during this test.
The brake must be free of residual torque.
1. Remove the motor cover and seal ring, if mounted.
1. Unbolt screws (Fig. 8).
2. Measure the rotor thickness using a caliper gauge.
2. Screw the threaded sleeves into the stator by using a
3. Compare measured rotor thickness with minimally
spanner. 1/6 revolution reduces the air gap by approx.
permissible rotor thickness (for values see page 04-3-
0.15 mm.
3).
3. Tighten the screws, (for torques see page 04-3-3).
4. Replace the complete rotor if necessary. See page 04-
7-3 for description. 4. Check the air gap "s" near the screws using a feeler
gauge, ("s" see page 04-3-3).
5. If the difference between the measured air gap and "s"
Check air gap is too large, repeat the readjustment.

! DANGER Rotor replacement

The motor must not run during this test.

1. Measure the air gap "s" between armature plate and

! DANGER
stator using a feeler gauge (see page 04-3-3). The brake must be free of residual torque.
2. Compare the measured air gap to the maximum per-
missible air gap "s_max." (see table in page 04-3-3). 1. Switch off voltage!
2. Disconnect the supply cable.
3. If necessary, adjust the air gap to "s". See page 04-7-
3 for details. 3. Loosen the screws evenly and remove them com-
pletely.

SM 844 04-7-3

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 Group 04, Brake

4. Remove the complete stator from the end shield. Spare-parts list
Observe the supply cable.
• Only parts with item numbers are available.
5. Pull the complete rotor off the hub.
• The item numbers are only valid for the standard
6. Check hub teeth.
design.
7. Replace the hub as well if worn.
8. Check the friction surface at the end shield. In case of
strong scoring at the flange, replace the flange. If
scoring occurs at the end shield, re-finish end shield.
9. Measure rotor thickness (new rotor) and sleeve bolt
head with a caliper gauge.
10. Calculate the gap between the stator and the armature
plate as follows:
Gap = rotor thickness + s - head height
("s" see table in page 04-3-3)
11. Unscrew the sleeve bolts evenly until the calculated
gap between stator and armature plate is reached.
12. Install and adjust new rotor and stator (see page 04-4-
3).
13. Reconnect the supply cable.
(Fig. 9) Spring-applied brake 14.442.12-100

Item Name Variant

Stator of braking Voltage / braking
1
steps 1 + 2 torque
6 Complete rotor
Fixing screw set-
8 DIN 912 cheese
head screw

SM 844 04-7-4

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 Group 04, Brake

Section 8

Troubleshooting and Fault Elimination

If any malfunctions should occur during operation of the drive system, please check the possible causes using the following
table. If the fault cannot be eliminated by one of the listed measures, please contact the aftersales service.
Fault Cause Remedy
• Check coil resistance using a multimeter:
Coil interruption − If resistance is too high, replace the complete sta-
tor.
• Check coil resistance using a multimeter:
− Compare result with rated resistance. For values
see page 04-3-3. If resistance is too low, replace
the complete stator.
Coil has interturn fault or short cir- • Check coil for short circuit to ground using a multi-
Brake cannot be released, cuit to ground meter:
air gap is not zero − Replace the complete stator if short circuit to
ground is detected.
• Check brake voltage (see "defective rectifier, volt-
age too low").
• Check and correct wiring.
Wiring incorrect or defective • Check cable continuity using a multimeter:
− Replace defective cable.
Air gap too large Adjust air gap (see page 04-7-3)
Check air gap “s” and readjust it, if necessary (see
Rotor cannot rotate freely Air gap s too small
page 04-7-3).
Rotor not thick enough Rotor has not been replaced in time Replace rotor (see page 04-7-3).

SM 844 04-8-1

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 GROUP 05

GROUP 05

DRIVE AND STEERING SYSTEM

Drive Wheel .................................................... Section 1

Load Wheels ....................................................Section 2

Steering Unit ....................................................Section 3

Steering Arm / Wheel / Lever ........................Section 4

SM 844 05-0

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 Group 05, Drive and Steering System

Section 1

Drive Wheel

Repair and Rebuild

Replace worn tire with new as necessary.
Drive Tire

Drive
Dr ve Wheel

Nuts
Nu

(SI-49294)

Nut

Removal
Theory of Operation
1. Turn steering wheel all the way to the left to access
The drive wheel is mounted on the transmission final drive drive wheel mounting bolts.
axle. The drive wheel is part of the drive motor assembly.
2. Turn key switch OFF and depress Emergency Power
OFF (EPO) switch. Disconnect battery connector
Maintenance from truck.

See “Planned Maintenance Schedule” on page 01-2-2. ! WARNING

Use extreme care whenever the truck is
Troubleshooting jacked up. Never block the truck between the
Inspect wheel and tire for wear and damage. Trash that is column and the floor. Keep hands and feet
wrapped around wheel and axle will cause premature tire clear from truck while jacking the truck.
wear and bearing damage. The floors should be kept clear After the truck is jacked, place solid blocks
of trash to reduce risk of damage to wheel and tire. beneath it to support it. DO NOT rely on the
jack alone to support the truck.

3. Jack and block truck under truck frame (see page 01-
1-2).
4. Remove chassis covers (see page 02-1-1).
5. Remove drive wheel mounting nuts.
6. Remove drive wheel.

SM 844 05-1-1

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 Group 05, Drive and Steering System

Installation tioned upward. The outside edge of hub has a chamfer

1. Install drive wheel on drive wheel shaft. to help guide the new tire onto the wheel. The cham-
fered edge must always be the leading edge when a
2. Install drive wheel mounting bolts and torque to
tire is pressed onto hub.
114~133 ft-lbs (155~180 N•m).
5. Center hub assembly on the top of the ram and make
3. Install chassis covers (see page 02-1-1).
sure they mate squarely.
4. Remove block and lower truck with jack.
6. Position new tire with its chamfered insert facing hub.
5. Reconnect battery connector to truck. Energize EPO Align new tire and hub so they are concentric.
switch and turn key switch ON. Test truck for proper
operation before returning to service. ! CAUTION
Tire Pressing Procedure Any misalignment of tire and hub while tire is
being pressed onto hub can cause damage to
Outside
de of Hub hub. For this reason, chamfers have been pro-
and Tire
re A
Assembly vided on the outside edge of the hub and on
the end of the inside diameter of the tire’s
Ne
New metal insert. The chamfers help to center the
Tire hub and tire during the pressing operation
and decrease the possibility of misalignment.
To reduce damage, the hub must be installed
Worn on circular ram with its chamfered side up.
Tire
Circu
rcular
Ram
Ra NOTE! If new tire does not press on with a min-
imum of 5 tons (4535 kg) force, replace
hub.
Press 7. Begin pressing new tire onto hub and old tire off hub.
Tab
able
Run press slowly for the first few inches of travel,
because this is the critical stage of the operation. If
tire begins to cock to one side, stop press and realign
tire. A sharp jar with a softheaded mallet will usually
realign tire on hub.
1. Check the inside surface of metal insert on the new 8. Release the press. Remove wheel, tire assembly, and
tire. Remove any scaling or rust with sandpaper. old tire from press table. Inspect wheel and tire
Clean the inside of metal insert and lubricate with a assembly.
soap solution.
9. Install wheel assembly following the procedure for
2. Place a circular ram on press table. The length of ram the specific type of wheel.
must be longer than the width of the old tire to allow
complete removal of old tire. The outside diameter of
ram must be small enough to fit loosely in the insert
of tire, but large enough to rest squarely on the flat
surface on the outer edge of hub.
3. If the outside edge of the hub is not flush with the
edge of the metal insert in old tire, measure how far
hub is recessed inside the tire. The new tire must be
placed in the same position the old tire was installed
on the hub. A spacer (slightly smaller in diameter than
the inside diameter of the tire insert and the same
thickness as the depth of the recess) can be used to
obtain proper amount of recession.
4. 4. Position hub assembly with the old tire on the top
of circular ram so the outside of the wheel is posi-

SM 844 05-1-2

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 Group 05, Drive and Steering System

Section 2

Load Wheels

OzpT[`Y`\P

SM 844 05-2-1

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 Group 05, Drive and Steering System

Theory of Operation 7. Drive the axle back out through the wheels. Remove
rocker (4). Remove washers (5) and shims on each
The load wheels are mounted on the baselegs of the truck side of the wheel. The axle is welded into the rocker
to enable the truck to travel smoothly. The side guide roll- plate (3). Remove the load wheel (1) from the toe box.
ers can be mounted on the truck as an option to assist the
8. Inspect bearings (2).
operator in locating items on a rack or shelf.
Installation
Maintenance 1. Pack bearings (2) with grease and install in the load
wheel.
Inspect the wheels and tires daily for wear and debris
2. Install load wheel assembly in toe box.
wrapped around wheels. Check load wheel bearings for
binding or excessive play. See “Planned Maintenance NOTE! Place a block behind the axle to hold it in
Schedule” on page 01-2-2. place while assembling the rocker plate
and snap rings.
Troubleshooting 3. Install axle, washers (5), shims and rocker plate (3).
4. Install snap rings (7) on axle.
Every two months inspect load wheel bearings for chunk-
5. Remove blocking. Lower truck to the floor.
ing, bond failure and excessive or uneven wear. Make sure
tires are functioning smoothly. Make sure sufficient grease 6. Reconnect battery connector to the truck. Energize
is applied to load wheels. EPO switch and turn key switch ON. Test truck for
proper operation before returning to service.

Repair and Rebuild

Load wheels or guide wheels can not be repaired or rebuilt.
Replace worn wheel or wheel assembly with new as nec-
essary.

Tandem Articulated Load Wheel

NOTE! Call-outs in the following procedures
refer to illustration on page 05-2-1.

Removal
1. Park the truck on a flat surface.

! DANGER
Securely block mast columns to reduce risk of
lowering when working on or near mast. If
not blocked, unexpected movement could
occur resulting in personal injury or death.

2. Lower platform.
3. Turn key switch OFF and depress EPO switch. Dis-
connect battery connector from truck.
4. Check to make sure the battery retainer plates are in
place.
5. Hoist truck so load wheels are approximately 2 inches
(51 mm) off the floor and securely block.
6. Remove snap ring (7) from the axles.

SM 844 05-2-2

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 Group 05, Drive and Steering System

Section 3

Steering Unit

OzpT[`X_[P

SM 844 05-3-1

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 Group 05, Drive and Steering System

Theory of Operation
The steer motor drives a gear ring enabling the drive unit
to be rotated through 180 degrees (90 degrees in either
direction). The steer motor operates the electric transducer
to the steer power card. Steering angle is limited to 180° +
90°.

Maintenance
See “Planned Maintenance Schedule” on page 01-2-2.

Repair and Rebuild

The steering motor can not be repaired or rebuilt. Replace
steering motor with new as necessary.
NOTE! Call-outs in the following procedures
refer to illustration on page 05-3-1.

Removal
1. Park the truck on a flat surface.
2. Turn key switch OFF and depress Emergency Power
OFF (EPO) switch. Disconnect battery connector
from truck.
3. Remove chassis covers (see page 02-1-1).
4. Disconnect electrical connections from steer/ tractor
manager.
5. Remove steer switches.
6. Remove mounting screws (5). Pull steer motor (4).

Installation
1. Install new steer motor (4) assembly on pivot ring and
secure with screws (5).
2. Install new steer motor assembly on pivot ring. Apply
Loctite 242® to bolts. Secure bolts to assembly.
3. Install steer switches.
4. Reconnect electrical connections to steer/tractor man-
ager.
5. Install chassis covers (see page 02-1-1).
6. Reconnect battery connector to truck. Energize EPO
switch and turn key switch ON. Test truck for proper
operation before returning to service.

SM 844 05-3-2

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 Group 05, Drive and Steering System

Section 4

Steering Arm / Wheel / Lever

SM 844 05-4-1

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 Group 05, Drive and Steering System

Theory of Operation
The steer wheel is mounted to the console. The wheel
steers the truck in a direction of travel.

Maintenance
See “Planned Maintenance Schedule” on page 01-2-2.

Repair and Rebuild

Steering Wheel
NOTE! Call-outs in the following procedures
refer to illustration on page 05-4-1.

Removal
1. Park truck on level surface.
2. Turn key switch OFF and depress Emergency Power
OFF (EPO) switch. Disconnect battery connector
from truck.
3. Remove dash panel cover (see page 02-1-4).
4. Loosen capscrew(14) on the bracket (13).
5. Remove screw(15), washer(16,17) and step(11).
6. Remove shaft (12).
7. Remove bearing (9), snap ring (8) from bracket.

SM 844 05-4-2

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 GROUP 06

GROUP 06

ELECTRICAL SYSTEM

General ............................................................ Section 1

Battery ..............................................................Section 2

Component Function ......................................Section 3

Diagram and w/harness ..................................Section 4

Dash Display ....................................................Section 5

Fuse Box ...........................................................Section 6

Electrical Components....................................Section 7

SM 844 06-0

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 Group 06, Electrical System

Section 1

General

Summary for electrical components

Electrical system is composed with 4 sections as below.

1. Main power line

; Conduct driving, hydraulic operation, and steering controlled by 2 AC controllers.

2. Control signal line

; The signals from all of the switches and sensors communicate with control boards.

3. Display
; Display communicate all of signals with controller and switches by CAN-BUS, It display the diagnosis and
status of truck at real-time, and could be displayed information by pressing the membrane switch on it.

4. Accessories
; The truck is equipped with lamps, horn, and backup alarm.

SM 844 06-1-1

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 Group 06, Electrical System

Section 2

Battery

Battery Specification
Battery Capacity Battery Compartment
Voltage (V) Weight (kg) Connector
(AH) (W x L x H) (mm)
24V 1240 AH 975 SB350-RED(REMA)
975 x 362 x 800
36V 775 AH 1600 SB350-GRAY(REMA)

H
L
w

Feature
Using one touch vent plug, easy to find an electrolyte lack and has easier serviceability.

[ Full ] [ Empty ]

(Plug up) (Plug down)

SM 844 06-2-1

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 Group 06, Electrical System

Theory of Operation Charging

A 24 volt or 36 volt battery is not supplied with the truck. OSHA regulations require that battery charging installa-
Check the truck’s data plate for the size of battery required tions be located in areas designated for that specific pur-
for the truck. Contact your local battery supplier for the pose. Such areas must provide for flushing and
purchase of a proper voltage battery. neutralizing spilled electrolyte, fire protection, protecting
charging equipment from damage by trucks and adequate
ventilation of fumes from gassing batteries.
Maintenance
To charge a battery, direct current is passed through the
Information in this section does not supercede or replace battery cells in the direction opposite that of discharge.
information supplied by the battery and battery charger Charging time is 5% to 20% longer than discharge time.
supplier. Read, understand, and follow the procedures in
the manual supplied with the battery and battery charger. Read, understand, and follow procedures, recommenda-
Notify your supervisor if there are any concerns or ques- tions and specifications in the battery and battery charger
tions regarding the battery or procedures. supplier’s manuals.

Inspection and Care

NOTE! Read, understand, and follow proce-
dures, recommendations, and specifica-
tions in the battery and battery charger
supplier’s manuals.
Batteries in industrial trucks pick up various kinds of dirt
and dust depending on their surroundings and the types of
material handled. If cells are overfilled and electrolyte col-
lects on the covers, the following occurs:
1. The top of the battery becomes wet and stays wet,
since the acid in the electrolyte does not evaporate.
2. This moist surface, in combination with certain kinds
of dirt, becomes electrically conductive and permits
stray currents to flow externally over the top of the
battery. This degrades battery performance and truck
operation. ! CAUTION
3. The acid also causes corrosion of cell posts, nuts, con- NEVER plug the battery charger into the
nectors and the steel battery case. truck. This will severely damage the truck’s
electrical system. Plug the charger into the
When inspecting batteries, check the following: connector from the battery.
1. Wet covers can indicate overfilling, leaky seals at
posts, or excessive gassing during charge. If covers Storage
are wet, determine the cause and correct the problem.
Before storing battery, make sure the electrolyte is at the
2. Make sure batteries cannot move more than 0.5 inch
proper level in all the cells, the filler plugs are tight, and the
(13 mm) in any horizontal direction. Shim or block
battery is fully charged. Store battery in a clean, cool, dry
the batteries to restrain them.
location away from radiators and other sources of heat.
Check electrolyte level and specific gravity every 30 days
Exterior Cleaning during storage. Whenever specific gravity is less than
1.230, charge the battery.
Refer to recommended battery supplier’s guidelines for
details.

SM 844 06-2-2

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 Group 06, Electrical System

History Record Repair and Rebuild

A battery record system is essential because battery failure Contact your local battery supplier for replacements or
can cause production slowdowns and increased battery rebuilds.
operating costs. A properly supervised record system can
detect and call attention to such operating irregularities as: ! WARNING
• Overcharging Battery electrolyte is a solution of sulfuric acid
• Undercharging and water. Battery acid causes burns. Should
• Over-discharging any electrolyte come in contact with clothing or
skin, flush the area immediately with cold
• Excessive water consumption water. Should the solution get on your face or
• Excessive dirt and corrosion in the eyes, flush the area with cold water and
• Worn-out batteries receive medical attention immediately.
• Excessive current consumption of trucks
! CAUTION
Records should be kept for each battery. Your battery sup- Before working on the battery, review Battery
plier should be able to provide maintenance record sheets. Safety. Batteries may weigh more than 24 volt
Each report should contain: : 1520 pounds (689 kg), 36 volt : 1600 pounds
• Battery number, type, serial number, and service (726 kg). Use extreme care during replacement.
data Use a suitable replacement device or hoist for
• Specific gravity and voltage readings for each cell lifting.
• Temperature of the air and electrolyte
NOTE! The distance from the floor to the top of
• Electrolyte the battery rollers is 7 inches (175 mm).
• Amperes
• Condition of connectors, covers, sealing compound Removal
and tray
1. Turn key switch OFF and depress Emergency Power
• General cleanliness
OFF (EPO) switch. Disconnect battery connector
• Number of total cycles from truck.
• Average specific gravity drop
2. Position battery removal device in accordance with
• Watering frequency supplier’s recommendations.
3. Remove battery stop plates (see page 02-2-2).
4. Remove battery from truck onto suitable battery table
Troubleshooting or battery lifting device.
Many electrical problems are caused by a faulty or dirty
battery. Make sure the battery is clean. Check the electro- Installation
lyte level and battery level. Look for simple causes of
problems. A qualified technician should perform testing 1. With a fully charged and tested battery on the battery
and troubleshooting on batteries. handling device, position the handling device at the
truck according to the supplier’s recommendations.
2. Move the battery into the compartment and install
battery stop plates (see page 02-2-2). Be sure the bat-
tery has no more than 0.50 inch (13 mm) of “free
play” movement in the battery compartment.
3. Move handling device from the area.
4. Reconnect battery connector to truck. Energize EPO
switch and turn key switch ON. Test truck for proper
operation before returning to service.

SM 844 06-2-3

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 Group 06, Electrical System

Battery Connector 5. Check inside connectors at internal contacts for dam-

age, dirt, or corrosion. DO NOT use a metal object
to clean connectors.
Theory of Operation 6. Connector housings must not be cracked or broken.
The truck battery connector is located on the right side of
the truck. The battery and charger have similar battery con- Truck Batte
Battery
nectors. It is necessary to connect the battery to the truck ector
Connec
before powering ON.

Maintenance
Visually inspect cables and connectors. Negative and pos-
itive cables should be visually inspected for breaks and
wear. Check connectors for damage and to ensure proper
connections of cables.

Inspection
1. Turn key switch OFF and depress Emergency Power Troubleshooting
OFF (EPO) switch. Disconnect battery connector Make sure of the cable wires are in good condition and
from truck. connector has proper connections to cables.
2. Check battery connectors for damaged cables.
3. Check to see if cables are pulling out of the connec- Repair and Rebuild
tors.
Do not attempt to repair or rebuild the battery connectors
4. Check cables at battery terminals. Connections or power cables. Replace any damaged pieces with new.
should be tight, with no corrosion.

B
B-B

SM 844 06-2-4

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 Group 06, Electrical System

Removal, Repair, and Installation

The cables to the battery connectors have a lip on the for-
ward end. This lip snaps over a spring-loaded retainer
which is part of the connector. To remove a cable from the
connector, push retainer down while pushing cable
towards the rear and out of the connector.

! WARNING
Battery charger unintentionally connected to
battery connector at truck frame could lead
to premature failure. Installation of a spacer
block onto charger half of battery connector
could reduce the risk of a battery charger to a
truck connection.

1. Disconnect power supply to battery charger.

2. Reconnect supply to battery charger.

SM 844 06-2-5

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 Group 06, Electrical System

Section 3

Component Function

Motor

EPS Motor

Traction Motor

Pump Motor

SM 844 06-3-1

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 Group 06, Electrical System

Traction motor Pump motor

Terminal Non contacted-

board Pickup sensor
Non contacted- (U,V,W)
Thermal sensor type.
Pickup sensor type. (inside of Body )
Thermal sensor
Terminal board
(U,V,W)
(inside of Body )

Spec : 4.7Kw/3265rpm/24V/160A Spec : 14Kw/2325rpm/24V/450A

Insulation : “F” IP Grade : IP43 Enclosed Motor Insulation : “F” IP Grade : IP43 Enclosed Motor
− No brushes to change or commutator to turn.....ever − No brushes to change or commutator to turn.....ever
− Enclosed Motor (IP43), Keeps out dust and contami- − Enclosed Motor (IP43), Keeps out dust and contami-
nates nates
− Short distance on plugging mode. − Short distance on plugging mode.
− All motors are equipped with a thermistor which con- − All motors are equipped with a thermistor which con-
stantly monitors temperature. Should the temperature stantly monitors temperature. Should the temperature
approach the thermal limit, the control cuts back cur- approach the thermal limit, the control cuts back cur-
rent. rent.
− When motor is stall condition(during 15 seconds), it − When motor is stall condition(during 15 seconds), it
reduce the power to motor to protect overheating and reduce the power to motor to protect overheating and
damage. damage.
− Equipped with non contacted pickup speed sensor. − Equipped with non contacted pickup speed sensor.
Strength durability and serviceability. (Before used Strength durability and serviceability. (Before used
contacted bearing sensor) contacted bearing sensor)

SM 844 06-3-2

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 Group 06, Electrical System

EPS motor

Non contacted- Terminal

Pickup sensor board
(U,V,W)
type.

Thermal sensor
(inside of Body )

Spec : 400W/2750rpm/24V/21A
Insulation : “H” IP Grade : IP43 Enclosed Motor
− No brushes to change or commutator to turn.....ever
− Enclosed Motor (IP43), Keeps out dust and contami-
nates
− Short distance on plugging mode.
− All motors are equipped with a thermistor which con-
stantly monitors temperature. Should the temperature
approach the thermal limit, the control cuts back cur-
rent.
− When motor is stall condition(during 15 seconds), it
reduce the power to motor to protect overheating and
damage.
− Equipped with non contacted pickup speed sensor.
Strength durability and serviceability. (Before used
contacted bearing sensor)

SM 844 06-3-3

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Controller

Traction Controller Pump Controller

EPS Controller

1. 3Phase inverter has much controllable area than DC 9. Auto centering option
system. − When key switch off-on, the steer axle always return
2. Steering sensor enable driving left and right motor to 0-position.
independently to secure small turning radius. 10. Wire guidance option
3. Height switch enable reduce the lift and travel speed − When wire guidance function “ON” truck is moving
as follow the height of cabin. straightly regardless the position of steer handle.
4. Watchdog functioning before starting truck.
5. Maximize the truck depending on working condition
and operator. (Travel speed, pump speed, fine operat-
ing zone, acceleration/deceleration rate)
6. Can-Bus communication.
7. Dead-man switch equipped as standard, protect
operator who took platform off from travel and lift
work.
8. Cooled controller on the surface of counterweight and
operating fan for ventilating heated air inside of con-
trol room.
− Fan operates only the case of heated controller to 40
degrees, It is for reducing the fan operating noise.
− Selectable fan operating mode depending on working
condition. (Turning on whenever gear in.)
− Selectable travel alarm operating mode depending on
working condition. (Forward and Backward or Back-
ward only )

SM 844 06-3-4

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Safty Switches
1. Emergency Switch
− This switch cut off all of the power to the truck, and
conducted just by pressing red button. Located easy
reach of operator.

2. Deadman Switch
− Engaged inductive sensor for long life cycle

SM 844 06-3-5

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Directional lever − Dual signal is installed to protect malfunction on elec-

trical signal.
− More durable sensor using Hall effect sensor − Accelerator signal is activated only pressing mechan-
− Protected from pollution, sensor is molded with ically.
epoxy : IP65 (Grade)

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Section 4

Diagram and w/harness

1) Wiring-Diagram (24V)

2) Wiring-Diagram (36V)

3) W/harness - Main (24V)

4) W/harness - Main (36V)

5) W/harness - Operator platform (24V)

6) W/harness - Operator platform (36V)

7) W/harness - Accessory (24V)

8) W/harness - EXT Accessory

9) W/harness - Accessory (36V)

10) INSTL - Elec comp

11) INSTL - Accessory

12) INSTL - Mast Switch

13) INSTL - Cables

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1) Wiring-Diagram (24V) - 1/4

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1) Wiring-Diagram (24V) - 2/4

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1) Wiring-Diagram (24V) - 3/4

OpuTY_[YYP

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1) Wiring-Diagram (24V) - 4/4

OpuTY_[YYP

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2) Wiring-Diagram (36V) - 1/4

OpuTY_[YZP

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2) Wiring-Diagram (36V) - 2/4

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2) Wiring-Diagram (36V) - 3/4

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2) Wiring-Diagram (36V) - 4/4

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3) W/harness - Main (24V) - 1/2

O_W^\[WWP

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3) W/harness - Main (24V) - 2/2

O_W^\[WWP

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4) W/harness - Main (36V) - 1/2

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4) W/harness - Main (36V) - 2/2

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5) W/harness - Operator platform (24V) - 1/2

O_W^[_[XP

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5) W/harness - Operator platform (24V) - 2/2

O_W^[_[XP

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6) W/harness - Operator platform (36V) - 1/2

O_W^[_[YP

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6) W/harness - Operator platform (36V) - 2/2

O_W^[_[YP

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7) W/harness - Accessory (24V)

O_W^[\\\P

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8) W/harness - EXT Accessory

O_W^[\\]P

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9) W/harness - Accessory (36V)

O_W^[\\^P

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10) INSTL - Elec comp (1/2)

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10) INSTL - Elec comp (2/2)

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SM 844 06-4-22

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11) INSTL - Accessory

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12) INSTL - Mast Switch

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13) INSTL - Cables (1/2)

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13) INSTL - Cables (2/2)

OzpT[`XZ`P

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Section 5

Dash Display

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Display introduction Display initialization (When keyed on)

Key on
Display appearance
1. Initializing as picture
2. Basic data is displayed in the screen after initializing
for 1 second. (At real time for clock)
3. Seat belt LED and buzzer :Operate for 3 seconds with
1hz
4. Icons upper mode switch operate for 1 second with
1hz.

Name of section
1. Fuel remaining amount indication
2. Movable time and speed indication
3. Model name, message and breakdown contents indi-
cation
4. Currently date / timely indication
5. SLOW SPEED set indications
6. Vehicle travelling direction indication Basic display
7. Functional switches and warning light 1. Displayed after initializing
− MODE switch 2. Display the data receiving from other controller and
switches through CAN-BUS
− ENTER switches
− speed limit switch 3. Clock is operated by internal system of display at a
real time
− travelling mode switch
− parking warning light
− warning light

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Explanation of display function

Battery charging level

1. Function : Display the battery level at the present
time.

2. One unit means 10% of battery charging status. Error message

3. If a red unit is displayed, hydraulic function is dis-
1. Function : Model name, Travel direction, Alert and
abled and truck should go the charging pot using
error message displayed
remained power and be charged.
2. Status
− On normal status : Model name, Travel direc-
Hourmeter and speed meter
tion
1. Function : Display the working hour by now, and
speed at real time
2. Operating sequence
− If the speed is lower than 0.5km/h, it display the
hourmeter − When error is occured: Error number and mes-
sage displayed as below.

− If the speed is above 0.5km/h, it display the

speed. − Message display : It could be checked as oper-
ating function switch on right side of display.
− Function switch could be operated similar with
Handset and used for serviceable function. For
more detailed description, please refer to the
page 06-5-7.
− Speed unit could be displayed to Km/h and
MPH by mode selecting .

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Clock (Date/Time) Functional switch and alert icon

1. Function : Dsiplay date and time at real time. Function
− It is used for display system datas.
− Able to change variable value.

Explanation of function
− Mode buttons are composed with 6 at the righ
side of display.
− Each button is used as switch and setting set.
− Refer to page 06-5-7 “Function setting and
2. Data for date and hour could be stored in display operation” for the detail
memory for 1 month without external power by inter-
nal battery (Whenever keyed on, internal battery is
charged promptly)
3. TIME setting : Refer to the page 06-5-13. time set-
ting.

Button Function
1. When press this button at normal condition, it will go the Menu mode.
2. At the Menu mode, this switch is used for going to lower menu.

3. It also used for store key, when changing password and major factor.

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1. At the Menu mode, this switch is used for going to higher menu.

1. At the Menu mode, this switch is used for going to left menu.

2. At the normal operation mode, it is used for seletion of slow speed (turtle mode)

− When press this button, it go to the turtle mode. And to release this turtle mode, press
one more time

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1. At the Menu mode, this switch is used for going to right menu.

2. At the normal operation mode, it is used for seletion of power mode

− P OWER Mode is devided with 3 step.
− Whenever press ‘P’ button, it will be changed to Economy → Normal → Power Mode
1) Economy : Slow speed up mode, it will minimize the acceleration of the truck and
could be save the battery power.
2) Normal : Normal operation mode, operator could control the truck smoothly.
3) Power : operator could control the truck with powerful acceleration
1. At the normal mode, it is used for increasing the data.

1. At the normal mode, it is used for decreasing the data.

Icons

1. Parking brake : Display parking brake set status.

2. Seat belt icon : Alarm seat belt set when KEY ON.
3. Maintenance icon : When there is fault on the truck, this icon is turn on and error code and description will be dis-
played on monitor.

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Function setting and Operation

Method of Mode Switch

Mode Switch

Mode Switch Explaining

Switch Function

Pressing this button in normal operating condition, it will move to Menu mode.
Pressing it in Menu mode, it will move to lower menu.

1. Pressing this button, it will move to upper menu.

2. It will also take role of "Enter" button when confirming the changed password or main parame-
ters.

Pressing this button, it will move to left menu.

Pressing this button, it will move to right menu.

Increase the data as set value in the current Menu mode.

Decrease the data as set value in the current Menu mode.

SM 844 06-5-7

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Menu mode Chart

Menu Mini- Maxim- Adj-
Parameter Overview Reference
No. mum um usted
The digital and the analog input/output conditions of the driv-
1 STATUS-TRACTION
ing controller are displayed.
1.1 BATTERY VOLTAGE The present battery voltage is displayed. 0.00V 115.00V ACTUAL
1.2 HOUR METER The driving hour of the vehicle so far is displayed. 0Hr 59999Hr ACTUAL
1.3 ACCELERATOR The accelerator voltage is displayed. 0.00V 5.00V ACTUAL
The sensor operating voltage of the LIFT/LOWER lever is dis-
1.4 LIFT & LOWER 0.00V 5.00V ACTUAL
played.
1.5 STEER ANGLE The steering angle is displayed. -128 128 ACTUAL
The open/closed conditions of the DEADMAN switch are dis-
1.6 DEADMAN SWITCH OPEN CLOSE ACTUAL
played.
The open/closed conditions of the 1st MAST switch are dis-
1.7 MAST SWITCH-1ST OPEN CLOSE ACTUAL
played.
The open/closed conditions of the 2nd MAST switch are dis-
1.8 MAST SWITCH-2ND OPEN CLOSE ACTUAL
played.
The open/closed conditions of the 3rd MAST switch are dis-
1.9 MAST SWITCH-3RD OPEN CLOSE ACTUAL
played.
The open/closed conditions of the 4th MAST switch are dis-
1.10 MAST SWITCH-4TH OPEN CLOSE ACTUAL
played.
The open/closed conditions of the left side gate switch are dis-
1.11 SIDE GATE SWITCH-LH OPEN CLOSE ACTUAL
played.
The open/closed conditions of the right side gate switch are
1.12 SIDE GATE SWITCH-RH OPEN CLOSE ACTUAL
displayed.
1.13 ENCODER The encoder frequency of the driving motor is displayed. -200Hz 200Hz ACTUAL
1.14 TEMPERATURE The present temperature of the driving controller is displayed. -40°C 127°C ACTUAL
1.15 MOTOR TEMPERATURE The present temperature of the driving motor is displayed. -40°C 300°C ACTUAL
1.16 CURRENT RMS The current consumption of the driving controller is displayed. 0A 1000A ACTUAL

The digital and the analog input/output conditions of the

2 STATUS-PUMP
hydraulic controller are displayed.
2.1 ENCODER The encoder frequency of the hydraulic motor is displayed. -200Hz 200Hz ACTUAL
The present temperature of the hydraulic controller is dis-
2.2 TEMPERATURE -40°C 127°C ACTUAL
played.
2.3 MOTOR TEMPERATURE The present temperature of the hydraulic motor is displayed. -40°C 300°C ACTUAL
The current consumption of the hydraulic controller is dis-
2.4 CURRENT RMS 0A 1000A ACTUAL
played.

The digital and the analog input/output conditions of the steer-

3 STATUS-EPS
ing controller are displayed.
3.1 0° SWITCH OPEN CLOSE
3.2 90° SWITCH OPEN CLOSE
3.3 TEMPERATURE The present temperature of the EPS controller is displayed. -128°C 127°C
3.4 MOTOR TEMPERATURE The present temperature of the EPS motor is displayed. -40°C 250°C
3.5 CURRENT RMS The current consumption of the EPS controller is displayed. 0A 2000A

SM 844 06-5-8

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Menu Mini- Maxim- Adj-

Parameter Overview Reference
No. mum um usted
4 DISPLAY SETTING The settings and the details of other items are displayed.
The maximum speed of the vehicle is set. 3Km/h 14Km/h 10Km/h
4.1 SLOW SPEED +/-
(in the turtle mode only) 1MPH 9MPH 6MPH
4.2 SPEED UNIT The speed unit of the vehicle is set.( km/h or MPH) Km/h MPH Km/h +/-
4.3 SOFTWARE VERSION The present software version of the TFT display is displayed. V1.00 ~ X

5 TIME SETUP The year, the date, the day and the hour are set.
5.1 YEAR The year is set. 2000 2099 +/-
5.2 MONTH The month is set. 1 12 +/-
5.3 DATE The date is set. 1 31 +/-
5.4 WEEK The day is set. MON SUN +/-
5.5 HOUR The hour is set. 0 23 +/-
5.6 MINUTE The minute is set. 0 59 +/-
5.7 AM/PM AM/PM is set. AM PM +/-

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Menu Mode (Tree structure)

− Data Refer to Setup Sheet

Menu mode operation menual

Truck status checking

Check the truck status at real time.

1. Battery voltage

2. Hourmeter

3. Accelerator voltage

4. Lift / Lower lever sensor

5. Steer angle

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Switch status ON/OFF checking

Check the switch ON/OFF status on the truck at real time

1. DEADMAN SWITCH OPEN / CLOSE

2. 1ST MAST SWITCH OPEN / CLOSE

3. 2ND MAST SWITCH OPEN / CLOSE

4. 3RD MAST SWITCH OPEN / CLOSE

5. TH MAST SWITCH OPEN / CLOSE

6. LEFT SIDE GATE SWITCH OPEN / CLOSE

7. RIGHT SIDE GATE SWITCH OPEN / CLOSE

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Annex function set

It is allowed to change the details of the vehicle, which are available of setting and changing, to comply with the require-
ments of the users.

Setting the speed unit

The unit of the speed of the vehicle displayed on the speed sensor is set.
It is allowed to set the unit in km/h or MPH.

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Year, date, day and hour

This function sets the date and the hour displayed in the vehicle.
It is allowed to change the year, the month, the date, the day and the hour.

SM 844 06-5-13

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Failure diagnosis

Automatic diagnosis function

The automatic diagnosis function detects, displays and
alarm failure of the vehicle.

CAN communication diagnosis

Malfunction of the driving controller, or problem on the
CAN bus line is displayed.
Inspect the CAN bus, and check if the power line fuse has
blown.

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Section 6

Fuse Box

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Function
Damage to the electric component by excessive current is prevented.

FUSE SPEC (36V)

NO CAPACITY LOAD NAME
F1 10A DC-DC CONVERTER
F2 15A READING LAMP
F3 10A WORK LAMP
F4 5A FAN
F5 5A DC-DC(DISPLAY)
F6 5A DISPLAY
- 5A SPARE
- 10A SPARE

FUSE SPEC (24V)

NO CAPACITY LOAD NAME
F1 10A READING LAMP
F2 15A WORK LAMP
F3 10A FAN
F4 5A DISPLAY
- 5A SPARE
- 10A SPARE

ATO (Autofuse) Blade Fuse - 297 Series

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LINE FUSE SPEC (24V/36V)

NO CAPACITY LOAD NAME
F1 20A KEY SWITCH
F2 10A EPS CONTROLLER
F3 10A TRACTION CONTRLLER


F3 F2 F1

ATO (Autofuse) Blade Fuse - 257 Series

SM 844 06-6-3

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Section 7

Electrical Components

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Strobe light
Function
The strobe light is used for alarming operation of equipment around the equipment.


Battery

No Description
1 LENS
2 BULB
3 BASE

Specification
Item Spec.
Rated Voltage DC 12V~24V ± 10%
Consumption
Max 200mA
Electric Current
Frequency 60times/min ± 3

Testing
Supply the power as shown on the figure, and check if the strobe light normally operates. (When supplying the power, the
positive pole and the negative pole of the battery shall correctly be connected. Connecting the poles in the wrong way, the
component is damaged.)

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Work lamp Lamp-Interior

Function Function
The work lamp provides view in the front and the rear The interior lamp lights up the driver compartment for con-
when working at night or indoor. venient operation when working at night or indoor.

[ 12V ] [ 24V ]

Specification Specification
Item Spec. Item Spec.
Rated Voltage DC 12V DC 24V Rated Voltage DC 12.8V DC 28V
Bulb Spec. GE862, 37.5W H3, 70W Bulb Spec. 1156, 27W 1683, 28W

Testing Testing
Supply 12/24V power to check if the work lamp operates Check the interior lamp for proper operation 12/24V as
normally. shown above.

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Fan
Function
The fan circulates the air into the driver compartment dur-
ing indoor work for convenient operation.

Specification
Item Spec.
Rated Voltage DC 12V DC 24V
Consumption
8.5W 9.5W
Electric Current
Rotation Speed 3400 rpm 3400 rpm

Testing
Check the fan for proper operation 12/24V as shown
above.

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Start Switch
Function
This functions to start the forklift and supplies electrical power to some electrical parts.

No Description
1 Master Key


Specification
Item Spec.
Rated voltage DC 48V
ON current 30A

Lamp and Fan Switch

Function
The lamp and fan switch turns on and off the lamp and the fan.

Specification
Item Spec.
Rated voltage DC 12V DC 48V
Contact current 20A 15A

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Relay
Function
The relay supplies the power to the lamp and the fan.

Resist.

Circuit

Specification
Item Spec.
Rated voltage DC 12V DC 24V
Contact current NO : 20A NO : 20A
NC : 15A NC : 15A

Testing
Position multi-meter to resistance mode and measure resistance between both terminals as above.
Normal : 85±5Ω(12V) / 340±5Ω(24V)

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SSR Relay
Function
The relay supplies the power to the cooling fan of the controller.

Specification
Item Spec.
Rated voltage DC 7 ~ 60V
Load current 0.02 ~ 7A
Operating voltage NO : Max 7Vdc, OFF : Min 1Vdc

Maintenance switch
Function
The switch controls the hydraulic operation when maintaining the vehicle outside.

Specification
Item Spec.
Rated voltage DC 28V
Load current 3A

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DC-DC Converter (DISPLAY)

Function
The converter supplies the power to the display.

Block Diagram

Specification
Item Spec.
Rated voltage DC 25V ~ 26V
Load current 1A, 12Vdc

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DC-DC Converter Backup Alarm

Function Function
The converter supplies the power to some of the electric The alarm provides audible warning when driving back-
systems. ward.

Specification Specification
Item Spec. Item Spec.
Rated voltage DC 36/ 48V Rated voltage DC 12/ 48V
Load current 300W, 12Vdc Load current 600mA ± 10%
Sound pressure 77 ~ 97dB

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Horn
Function
The horn is one of the alarming devices, and makes the sound with the sound pressure of defined setup when the horn
switch is turned on.

[ Connection ]

Specification
Item Spec.
Rated voltage DC 12/48V
Load current 0.25A at 28Vdc
Sound pressure 105 dB

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Lamp Switch
- The switch is water tight, and vibration resistant. IP68 (Grade)
- The switch is mounted on the dashboard for easy access by the driver.
- Switch Spec.
Carling Technologies company, V-series
4VA@24VDC (Max.)
Mechanical endurance : 150,000 cycles minimum

V-Series Contura Sealed Rocker Switches

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 GROUP 07

GROUP 07

MOTOR CONTROLS

Controller Mounting ................................. Section 1

Description ..................................................Section 2

Factory Control Settings............................Section 3

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Section 1

Controller Mounting

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 Group 07, Motor Controls

Controller Mounting

OzpT[`Y]ZP

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 Group 07, Motor Controls

Section 2

Description
The CLARK OSX15 uses a Dual AC controller to control both drive motors and a single AC controller to
control the single motor/pump combination which supplies flow to all hydraulic functions and steering.

Traction Control and Motors the desired flow rate. Tilt and aux switches mounted on the
hydraulic valve provide unique inputs to the control. The
The dual AC traction control consists of two motor con- speed of each function can be programmed independently
trols mounted to a single heat-sink plate and enclosed by a so that only the required flow rate is produced, minimizing
single cover. The right portion of the control is reference power losses. If the control receives an input from the lift
to as the "slave" control and operates the left drive motor. potentiometer, tilt or aux switches, then it will ramp up the
The left portion of the control is referred to as the "mas- motor speed to match the desired speed. Once the request
ter" control and operates the right drive motor. The con- is removed the motor speed will return to the fixed level.
trol receives inputs from the speed control (accelerator) As with the traction control and motors, the lift control and
pedal, steer tire position sensor (steer pot), direction motor have thermistors for thermal protection and the
switches, foot brake switch, motor encoders, motor ther- motor has a built-in encoder for speed feedback.
mistors and other miscellaneous switches. The control is
able to proportional reduce the speed of the pivot tire
when the truck is in a turn, based on the steer angle input EPS Control and Motor
from the steer sensor. Once the steer angle exceeds a cer- The EPS-ac0 perform auto-centering function on the truck.
tain value, the pivot wheel will start to reverse. The speed Feedback sensors are mandantory to close the loop when
of the vehicle is controlled by the accelerator control an automatic function is required. The EPS-ac0 runs an
pedal. For a given pedal position the control will maintain inexpensive, rust and maintenance free three phases AC
a set speed, as determined by control parameter settings. induction motor. The EPS control and motor have ther-
These settings are adjustable to meet your customer's mistat for thermal protection and the motor has built-in
needs. One feature of AC controller is "release braking". encoder for speed feedback.
This feature will apply a regenerative braking force every
time the driver lifts up off the accelerator pedal. The final
travel speed will be determined by the new pedal position.
The control receives motor speed feedback from the
motor encoders which allow for precise speed regulation.
Every motor also has a built-in thermistor which con-
stantly monitors the winding temperature and reports this
information to the control. Should it sense that the motor
is approaching the temperature limit, the control will cut-
back motor current until the temperature decreases. Since
it is cutting back current and not voltage, the top end
speed will not be effected, unless on a grade. Each control
also has built-in thermal protection that will reduce output
current should the control approach the thermal limit.

Lift Control and Motor

A single motor is used for hydraulic function. The motor is
controlled by a dedicated controller. The lift lever is
equipped with a linear potentiometer that measures the dis-
tance the lever is stroked and provides this input to the con-
trol. The control uses this information to increase motor
speed in proportion to the distance stroked, providing only

SM 844 07-2-1

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 Group 07, Motor Controls

Section 3

Factory Control Settings

SM 844 07-3-1

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 Group 07, Motor Controls

1. Traction Control

SM 844 07-3-2

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 Group 07, Motor Controls

SM 844 07-3-3

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 Group 07, Motor Controls

2. Pump Control

SM 844 07-3-4

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 Group 07, Motor Controls

3. EPS Control

SM 844 07-3-5

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 Group 07, Motor Controls

SM 844 07-3-6

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 GROUP 08

GROUP 08

MOTOR - DRIVE AND PUMP

Drive Motor Intallation ................................. Section 1

Drive Motor Maintenance Instruction ..........Section 2

Pump Motor Mounting...................................Section 3

Pump Motor Maintenance Instruction .........Section 4

SM 844 08-0

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 Group 08, Motor - Drive and Pump

Section 1

Drive Motor Intallation

OzpT[`Y][P

SM 844 08-1-1

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 Group 08, Motor - Drive and Pump

Section 2

Drive Motor Maintenance Instruction

Before starting the maintenance please disconnect the power supply.

Screws should be tightened according to the screw quality (please see your torque chart with torque wrench).

1. BALL BEARING
Both ball bearings are maintenance free. Should it be necessary to remove the bearings in case of repair, they should
be replaced. In any case the sealing parts (shaft sealing ring etc.) have to be replaced!
If a bearing which is to be replaced has only one sealing lip, this should be greased with quality bearing grease
(Staburags NBU 8EP).
After approximately 10,000 operating hours the bearings have to be replaced.

2. ASSEMBLY / DISASSEMBLY
The motor is assembled and disassembled according to the relevant sectional drawing and spare part list.

SM 844 08-2-1

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 Group 08, Motor - Drive and Pump

Sectional Drawing and Spare Part List

Pos. Mat.-No. Description QTY

51 50075394 STATOR AC 200 1
220 50058734 TERMINAL M10 3-POLIG 1
221 50043895 HEXAGON SCREW 3
222 50014730 HEXAGON NUT DIN934 M10-A1P 6
223 50014673 DISK DIN125-10,5-A1P 3
227 50015164 SCHNORR-DISK 10-A1P 3
241 50066336 CYLINDER SCREW 2
250 50066936 TERMINAL BASE 1
271 50073529 SENSOR COMPLETE 1
272 50075704 CYLINDER SCREW DIN912 M6x16-8.8-A1P-OT30 1
300 50075381 DRIVE END RING 200 1
400 50075389 COMMUTATOR END PLATE 200-AS 1
500 50036341 BALL BEARING 6205 2ZC3 HL 1
515 50062217 CYLINDER SCREW DIN912 M8x150-8.8-A1P 4
520 50052216 TEMP.SENSOR KTY 84-130 PPS 0,5m 1
530 50014631 CIRCLIP DIN472-52X2,0 1
700 50075399 ROTOR 200-AS 1
705 50014497 FITTING KEY 1
710 50014829 CIRCLIP DIN471-25X1,2 2
720 50013713 SPACER 1
730 11006750 SENSOR-TARGET 200-64 Ø128,0/Ø36,5 1
950 50051536 CONNECTOR AMP 282104-1 2-POLE 1
951 50051386 FLAT-TABS AMP 282404-1 2
952 50054153 PLUG SEAL AMP 281934-4 2
955 50051385 CONNECTOR AMP 282106-1 4-POLE 1
956 50051386 FLAT-TABS AMP 282404-1 4
957 50054153 PLUG SEAL AMP 281934-4 4
9999 50077269 S.D.- AC-MOTOR 1

SM 844 08-2-2

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 Group 08, Motor - Drive and Pump

Section 3

Pump Motor Mounting

OzpT[`Y_[P

SM 844 08-3-1

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 Group 08, Motor - Drive and Pump

Section 4

Pump Motor Maintenance Instruction

Before starting the maintenance please disconnect the power supply.

Screws should be tightened according to the screw quality (please see your torque chart with torque wrench).

1. BALL BEARING
Both ball bearings are maintenance free. Should it be necessary to remove the bearings in case of repair, they should
be replaced. In any case the sealing parts (shaft sealing ring etc.) have to be replaced!
If a bearing which is to be replaced has only one sealing lip, this should be greased with quality bearing grease
(Staburags NBU 8EP).
After approximately 10,000 operating hours the bearings have to be replaced.

2. ASSEMBLY / DISASSEMBLY
The motor is assembled and disassembled according to the relevant sectional drawing and spare part list.

SM 844 08-4-1

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 Group 08, Motor - Drive and Pump

Sectional Drawing and Spare Part List

Pos. Mat.-No. Description QTY

51 50075022 STATOR AC 170 1.000 ST
220 50058734 TERMINAL M10 3-POLIG 1.000 ST
221 50043895 HEXAGON SCREW 3.000 ST
222 50014730 HEXAGON NUT DIN934 M10-A1P 6.000 ST
223 50014673 DISK DIN125-10,5-A1P 3.000 ST
227 50015164 SCHNORR-DISK 10-A1P 3.000 ST
241 50066336 CYLINDER SCREW 2.000 ST
250 50064934 TERMINAL BASE 1.000 ST
271 50073529 SENSOR COMPLETE 1.000 ST
272 50075704 CYLINDER SCREW DIN912 M6x16-8.8-A1P-OT30 1.000 ST
300 50075106 DRIVE END COVER 1.000 ST
320 50036343 BALL BEARING 6206 2ZC3 HL 1.000 ST
330 50013927 SHAFT SEALING RING 28X52X7 BA 1.000 ST
400 50075057 NON DRIVE END PLATE 1.000 ST
500 50036340 BALL BEARING 6204 2ZC3 HL 1.000 ST
505 50074592 WAVY-WASHER 6204-EMOX-41 1.000 ST
515 11016244 SCREW M8 x 270 ISO4762-8.8 Zn5B 6g 4.000 ST
520 50052216 TEMP.SENSOR KTY 84-130 PPS 0,5m 1.000 ST
520 50057538 TEMP.SENSOR KPL KTY 84-130 0,5m PPS AMP 1.000 ST
700 50074999 ROTOR 170-AS 1.000 ST
730 11005462 SENSOR-TARGET 170-64 Ø102,0/Ø36,5 1.000 ST
950 50051536 CONNECTOR AMP 282104-1 2-POLE 1.000 ST
951 50051386 FLAT-TABS AMP 282404-1 2.000 ST
952 50054153 PLUG SEAL AMP 281934-4 2.000 ST
955 50051385 CONNECTOR AMP 282106-1 4-POLE 1.000 ST
956 50051386 FLAT-TABS AMP 282404-1 4.000 ST
957 50054153 PLUG SEAL AMP 281934-4 4.000 ST
9999 50077277 SD- ASYNCHRONOUS MOTOR 1.000 ST

SM 844 08-4-2

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 GROUP 09

GROUP 09

HYDRAULIC SYSTEM

Hydraulic Diagram ........................................ Section 1

Hydraulic System ............................................Section 2

SM 844 09-0

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 Group 09, Hydraulic System

Section 1

Hydraulic Diagram

OpuTY_[`XP

SM 844 09-1-1

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 Group 09, Hydraulic System

Hydraulic Oil
HYD. OIL
2776239 8027099
PART NO
(6094 - 10010) (6594 - 20030)
ESSO NUTO H32
GS RANDO HD32 RANDO HD CZ
REFERANCE
SK ZIC SUPERVIS AW32
S-OIL AZOLLA ZS 32R EQUIVIS ZS 46 III
MFH 4953~7468 19 L
OSX15
MFH 7925~9296 25 L

SM 844 09-1-2

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 Group 09, Hydraulic System

Section 2

Hydraulic System

SM 844 09-2-1

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 Group 09, Hydraulic System

Theory of Operation closes and the lift pump motor turns on, the proportional
(solenoid) valve ramps closed which forces hydraulic fluid
The hydraulic system consists of a compact hydraulic unit, into the cylinders and increases lift speed. The proportional
including mechanical valves, electric proportional (sole- (solenoid) valve provides a smooth transition between zero
noid) valve, manual release valve and cylinders for the lift speed lift and full speed lift and back to zero speed lift.
of the forks. The lift/lower potentiometer commands the When the lift potentiometer is released, the proportional
operator platform to lift or lower. Hydraulic fluid is placed solenoid ramps open and the lift contactor opens turning
in the reservoir tank to be circulated throughout the off the lift pump motor. During lift, the load-holding pro-
hydraulic hoses. portional (solenoid) valve remains closed (de-energized).
The truck has a two-speed lift system. Rotate the lift/lower
Lift potentiometer slightly forward to lift at the lower speed.
Rotate the lift potentiometer completely forward to lift at
When the lift potentiometer is rotated forward, the lift/
the faster speed.
lower proportional (solenoid) valve (normally open) stays
open while the lift contactor closes. After the contactor

Lift Hydraulic Circuit

OpuTY_[`XP

SM 844 09-2-2

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 Group 09, Hydraulic System

Lower a two-speed lowering system. Rotate the lower potentiom-

eter slightly backwards to lower at the slower speed.
When the lower potentiometer is rotated in reverse, the lift/ Rotate the lower potentiometer completely backward to
lower proportional (solenoid) valve closes and the load lower in the faster speed. When lowering is no longer
holding proportional (solenoid) valve opens. The propor- requested, the proportional (solenoid) valve ramps closed
tional valve ramps open and allows hydraulic fluid to and the load holding valve closes.
return from the lift cylinders to the reservoir. The truck has

Lower Hydraulic Circuit

OpuTY_[`XP

SM 844 09-2-3

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 Group 09, Hydraulic System

Maintenance 8. Remove female half of diagnostic fitting and hose.

9. If it is necessary to flush reservoir, remove reservoir.
When checking voltage at the solenoids, make sure
hydraulic lines and components are fully installed. When- 10. Dispose of old hydraulic fluid according to local reg-
ever possible, keep the key switch (S1) OFF and the bat- ulations for hazardous materials.
tery connector disconnected. Replace worn hoses. Drain
and add hydraulic fluid as necessary.
Check for proper fluid level and make sure proper oil/
lubricant has been selected for the hydraulic reservoir.
Before adding or changing hydraulic fluid, determine the
environment and usage of truck.

Changing Hydraulic System Fluid

NOTE! Be sure truck is in a clean area, away
from possible contaminating elements
that could enter the hydraulic system
during the changing process.
1. Lower the platform fully.
2. Drain hydraulic reservoir completely. Drain as much
fluid as possible from hydraulic lines and cylinders.
3. Fill hydraulic reservoir with proper fluid.
4. With lift system running, operate lift/lower and func-
tions for approximately two minutes to purge the sys-
tem.
5. Check for possible hydraulic leaks. Refilling System
6. Bleed entire hydraulic system before placing truck
into service. 1. If reservoir was removed for flushing, install reser-
7. Check reservoir fluid level. voir.
2. Install hydraulic filter.
The remainder of the original hydraulic fluid left in the
system, (approximately 5%), should not be harmful to the 3. Fill hydraulic reservoir tank with fluid.
operation of the truck. - MFH 4953 ~ 7468 : 19 L
- MFH 7925 ~ 9296 : 25 L

System Draining 4. Reconnect battery connector to the truck. Energize

EPO switch and turn key switch ON.
1. Lower the platform fully. 5. Bleed hydraulic system.
2. Turn the key switch OFF and energize EPO switch. 6. Install chassis covers.
Disconnect battery connector from the truck.
3. Remove chassis covers. Load bounces excessively when lowering
4. Use female half of the diagnostic fitting (24 inch [610
mm] hose) and direct the hydraulic fluid into a waste • Air in hydraulic system, TSU cylinders; set capac-
container with a capacity greater than 6.6 gallons (25 ity load on upright and lift form fully collapsed to
liters). full lift height for 10-15 cycles.
5. Reconnect battery connector to the truck. Energize • Defective upright load-lowering flow valve; check,
EPO switch and turn key switch ON. clean and replace valve if necessary.
6. Operate lift until air in the system is heard. • Defective velocity fuse; remove fuse from cylinder
7. Turn the key switch OFF and energize EPO switch. hydraulic port, clean and recheck for proper opera-
Disconnect battery connector from the truck. tion.

SM 844 09-2-4

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 Group 09, Hydraulic System

Troubleshooting Repair and Rebuild

When checking voltage at solenoids, make sure hydraulic The lift manifold, hydraulic reservoir, manual release
lines and components are fully installed. Inspect hydraulic valve, and lift pump can not be repaired or rebuilt. Replace
system for leakage, worn hoses, and fluid level in the items as necessary.
hydraulic reservoir tank. Inspect the hydraulics hose and
The reservoir tank can not be repaired or rebuilt. Replace
tubing for leaks, nicks, cuts, chafing and bulges. Inspect all
reservoir tank as necessary.
fittings for leaks.

Hydraulic Component Mounting

OzpT[`Y[[P

! WARNING
DO NOT use your hands to check for hydraulic leakage. Use a piece of cardboard or paper to search for
leaks. Escaping fluid under pressure can penetrate the skin causing injury. Relieve pressure before dis-
connecting hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and
body away from pinholes and nozzles which eject fluids under high pressure.

SM 844 09-2-5

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 Group 09, Hydraulic System

Lift Valve Assembly

Lift Valve 4. Remove mast supply hose from lift valve.

5. Remove control wires from lift manifold solenoid
Removal coils.
1. Lower the platform fully. 6. Drain reservoir.
2. Turn key switch OFF and depress EPO switch. Dis- 7. Remove hose and pipe fitting from lift manifold.
connect battery connector from truck. 8. Remove lift valve assembly from mounting bracket
3. Remove chassis covers. assembly.

! WARNING
Verify pressure is released from system; press
and hold manual release valve (see page 09-2-
8).

SM 844 09-2-6

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 Group 09, Hydraulic System

Valve Replacement Installation

1. Remove applicable valve(s). 1. Apply Loctite 587® to the top of reservoir tank.
2. Clean, inspect and if necessary replace valve(s). 2. Install control wires onto lift valve solenoid coils.
3. Install mast supply hose to lift valve.
! CAUTION
4. Fill reservoir tank with fluid if necessary.
DO NOT over tighten proportional valve. If
5. Install chassis covers.
overtighten, it could result in the valve not
functioning properly. 6. Reconnect battery connector to truck. Energize EPO
switch and turn key switch ON. Test truck for proper
NOTE! To assure proper installation, take notice operation before returning to service.
of the flow arrows pointing outward on
the control valve.

Hydraulic Main Lines

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SM 844 09-2-7

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 Group 09, Hydraulic System

Hydraulic Reservoir Manual Release Valve

Removal
1. Turn key switch OFF and depress EPO switch. Dis-
connect battery connector from truck.
2. Remove chassis covers.
3. Remove mast supply hose from lift manifold.
4. Remove pump motor power cables.
5. Remove control wires from lift manifold solenoid
coils.
6. Remove pump / motor, and lift manifold as an assem-
bly from chassis.
7. Remove oil filter from lift manifold.
8. Remove reservoir tank mounting bolts from chassis
mounting bracket.
9. Remove reservoir
10. Drain reservoir.

Installation
1. Install reservoir tank to the chassis mounting bracket.
2. Install pump / motor, and lift manifold as an assembly
onto the chassis.
3. Install oil filter onto lift manifold. This truck is equipped with a hydraulic manual release
4. Install control wires onto lift manifold solenoid coils. valve located on the hydraulic control valve. When electri-
5. Install pump motor power cables. cal functions do not operate, the platform can be lowered
6. Install the mast supply hose to lift manifold. manually. Proceed as follows:
7. Fill reservoir tank with fluid. NOTE! The operator should stay on the operator
platform. Another qualified person in the
8. Install chassis covers.
area should manually release the valve.
9. Reconnect battery connector to truck. Energize EPO
switch and turn key switch ON. Test truck for proper 1. Remove the rear cover.
operation before returning to service. 2. Twist the release valve 180° counterclockwise. The
valve will then pop out and the operator platform will
safely lower to the floor.
NOTE! After lowering the operator platform,
push in the valve and twist 180° clock-
wise to retighten the valve.

Replacement
1. Lower the platform fully.
2. Turn key switch OFF and depress EPO switch. Dis-
connect battery connector from truck.
3. Disconnect wires from proportional (solenoid) valve.
4. Remove coil and valve (SP2).
5. Place new valve in lift manifold and secure.
6. Place coil on valve barrel.
7. Reconnect wires to proportional (solenoid) valve.

SM 844 09-2-8

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 Group 09, Hydraulic System

Cleaning
1. Remove valve from lift manifold.

! WARNING
When using compressed air, wear effective
chip-guarding and personal protective equip-
ment. Compressed air used for cleaning
MUST be reduced to less than 30 psi (207
kPa).

2. Clean valve with compressed air. If necessary, use a

blunt instrument (such as a wooden dowel) and push
bottom of internal spool to blow air into valve barrel.
3. Install valve in lift manifold.

SM 844 09-2-9

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 GROUP 10

GROUP 10

MAST CYLINDER

Three Stage Mast Staging Cylinder.............. Section 1

Three Stage Mast Primary Cylinder .............Section 2

SM 844 10-0

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 Group 10, Mast Cylinder

Section 1

Three Stage Mast Staging Cylinder

Bearing

Tube

SM 844 10-1-1

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 Group 10, Mast Cylinder

Theory of Operation not blocked, unexpected movement could

occur resulting in personal injury or death.
Two port cylinders are mounted on the outer column. The
range of mast height allows the platform to raise. 4. Use pendant to raise mast until approximately 12
inches (305 mm) of the staging cylinder rods are
Mast Height extended out of the cylinder tubes.
89.5 / 195 inch (2273 / 4953 mm) 5. Using a chain (minimum 4,000 pounds (192 kPa)
95 /210 inch (2413 / 5334 mm) rated capacity), route the chain over the top of the
107 / 240 inch (2718 / 6096 mm) upper tie bar on the outer mast column. Continue rout-
119 / 276 inch (3023 / 7010 mm) ing the chain around the lower tie bar on the interme-
diate mast column. Secure the chain to prevent the
125 / 294 inch (3175 / 7468 mm) intermediate column from lowering.
131 / 312 inch (3327 / 7925 mm) 6. Use pendant to lower mast assembly until the weight
143 / 330 inch (3632 / 8382 mm) of the intermediate mast column, and the platform are
149 / 348 inch (3785 / 8839 mm) supported by the chain.
155 / 366 inch (3937 / 9296 mm) 7. Remove bolts from the top of the staging cylinders.
.NOTE! New cylinder assemblies may not lower
Maintenance under their own weight. It may be required
that manual assistance is needed to fully
Inspect cylinders for leakage. Inspect cylinder rod for lower the cylinder rods.
gouges or pits. Lubricate bearings on cylinders.
8. On the lift manifold, loosen the check valve at port 4
on the topside of the manifold. While holding the
Troubleshooting manual lowering release valve in the fully upward
position, loosen the check valve three full turns. DO
Check cylinders for leakage.
NOT remove check valve. The staging cylinder rods
will begin to lower.
Repair and Rebuild
If cylinders contains gouges or pits, it can be repaired. The
bearing, seal, wear ring, O ring and rod wiper need to be
replaced with new as necessary.
NOTE! Call-outs in the following procedures refer
to illustration on page 10-1-1.

Bearing and Seals

Removal
1. Before removing bearing and replacing seals, fully
extend the cylinder to inspect rod for gouges or pits.
If gouges or pits are detected, remove cylinder for
repair. If no gouges or pits are evident, the bearing
seals may be replaced.
2. Park the truck on a level surface and apply the brake.
3. To use maintenance switch, lifting and lowering of
the mast assembly is working easily.

! DANGER
Securely block mast columns to reduce risk of 9. When cylinders are fully lowered, release the manual
lowering when working on or near mast. If lowering release valve and tighten the check valve.

SM 844 10-1-2

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 Group 10, Mast Cylinder

tube, making sure not to drop dust and debris into the
! WARNING cylinder tubes.
When using compressed air, wear effective 4. Thoroughly lubricate the wiper, seal, and wear ring
chip-guarding and personal protective equip- using hydraulic fluid.
ment. Compressed air used for cleaning 5. Lubricate cylinder rods with hydraulic fluid and slide
MUST be reduced to less than 30 psi (207 bearing down cylinder rod until the threads meet.
kPa).
6. Thread bearing into cylinder tubes and tighten with
10. Using compressed air, thoroughly clean all dirt and wrench.
debris from top and sides of the bearing where bear- 7. Thoroughly clean any excess oil from bearing and
ing meets cylinder tubes. cylinder tubes exterior.
11. Using a chain wrench, loosen bearing until it can be 8. Use the pendant and slowly raise the staging cylinder
threaded out of the cylinder tubes by hand. rods until they meet the underside of the intermediate
12. Before removing bearing from the cylinder tube, use mast column. Install bolts into the top of the cylinder
compressed air hose to thoroughly blow all dust and rods and torque to 30-33 ft-lbs (70-80 N.m).
debris away from the bearing and the cylinder tube 9. Raise mast assembly until there is slack in the chain,
assembly. which was used to support the mast columns and plat-
13. Remove bearing by sliding it up the cylinder rods. form during bearing removal.
14. For bearing seal kit removal and installation proce- 10. Remove chain and fully lower mast assembly.
dures (see page 10-1-3). 11. Reconnect battery connector to truck. Energize EPO
switch and turn key switch ON. Test truck for proper
Installation operation before returning to service.
1. Inspect the chamfered area of the staging cylinder for
burrs, scratches, or chrome flaking. Use an emery Bearing Seal Kit Removal
cloth to remove particles. 1. Using a cotter pin/seal removal tool, carefully remove
2. Cover the exposed cylinder tubes with a shop rag or the wiper, seal, and wear ring from the inside of the
cloth before sanding is applied bearing. Remove backup ring and O ring from the
outside of the bearing. Take special care when
Chamfered extracting the parts from the bearing, to not scratch,
Area nick or gouge the grooves in bearing.

Cotter Pin/Seal Re
Remova
val Too
ool

! WARNING
When using compressed air, wear effective
chip-guarding and personal protective equip-
ment. Compressed air used for cleaning
MUST be reduced to less than 30 psi (207
kPa).

3. Thoroughly clean the cylinder rods of dust and debris.

Carefully remove the shop rag or cloth from cylinder

SM 844 10-1-3

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 Group 10, Mast Cylinder

Bearing Seal Kit Installation 5. Wrap threaded end of bearing using masking or elec-
trical tape to reduce the risk of cutting the O ring
when installing.
6. Thoroughly lubricate the O ring with the same type of
oil as in the truck hydraulic reservoir.
7. Slide O ring over the threaded part of bearing until it
Bearing
makes contact with the base of the bearing. Remove
tape from threads.
8. Thoroughly lubricate the inside of the bearing with
the same type of oil as in the truck hydraulic reservoir.
9. Place bearing on a clean flat stable surface with the
threaded end of the bearing facing upward.
10. Using your index finger and thumb compress the
wear ring enough to slide inside the bearing. Continue
sliding the wear ring into the bearing, using your
index fingers, until the wear ring has seated into its
groove.

Wear Ring
1. Thoroughly clean all dust and debris from bearing. Wear Ring Inserted in Bearing
2. Thoroughly inspect grooves inside the bearing for
visual scratches, nicks, or gouges. If upper and lower
grooves have any visual deformations such as a
scratch, nick, or gouge, lightly sand with a 400 grit
sandpaper until smooth. If the center groove has any
visual deformations such as a scratch, nick or a
groove, bearing replacement is recommended.

11. Turn the bearing over. The threaded end of the bear-
Middle
Groove
ing will now be resting on the clean flat stable surface.
Upper 12. Thoroughly lubricate the seal with the same type of
Groove
oil as in the truck hydraulic reservoir.
Lower 13. Using a seal installation tool, collapse the seal and
Gr
Groove
install into the middle groove of the bearing with the
Be
Bearing
Base
Ba O ring side of the seal entering the bearing first. Using
your index finger work the seal into its seated posi-
tion.

Backup Ring
Back
Seal Installation Tool

Seal

ng
O Ring
Seal
3. If any sanding has been performed on the upper and
lower bearing grooves, thoroughly clean the bearing 14. Place bearing onto a small press with the threaded end
internally and externally of dust and debris. of the bearing resting on the table of the press.
4. Thoroughly lubricate the inside of the bearing with
the same type of oil as truck hydraulic reservoir.

SM 844 10-1-4

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Intended for CLARK dealers only
Do not sell or distribute
 Group 10, Mast Cylinder

Wiper

Bearing
Press

15. Thoroughly lubricate the wiper with the same type of

oil as in the truck hydraulic reservoir.
16. Place wiper onto the top of the bearing with the
grooved rubber side facing in the upward position and
lightly press into position.

SM 844 10-1-5

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Do not sell or distribute
 Group 10, Mast Cylinder

Section 2

Three Stage Mast Primary Cylinder

Bearing

Tube

SM 844 10-2-1

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Intended for CLARK dealers only
Do not sell or distribute
 Group 10, Mast Cylinder

Theory of Operation tions before applying pressure. Keep hands

and body away from pinholes and nozzles
The primary cylinder is the positive displacement type, which eject fluids under high pressure.
meaning there are NO seals on the lower end of the cylin-
der rod. The primary cylinder can be resealed without NOTE! Call-outs in the following procedures
being removed from truck. The range of mast height refer to illustration on page 10-2-1.
allows the platform to raise
Removal
Mast Height 1. Before removing bearing and replacing seals, fully
89.5 / 195 inch (2273 / 4953 mm) extend the cylinder to inspect rod for gouges or pits.
95 /210 inch (2413 / 5334 mm) If gouges or pits are detected, remove cylinder for
repair. If no gouges or pits are evident, the bearing
107 / 240 inch (2718 / 6096 mm)
seals may be replaced.
119 / 276 inch (3023 / 7010 mm)
2. Park truck on a level surface and apply brake.
125 / 294 inch (3175 / 7468 mm)
3. Place a chain and hoist strap around the mast assem-
131 / 312 inch (3327 / 7925 mm) bly to support it. Using a 2-ton (1814 kg) hoist (min-
143 / 330 inch (3632 / 8382 mm) imum) lift the platform approximately 6 inches (152
149 / 348 inch (3785 / 8839 mm) mm).
155 / 366 inch (3937 / 9296 mm) 4. Lower cylinder so chains, hoses, and electric cables
are loose.
5. Attach a hoist to the rear of the center bar of the over-
Maintenance head guard on the platform.
Inspect cylinder for leakage. Inspect cylinder rod for 6. Locate a 4 x 4 (102 x 102 mm) block long enough in
gouges or pits. Lubricate bearings on cylinder. length to cover the outside dimension of the straddle
arms.
Troubleshooting
! WARNING
Check cylinder for leakage. Use a suitable sling (minimum rated capacity
3 ton [2721 kg]) and suitable hoist (minimum
Repair and Rebuild rated capacity 2 ton [1814 kg]) for lifting.

If primary cylinder contains gouges or pits, it can be

repaired. The bearing, seal, wear ring, backup ring, O ring ! CAUTION
and rod wiper can not be repaired and need to be replaced Use caution not to pinch the mast cable
with new as necessary. behind the platform,

! DANGER
HOT OIL under pressure may be present. Be
certain truck is safely blocked and pressure is
released. Some spillage of hydraulic oil may
occur.

! WARNING
DO NOT use your hands to check for hydrau-
lic leakage. Use a piece of cardboard or paper
to search for leaks. Escaping fluid under pres-
sure can penetrate the skin causing injury.
Relieve pressure before disconnecting
hydraulic or other lines. Tighten all connec-

SM 844 10-2-2

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 Group 10, Mast Cylinder

Bracket

Sheave

4 X 4 Block

Chain

Anchor
Bolt

Primary cylinder
Platform

11. Remove the primary chains from the chain sheaves.

12. Remove the flanged nut and chain sheave from the
7. Raise the platform high enough above the straddle primary cylinder.
arms so that a 4 x 4 (102 x 102 mm) block may be
13. Remove flathead screw, bumper and washer from pri-
inserted between the bottom of the platform and the
mary cylinder.
top of the straddle arms. Place the 4 x 4 (102 x 102
mm) block towards the rear of the platform. 14. Loosen setscrew enough so that the shaft with the
remaining chain sheave and mast cable sheave may
8. Lower the platform onto the 4 x 4 (102 x 102 mm)
be removed from primary cylinder.
block. Leave hoist attached to the overhead guard on
the platform. There will be slack in the mast cable and
freelift chains for ease of removal. ! WARNING
9. Turn key switch OFF and depress EPO switch. Dis- When using compressed air, wear effective
connect battery connector from truck. chip-guarding and personal protective equip-
10. Remove the mast cable from the mast cable sheave. ment. Compressed air used for cleaning
MUST be reduced to less than 30 psi (207
kPa).

15. Use compressed air and thoroughly clean all dirt and
debris from the top and the side of the bearing where
the bearing meets the cylinder tube.
16. With a chain wrench, loosen the bearing until it can be
threaded out of the cylinder tube by hand.

SM 844 10-2-3

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 Group 10, Mast Cylinder

17. Before removing the bearing from the cylinder tube, 8. Carefully tighten the setscrew into the index hole on
use compressed air and thoroughly blow all dust and the shaft. Install washer and bumper to the top of the
debris from the bearing and tube assembly. cylinder rod with screw.
18. Remove bearing by sliding it up the cylinder rod. 9. Install remaining chain sheave onto shaft. Install
19. For bearing seal kit removal and installation see page flanged nut and tighten.
10-2-4. 10. Install freelift chains onto the chain sheaves.
11. Install mast cable onto the mast cable sheave.
Freelift Cylinder Bearing Installation
12. Reconnect battery connector to truck. Energize EPO
1. Inspect the chamfered area of the primary cylinder for
switch and turn key switch ON.
burrs, scratches, or chrome flaking. Use 400 grit sand-
paper to remove particles.
! WARNING
2. Cover the exposed cylinder tube with a shop rag or
cloth before sanding is applied to the chamfered edge Use a suitable sling (minimum rated capacity
of the cylinder rod. 3 ton [2721 kg]) and suitable hoist (minimum
rated capacity 2 ton [1814 kg]) for lifting.

13. Raise platform until the 4 inch x 4 inch (102 x 102

mm) block can be removed from under the platform.
14. Carefully lower the platform, watching the back side
Chamfered of the platform so as not to pinch mast cable assembly
Area
until the platform is fully lowered.
15. Remove hoist from overhead guard on platform.
16. Test truck for proper operation before returning to
service.

Bearing Seal Kit Removal

1. Using a cotter pin/seal removal tool, carefully remove
the wiper, seal, and wear ring from the inside of the
! WARNING
bearing. Remove backup ring and O ring from the
outside of the bearing. Take special care when
When using compressed air, wear effective extracting the parts from the bearing, to not scratch,
chip-guarding and personal protective equip- nick or gouge the grooves in bearing.
ment. Compressed air used for cleaning
MUST be reduced to less than 30 psi (207
kPa).

3. Using compressed air, thoroughly clean the cylinder

rod of dust and debris. Carefully remove the shop rag Cotter Pin/Seal Re
Remova
val Too
ool
or cloth from cylinder tube, making sure not to drop
dust and debris into the cylinder tube.
Bearing Seal Kit Installation
4. Lubricate cylinder rod with hydraulic fluid and slide
1. Thoroughly clean all dust and debris from bearing.
bearing down cylinder rod until the threads meet.
2. Thoroughly inspect grooves inside the bearing for
5. Thread bearing into cylinder tube and tighten with
visual scratches, nicks, or gouges. If upper and lower
wrench.
grooves have any visual deformations such as a
6. Thoroughly clean any excess oil from bearing and scratch, nick, or gouge, lightly sand with a 400 grit
cylinder tube exterior. sandpaper until smooth. If the center groove has any
7. With the chain and mast cable sheave attached to the visual deformations such as a scratch, nick or a
shaft assembly, slide the shaft from the right to the left groove, bearing replacement is recommended.
into the cylinder rod. Make sure index hole is in the
upward position.

SM 844 10-2-4

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 Group 10, Mast Cylinder

Wear Ring
Middle Wear Ring
Groove
Inserted in Bearing
Upper
Groove

Lower
Gr
Groove
Be
Bearing
Base
Ba

Backup Ring
Back 12. Turn the bearing over. The threaded end of the bear-
ing will now be resting on the clean flat stable surface.
13. Thoroughly lubricate the seal with the same type of
oil as in the truck hydraulic reservoir.
14. Using a seal installation tool, collapse the seal and
ng
O Ring
install into the middle groove of the bearing with the
O ring side of the seal entering the bearing first. Work
the seal into its seated position using your index fin-
3. If any sanding has been performed on the upper and
ger.
lower bearing grooves, thoroughly clean the bearing
internally and externally of dust and debris.
Seal Installation Tool
4. When installing backup ring, make sure to install flat
side of backup ring towards the base of bearing and
cupped-side of backup ring facing the O ring. Seal
5. Wrap threaded end of bearing using masking or elec-
trical tape to reduce the risk of cutting the backup ring
or O ring when installing. Seal
6. Thoroughly lubricate the backup ring or O ring with
the same type of oil as in the truck hydraulic reservoir. 15. Place bearing onto a small press with the threaded end
7. Slide backup ring or O ring over the threaded part of of the bearing resting on the table of the press.
bearing until it makes contact with the base of the
bearing. Remove tape from threads.
8. Thoroughly lubricate the inside of the bearing with Wiper
the same type of oil as in the truck hydraulic reservoir.
9. Place bearing on a clean flat stable surface with the
Bearing
threaded end of the bearing facing upward. Press
10. Thoroughly lubricate the wear ring with same type of
oil as in the truck hydraulic reservoir.
11. Using your index finger and thumb, compress the
wear ring enough to slide inside the bearing. Continue
sliding the wear ring into the bearing, using your
index fingers, until the wear ring has seated into its
groove.
16. Thoroughly lubricate the wiper with the same type of
oil as in the truck hydraulic reservoir.
17. Place wiper onto the top of the bearing with the
grooved rubber side facing in the upward position and
lightly press into position.

SM 844 10-2-5

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 GROUP 11

GROUP 11

ATTACHMENT AND PLATFORM

Mast ................................................................. Section 1

Fork Assembly.................................................Section 2

Platform Mounting..........................................Section 3

SM 844 11-0

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 Group 11, Attachment and Platform

Section 1

Mast

SM 844 11-1-1

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Do not sell or distribute
 Group 11, Attachment and Platform

Theory of Operation When performing inspection, observe the following chain

conditions: chain wear, rust and corrosion, cracked plates,
The mast, and associated components, provide the lifting protruding or turned pins, and chain side wear.
function in the truck. These components consist of the
mast columns, lift cylinders, lift chains, chain rollers, and Wear
operator platform. The hydraulic system provides the nec-
essary force and controls to do the work. When lifting, the
lift cylinders extend as hydraulic pressure and volume is
applied.
Chain
On a three-stage, the primary cylinder extends before the
staging cylinders, due to the physics involved with the Wear
Gauge
weight of the platform and the mast column. The primary
12”
cylinder extends pushing the mast chain rollers up. Lift
chains, attached to the inner column and routed over the
chain rollers, pull the operator platform up. When the pri-
mary cylinder has fully extended, the staging cylinders will
begin to extend. The staging cylinders, working in parallel,
push the intermediate column up. Staging lift chains,
attached to the top of the outer column and routed over the
chain rollers on the intermediate column, pull the inner
column and operator platform up. Lifting stops when no
more volume of hydraulic fluid is put into the lift cylinder,
either by stopping the pump or by extending the lift cylin- Stretched
New Chain Chain
ders to their maximum height.
Refer to the hydraulic section (see page 09-2-1) for further As the chain flexes on and off the sheaves, the joints grad-
information. ually wear. The “stretch” a chain develops in service is due
to material being worn off the pin on the outside diameter
Maintenance and the pitch hole inside diameter on the inside plates.
Chain wear can be measured by using a chain wear gauge
Visual Inspection or a steel tape measure. Discard chains when elognated
3%. (For example, one foot of chain may contain 16
Visually inspect the mast columns for abnormal wear pitches [links]. When 16 pitches measures 12 inches,
(0.09375 inch [2.38 mm] mast column flange wear) in the replace chains.) When checking chain wear, measure a
bearing contact area. Inspect column assemblies and weld- segment of chain that operates over a sheave.
ments for cracks.
NOTE! Do not repair chains by cutting out the
worn section and splicing in a new piece.
Chain Inspection
Unsatisfactory chain performance can be traced directly to Rust and Corrosion
inadequate maintenance. Highly stressed precision chains Lift chains are highly stressed precision components. It is
require periodic maintenance to deliver maximum service very important that maintenance is performed throughout
life. the chain service life. Corrosion will cause a major reduc-
The chain system on the mast was designed for efficient, tion in the load-carrying capacity of the lift chain because
reliable transmission of lifting force from the hydraulic corrosion may cause sideplate cracking. It is extremely
cylinder to the forks. Safe, uninterrupted use of the truck important to protect the lift chain from corrosion, whether
depends on proper care and maintenance of lift chains. in service or in storage.

Lift chains are very important components of the truck. NOTE! Do not steam clean or degrease new lift
After every 100 hours of truck operation, lift chains should chains.
be inspected and lubricated. When operating in a corrosive
environment, inspect chains every 50 hours.

SM 844 11-1-2

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 Group 11, Attachment and Platform

Stress-corrosion Cracking Broken Plate Caused by Overload

Lift chain lubricant serves both as a joint lubricant and cor-
rosion inhibitor. During inspection, carefully examine the All joints in the lift chain should flex freely. Tight joints
external lift chain surfaces for the presence of an oily film. resist flexing, increasing internal friction. This accelerates
Under normal operating conditions, oil lift chains every wear and fatigue problems. In lift chains, tight joints are
100 hours, and more frequently under adverse conditions. usually caused by rust. Replace chains if rusty.
NOTE! In all cases, the external surface of the
lift chains must be protected with a film
of oil.
Outside plates are susceptible to stress-corrosion cracking.
If lift chains are rusted or corroded, remove them from the
mast to thoroughly inspect for cracked plates. Replace all
lift chains on the truck if any plate is cracked. Lubricate the
chains when reinstalled on the truck.

Cracked Plates
Fatigue failure is the most common cause of plate crack- Tight joints reduce proper flexing of lift chain
ing. After many repeated heavy loads (loads higher than
the truck’s capacity), the plates may crack causing the
chains to eventually break. Fatigue cracks are almost
always found through the pitch holes perpendicular to the
pitch line. If cracks are present, replace all lift chains on
truck.

Bent or peened plates on lift chains can

cause tight joints and reduce flexing.

Ultimate Strength Failure Tight joints in lift chains may also be caused by the follow-
This type of failure is caused by overload ing:
in excess of the truck design load. • Bent pins or plates
• Rusty joints
• Peened plate edges
Peening of plate’s edges may be caused by worn or seized
sheaves, or unusually heavy loads.

SM 844 11-1-3

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 Group 11, Attachment and Platform

Protruding or Turned Pins Lubrication

Heavily loaded chains operating with too little lubrication Lubrication of the lift chain in field maintenance is a very
causes wear between the pin and plates. In some extreme important duty. Lift chains must be lubricated for accept-
cases, the torque in the joint can turn pins in the press-fit able service life. Specialty “chain lubes” are recom-
outside plate. mended. Heavy motor oil (40 weight) may also be used.
If the chain is allowed to operate in this condition, the pins Lubricate the entire length of all lift chains every 100
slowly work out of the chain, causing chain failure. Turned hours/50 hours in corrosive environment.
pins can be quickly spotted because the flats on the “V” The oil must penetrate the chain joint. Applying oil to the
head are no longer in line. external surface will reduce rust, but oil must flow into the
NOTE! Chains with turned pins or with protrud- live bearing surface for maximum wear life.
ing pins, should be replaced. Do not
Lubricate
attempt to repair the chain by driving the
pins back into the chain.

Protruding Pins

Lubricate

Turned Pins

Out-of-line flats on “V” heads indicate that pins have

turned in place.

Chain Side Wear

A wear pattern on pin heads and outside plates indicates
misalignment. This condition damages chain and sheaves Apply oil to chains with an applicator. If using motor oil, a
as well as increasing internal wear in the chain system. small brush or squirt applicator should be used. Flood the
chain with oil over its entire length.
Chain Anchors and Sheaves
An inspection of the chain system includes a close look at
the chain anchors and sheaves. Check chain anchors for
wear, breakage, and misalignment. Anchors with worn,
cracked, or broken fingers should be replaced. Anchors
should be adjusted to eliminate twisting or misalignment in
the chain. When the chain is misaligned, the load is not
spread uniformly between the plates. Prolonged operation
will result in premature failure. Worn or seized sheaves
should be replaced. Heavy flange wear indicates chain
misalignment.

SM 844 11-1-4

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Do not sell or distribute
 Group 11, Attachment and Platform

Adjustment Troubleshooting
Three-stage Mast Troubleshooting of mast and platform lift problems must
The three-stage mast has two pairs of lift chains that may be divided into hydraulic and mechanical functions. Gen-
be adjusted. Each pair should be adjusted so that they have erally, hydraulic problems will be evident of slow or no lift
equal tension and the proper length as described as fol- depending upon load weight. For problems that appear to
lows: be related to hydraulics, see page 09-2-5. Mechanical trou-
bleshooting consists primarily of inspection. Except in the
The staging chains must be adjusted first; correct case of disastrous mechanical failure, mechanical trouble-
length is defined by the tops of the mast columns shooting consists of physical inspection for the cause of
being equal and level when fully lowered. The freelift unusual noises (pops and grindings) and excessive lateral
chains should be adjusted so that they have equal ten- motion (shimming). To help determine mechanical fail-
sion and the top of the fork tips are 2.75 ± 0.025 inch ures see page 11-1-2.
(70mm ± 0.635mm) above the floor when fully low-
ered. The operator platform must not “bottom-out”
when fully lowered. Repair and Rebuild
Replace bearings and chains as necessary. The mast col-
umns can not be rebuilt. DO NOT WELD ON MAST.
DO NOT REPAIR BROKEN MAST COLUMNS.
Replace mast as necessary.

Adjusting Locking
Nut Nut

1. Fully lower platform.

2. Turn key switch OFF and depress EPO switch. Dis-
connect battery connector from truck.
3. Loosen locking nuts on staging chain anchors.
4. Turn adjusting nuts until mast columns are level and
equal across the top (± 0.50 inch [13 mm]).
5. Tighten adjusting nuts until both staging chains have
equal tension.
6. Retighten locking nuts to hold adjusting nuts in posi-
tion.
7. Align chains square to sheaves.
8. Loosen locking nuts on freelift chains.
9. Turn adjusting nuts until fork tips are at the proper
height and level.
10. Tighten adjusting nuts until both chains have equal
tension.
11. Retighten locking nuts to hold adjusting nuts in posi-
tion.
12. Align chains square to sheaves.

SM 844 11-1-5

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Do not sell or distribute
 Assembly of slider and adjustment of shim:

SM 844
Assemble the slider as the backside of rail and the
friction surface of slider are in parallel.
Match the outer rail end and inner rail end, and then
make the gap between the flange face of inner rail
and the slider will be within 0.5mm.

Mast Assembly

Assembly of slider and adjustment of shim:

Assemble the slider as the backside of rail and the
friction surface of slider are in parallel.
Match the outer rail end and inner rail end, and then
make the gap between the flange face of inner rail
and the slider will be within 0.5mm.

Copyrighted Material

Do not sell or distribute

Intended for CLARK dealers only
OzpT[`Y\`PGTGXVY

11-1-6
Group 11, Attachment and Platform
 Group 11, Attachment and Platform

OzpT[`Y\`PGTGYVY

SM 844 11-1-7

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 Group 11, Attachment and Platform

Mast Mounting

OzpT\WW[[P

Mast Removal
Mast
! DANGER
Securely block mast columns to reduce risk of
lowering when working on or near mast. If
not blocked, unexpected movement could
occur resulting in personal injury or death.

NOTE! Many mast repairs require removal of

the operator platform. If removal is nec- Platform
essary, the operator platform should be
removed before the mast is removed
from the truck.

SM 844 11-1-8

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 Group 11, Attachment and Platform

1. Fully lower mast. hand appropriate caps and plugs to cover

2. Turn key switch OFF and depress EPO switch. Dis- fittings and hose ends.
connect battery connector from truck. Remove bat- 4. Disconnect hose from the elbow on the battery com-
tery from truck. partment. Cap hose end. Tie hose back to reduce
interference when mast is lifted.
3. Remove chassis cover.
NOTE! Before removal of any hydraulic hose, 5. Remove nut from the elbow fitting. Push the elbow
thoroughly clean off all external dirt and fitting through the battery box wall and cap elbow fit-
debris around the hose fitting. Have on ting.

OzpT[`Y[\P

6. Loosen mast cable clamp adjacent to the battery box

by sliding cable braid down cable, releasing the
spring tension

SM 844 11-1-9

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 Group 11, Attachment and Platform

.
Sheave-Chain ! CAUTION
Use a double-leg sling for lifting mast. One
Sheave
sling leg should go to each side of the mast
Anchor Bolt rail. The sling or chain must be secured
around all mast rail top cross bars. Attempt-
Cable ing to lift with the sling secured to only a sin-
gle cross bar, or secured offcenter, can cause
Inner Rail the mast to tilt out of alignment or to extend
Hose
when lifted.

13. Remove lower mast bolts in the battery box.

14. Remove bolts and retainer plates from the sides of the
truck frame.
15. Raise mast until the stub shafts on the sides of the
outer mast rail clear the saddles of the truck frame.
Make sure the mast lifts straight up.

! CAUTION
Strap or otherwise secure columns to reduce
moving of the platform and columns when
7. Remove nut and spring from stud on battery compart- laid down.
ment wall.
16. Lay the mast down on the floor with the platform side
8. Remove the mast cable harness connectors from w/ of the mast facing in the upward position so shimming
harness platform. can be correctly checked.
9. If truck is equipped with a fan/light package or work
lights removed connectors from w/harness platform. Mast Installation
If truck is equipped with any other optional features,
wire(s) will need to be disconnected. ! CAUTION
10. Separate mast cable from wire harness in chassis, cut- Use a double-leg sling (rated capacity 3 ton
ting and removing wire ties as necessary. [2721 kg)) for lifting mast. One sling leg
NOTE! Ensure that all necessary wires are dis- should go to each side of the mast rail. The
connected; i.e., AAA and BBB if acces- sling or chain must be secured around all
sory power is connected. mast rail top cross bars. Attempting to lift
with the sling secured to only a single cross
11. Remove mast cable and wire harnesses through bat- bar, or secured off-center, can cause the mast
tery box frame. Tie back wires as necessary, so they to tilt out of alignment or to extend when
clear the truck. lifted.

! WARNING 1. Attach chain or sling around top tie bars of mast

Use a suitable sling (minimum rated capacity assembly.
3 ton [2721 kg]) and suitable hoist (minimum
rated capacity 2 ton [1814 kg]) for lifting. ! CAUTION
Always watch for pinch points when raising
12. Attach a chain or sling around the top tie bars of the mast assembly. Use caution to not damage
mast assembly. Raise with hoist until the slack is out mast cable during installation.
of the hoist chain.
2. Use a hoist to raise the mast assembly high enough to
clear the saddles of the main frame.

SM 844 11-1-10

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 Group 11, Attachment and Platform

3. Lower mast into the saddles of the main frame and 10. Wire tie mast cable neatly into place (see photos
install lower mast bolts. below). Pull excess mast cable back into battery box
4. Install block and bolts. and neatly tie back excess wire.
11. Install steer/tractor manager cover to chassis with
5. Set cable braid on cable so that spring end is about 3
screws.
inches (76 mm) from stud on battery compartment
wall. 12. Install battery into truck.
6. Stretch spring and place end over stud. Secure in 13. Reconnect battery connector to truck. Energize EPO
place with nut. switch and turn key switch ON. Test truck for proper
7. Install elbow fitting to battery compartment and operation before returning to service.
attach hose assembly from the lift pump to elbow fit- 14. Install chassis cover.
ting.
Mast Disassembly
8. Install mast cable and switch harness through the
grommets in the battery box. 1. Remove platform.
2. Remove mast from truck.
NOTE! The mast cable will have three multiple
pin connectors attached to it. 3. Lay the mast on the floor with the platform side of the
mast facing upward.
9. Connect mast cable and switch harness to w/harness
platform. 4. Remove the mast wiring harness.
NOTE! Make sure all wires are reconnected 5. Remove the primary and staging chains.
properly; i.e., AAA to wire 15 and BBB 6. Remove primary cylinder mounting bolts. Remove
to wire 40 if accessory power is required. hose assembly. Cap the flow limit valve. Remove the
primary cylinder from the mast assembly.

Outer
Rail Nut

Inner
Rail
Tee Hose

Valve

Hose
Hose
Secondary
Cylinder Tee
Connector

Bolt

Primary
Cylinder
Valve

Capscrew
Fitting

SM 844 11-1-11

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 Group 11, Attachment and Platform

7. Remove fitting, nut, and hose assembly. Cap the flow 10. Remove the tee fitting from the flow limit valve at the
valve on the lefthand staging cylinder. base of the left-hand staging cylinder and cap the flow
limit valve.
! WARNING 11. Remove the bolts from the top of the staging cylin-
Use a suitable sling (minimum rated capacity ders. Remove the staging cylinders.
3 ton [2721 kg]) and suitable hoist (minimum 12. Remove hose sheave.
rated capacity 2 ton [1814 kg]) for lifting.
13. Remove lower mast cable sheave.
8. Place a chain or sling around the mast rails. With a 14. Remove staging chain sheaves.
hoist, roll mast over to the opposite side.
15. Remove upper mast cable sheave.
16. Place a chain or sling around mast rails. With a hoist,
roll mast back over so that platform side (inner col-
Mast umn) is on top.
Rails NOTE! Mast bearings may be shimmed without
fully separating mast columns. How-
ever, it is recommended to complete
mast disassembly and do a thorough
cleaning before shimming. To separate
mast columns continue to step 17.
17. Support inner mast column with hoist and slide col-
umn out bottom of intermediate rail.
18. Support intermediate column with hoist and slide col-
umn out bottom of outer rail.
Shim
Mast Shimming and Assembly
Bearing

! WARNING
When using compressed air, wear effective
chip-guarding and personal protective equip-
ment. Compressed air used for cleaning
MUST be reduced to less than 30 psi (207
kPa).
Sheave
-Hose
Sheave
-Chain ! CAUTION
Roller to flange contact may cause flaking of
metal on new columns. This is normal and
will continue until the surface becomes work
hardened. Apply grease in these areas to
reduce new columns from flaking.
Inner Rail
NOTE! Mast must be removed, disassembled
and thoroughly cleaned before shim-
ming mast bearings.
Inner Rail Mast rails must be shimmed properly
during assembly.
Inner Rail
For the following procedures, except
9. Remove hose assembly from the right-hand staging where noted, refer to drawing on page
cylinder flow limit valve and cap the flow limit valve. 11-1-12.

SM 844 11-1-12

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Do not sell or distribute
 Group 11, Attachment and Platform

1. Thoroughly clean all parts and air dry. bearing and web on one side. Add shims until no more
2. Replace mast bearings, as necessary. Reuse original can be added, allowing a maximum of 0.030 inch
shims behind bearings if they are usable. Shimming (0.762 mm) of free play clearance. Mark these shims
will be set in a later step. for where they are to be used and set them aside.
6. Support intermediate column with hoist and slide it
3. Place outer mast column, platform side up, on solid
out the bottom of outer column only far enough to
work surface or floor.
expose bearings top and bottom.
4. Support intermediate mast column with hoist, plat- Working at the top, and then at the bottom, remove all
form side up, and slide it into outer column from the bearings and shims. Add the additional shims deter-
bottom. mined in step 5 and divide entire shim pack as equally
as possible on both sides. Install shims under bearings
Shim and install bearings.
Here
7. Reinstall intermediate column in outer column. Sup-
port intermediate column at top with hoist and extend
column out the top as far as it will go. Recheck bear-
ing shimming as column is extended. If tight spots are
encountered where the mast will not move freely,
remove shims as necessary.
8. Repeat steps 4 through 7 with inner column.
NOTE! Continue with mast assembly after bear-
Contact Area on Flange ing shimming is complete.
Lower End of Column 9. Install upper mast cable sheave (see page 461).
10. Install staging chain sheaves.
Shim
Here 11. Install lower mast cable sheave.
12. Install hose sheave.
13. Install staging cylinders and install bolts into top of
each cylinder rod.
14. Install tee fitting onto the lower left-hand flow limit
valve.
15. Install hose assembly into tee fitting and to the lower
Contact Area on Flange right-hand flow limit valve.

Upper End of Column 16. Wrap a chain or sling around the mast rails and with
a hoist roll the mast over to the opposite side.
5. With the intermediate column installed in outer col- 17. Install fitting and nut.
umn, determine the amount of shims required.
At lower end of column, pry column to one side and 18. Install the primary cylinder into the inner rail assem-
then the other. Be certain that bearings are fully seated bly and install mounting bolts.
on shaft. Slip additional shims between bearing and 19. Install hose assembly to the fitting and then to the
web on one side. Add shims until no more can be flow limit valve at the base of the primary cylinder.
added, allowing a maximum of 0.030 inch (0.762
20. Install the primary and staging chains.
mm) of free play clearance. Mark these shims for
where they are to be used and set them aside. 21. Install mast onto truck frame.
At upper end of column, support intermediate column
with hoist attached to upper cross bar; lift only till
bearings are in contact with flange. Pry column to one
side and then the other. Be certain that bearings are
fully seated on shaft. Slip additional shims between

SM 844 11-1-13

Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
 Group 11, Attachment and Platform

Lift Chain Replacement

1. All chains should be replaced if any length has wear
elongation of 3% or if any of the conditions listed in
“Wear” on page 11-1-2 are evident during inspection.
2. Replace all chains as a set.
3. Do not degrease or paint new chains.
4. Replace anchors and anchor pins when installing new
chains.
5. Adjust chains properly (see page 11-1-5).
Platform
Freelift Cylinder Bearing Removal
1. Turn key switch OFF and depress EPO switch. Dis- 4. Raise the platform high enough above the straddle
connect battery connector from truck. arms so that a 4 x 4 (102 x 102 mm) block may be
2. Attach a hoist to the rear of the center bar of the over- inserted between the bottom of the platform and the
head guard on the platform. top of the straddle arms. Place the 4 x 4 (102 x 102
mm) block towards the rear of the platform.
3. Locate a 4 x 4 inch (102 x 102 mm) block long
enough in length to cover the outside dimension of the 5. Lower the platform onto the 4 x 4 (102 x 102 mm)
straddle arms. block. Leave hoist attached to the overhead guard on
the platform. There will be slack in the mast cable and
! WARNING freelift chains for ease of removal.
Use a suitable sling (minimum rated capacity 6. Remove the mast cable from the mast cable sheave.
3 ton [2721 kg]) and suitable hoist (minimum
rated capacity 2 ton [1814 kg]) for lifting.

! CAUTION
Use caution not to pinch the mast cable Bracket
behind the platform,

Sheave

Chain
4 X 4 Block

Anchor
Bolt

Primary cylinder

7. Remove the primary chains from the chain sheaves.

SM 844 11-1-14

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 Group 11, Attachment and Platform

8. Remove the nut and chain sheave from the primary

cylinder.

! WARNING
Bearing
When using compressed air, wear effective
chip-guarding and personal protective equip-
ment. Compressed air used for cleaning
MUST be reduced to less than 30 psi (207
kPa).

9. Use compressed air and thoroughly clean all dirt and

debris from the top and the side of the bearing where
the bearing meets the cylinder tube.
10. With a chain wrench, loosen the bearing until it can be
threaded out of the cylinder tube by hand.
11. Before removing the bearing from the cylinder tube,
use compressed air and thoroughly blow all dust and
debris from the bearing and tube assembly.
12. Remove bearing by sliding it up the cylinder rod.
Tube
13. For bearing seal kit removal and installation see page
11-1-18.

Primary Cylinder Bearing Installation

1. Inspect the chamfered area of the primary cylinder for
burrs, scratches, or chrome flaking. Use 400 grit sand-
paper to remove particles.
2. Cover the exposed cylinder tube with a shop rag or
cloth before sanding is applied to the chamfered edge
of the cylinder rod.

Chamfered ! WARNING
Area
When using compressed air, wear effective
chip-guarding and personal protective equip-
ment. Compressed air used for cleaning
MUST be reduced to less than 30 psi (207
kPa).

3. Using compressed air, thoroughly clean the cylinder

rod of dust and debris. Carefully remove the shop rag
or cloth from cylinder tube, making sure not to drop
dust and debris into the cylinder tube.
4. Lubricate cylinder rod with hydraulic fluid and slide
bearing down cylinder rod until the threads meet.
5. Thread bearing into cylinder tube and tighten with
wrench.

SM 844 11-1-15

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 Group 11, Attachment and Platform

6. Thoroughly clean any excess oil from bearing and 6. Remove bolts from the top of the staging cylinders.
cylinder tube exterior. NOTE! New cylinder assemblies may not lower
7. With the chain and mast cable sheave attached to the under their own weight. It may be
shaft assembly, slide the shaft from the right to the left required that manual assistance is
into the cylinder rod. Make sure index hole is in the needed to fully lower the cylinder rods.
upward position. 7. On the lift manifold, loosen the check valve at port on
8. Carefully tighten the setscrew into the index hole on the topside of the manifold. While holding the manual
the shaft. Install washer and bumper to the top of the lowering release valve in the fully upward position,
cylinder rod with flathead screw. loosen the check valve three full turns. DO NOT
remove check valve. The staging cylinder rods will
9. Install remaining chain sheave onto shaft. Install
begin to lower.
flanged nut and tighten.
10. Install primary chains onto the chain sheaves.
11. Install mast cable onto the mast cable sheave.

! WARNING
Use a suitable sling (minimum rated capacity
3 ton [2721 kg]) and suitable hoist (minimum
rated capacity 2 ton [1814 kg]) for lifting.

12. Raise platform until the 4 x 4 (102 x 102 mm) block

can be removed from under the platform.
13. Carefully lower the platform, watching the back side
of the platform so as not to pinch mast cable assembly
until the platform is fully lowered.
14. Remove hoist from overhead guard on platform.
15. Reconnect battery connector to truck. Energize EPO
switch and turn key switch ON. Test truck for proper
operation before returning to service.

Staging Cylinder Bearing Removal

8. When cylinders are fully lowered, release the manual
1. Reconnect battery connector to truck. Energize EPO
lowering release valve and tighten the check valve.
switch and turn key switch ON.
2. To use maintenance switch, lifting and lowering of ! WARNING
the mast assembly is working easily.
When using compressed air, wear effective
3. Use pendant to raise mast until approximately 12 chip-guarding and personal protective equip-
inches (305 mm) of the staging cylinder rods are ment. Compressed air used for cleaning
extended out of the cylinder tube. MUST be reduced to less than 30 psi (207
4. Using a chain (minimum 4,000 pounds (192 kPa) kPa).
rated capacity), route the chain over the top of the
upper tie bar on the outer mast column. Continue rout- 9. Using compressed air, thoroughly clean all dirt and
ing the chain around the lower tie bar on the interme- debris from top and sides of the bearing where bear-
diate mast column. Secure the chain to prevent the ing meets cylinder tube.
intermediate column from lowering. 10. Using a chain wrench, loosen bearing until it can be
5. Use pendant to lower mast assembly until the weight threaded out of the cylinder tube by hand.
of the intermediate, inner mast column, and the plat- 11. Before removing bearing from the cylinder tube, use
form are supported by the chain. compressed air hose to thoroughly blow all dust and

SM 844 11-1-16

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Do not sell or distribute
 Group 11, Attachment and Platform

debris away from the bearing and the cylinder tube

assembly.
12. Remove bearing by sliding it up the cylinder rod.
13. For bearing seal kit removal and installation proce- Bearing

dures (see page 11-1-18).

Staging Cylinder Bearing Installation

1. Inspect the chamfered area of the staging cylinder for
burrs, scratches, or chrome flaking. Use 400 grit sand-
paper to remove particles.
2. Cover the exposed cylinder tube with a shop rag or
cloth before sanding is applied to the chamfered edge
of the cylinder rod. Tube

Chamfered
Area

! WARNING
When using compressed air, wear effective
chip-guarding and personal protective equip-
ment. Compressed air used for cleaning
MUST be reduced to less than 30 psi (207
kPa).

3. Thoroughly clean the cylinder rod of dust and debris.

Carefully remove the shop rag or cloth from cylinder
tube, making sure not to drop dust and debris into the
cylinder tube.
4. Thoroughly lubricate the wiper, seal and wear ring
using hydraulic fluid.
5. Lubricate cylinder rod with hydraulic fluid and slide
bearing down cylinder rod until the threads meet.

SM 844 11-1-17

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Do not sell or distribute
 Group 11, Attachment and Platform

6. Thread bearing into cylinder tube and tighten with Bearing Seal Kit Installation
wrench.
7. Thoroughly clean any excess oil from bearing and
cylinder tube exterior.
8. Use the pendant and slowly raise the staging cylinder
rods until they meet the underside of the intermediate Bearing
mast column. Install bolts into the top of the cylinder
rods and torque to 30-33 ft-lbs (70-80 N.m).
9. Raise mast assembly until there is slack in the chain,
which was used to support the mast columns and plat-
form during bearing removal.
10. Remove chain and fully lower mast assembly.
11. Reconnect battery connector to truck. Energize EPO
switch and turn key switch ON. Test truck for proper
operation before returning to service.

Bearing Seal Kit Removal

1. Using a cotter pin/seal removal tool, carefully remove
the wiper, seal, and wear ring from the inside of the 1. Thoroughly clean all dust and debris from bearing.
bearing. Remove backup ring, if applicable, and O 2. Thoroughly inspect grooves inside the bearing for
ring from the outside of the bearing. Take special care visual scratches, nicks, or gouges. If upper and lower
when extracting the parts from the bearing, to not grooves have any visual deformations such as a
scratch, nick or gouge the grooves in bearing. scratch, nick, or gouge, lightly sand with a 400 grit
sandpaper until smooth. If the center groove has any
visual deformations such as a scratch, nick or a
groove, bearing replacement is recommended.

Cotter Pin/Seal Re
Remova
val Too
ool Middle
Groove
Upper
Groove

Lower
Gr
Groove
Be
Bearing
Base
Ba

Backup Ring
Back

ng
O Ring

3. If any sanding has been performed on the upper and

lower bearing grooves, thoroughly clean the bearing
internally and externally of dust and debris.

SM 844 11-1-18

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 Group 11, Attachment and Platform

4. When installing applicable backup ring, make sure to

install flat side of backup ring towards the base of Seal Installation Tool
bearing and cupped-side of backup ring facing the O
ring.
5. Wrap threaded end of bearing using masking or elec- Seal
trical tape to reduce the risk of cutting the backup ring
or O ring when installing.
Seal
6. Thoroughly lubricate the backup ring or O ring with
the same type of oil as in the truck hydraulic reservoir.
15. Place bearing onto a small press with the threaded end
7. Slide backup ring or O ring over the threaded part of
of the bearing resting on the table of the press.
bearing until it makes contact with the base of the
bearing. Remove tape from threads.
8. Thoroughly lubricate the inside of the bearing with Wiper
the same type of oil as in the truck hydraulic reservoir.
9. Place bearing on a clean flat stable surface with the Bearing
threaded end of the bearing facing upward. Press

10. Thoroughly lubricate the wear ring with same type of

oil as in the truck hydraulic reservoir.
11. Using your index finger and thumb compress the
wear ring enough to slide inside the bearing. Continue
sliding the wear ring into the bearing, using your
index fingers, until the wear ring has seated into its
groove. 16. Thoroughly lubricate the wiper with the same type of
oil as in the truck hydraulic reservoir.
Wear Ring
Wear Ring Inserted in Bearing
17. Place wiper onto the top of the bearing with the
grooved rubber side facing in the upward position and
lightly press into position.

12. Turn the bearing over. The threaded end of the bear-
ing will now be resting on the clean flat stable surface.
13. Thoroughly lubricate the seal with the same type of
oil as in the truck hydraulic reservoir.
14. Using a seal installation tool, collapse the seal and
install into the middle groove of the bearing with the
O ring side of the seal entering the bearing first. Using
your index finger work the seal into its seated posi-
tion.

SM 844 11-1-19

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 Group 11, Attachment and Platform

Section 2

Fork Assembly

OzpT[`Y_`P

SM 844 11-2-1

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 Group 11, Attachment and Platform

Theory of Operation 4. Install correct amount of washers or shim at back side

of fork to maintain a level fork.
The forks are raised by means of an electric powered
5. Install socket head cap screw at chassis end of fork.
hydraulic pump unit. The lift and lower forks thumb knob
is on the end of the control handle. Rotating the thumb 6. Remove block from platform.
knob up will lift the forks and rotating the thumb knob 7. Lower platform to floor and make sure forks are level.
down will lower the forks. If forks are not level, add more shim to fork.

Maintenance
See “Planned Maintenance Schedule” on page 01-2-2.

Troubleshooting
Make sure forks are in good condition.

Repair and Rebuild

The forks and pallet can not be rebuilt. Replace forks and
pallet as necessary.

Forks
Removal
1. Raise platform high enough to reach bottom of forks.
2. Block platform with 4 inch x 4 inch (10 x 10 cm)
upright block.
3. Secure fork to hoist using a suitable strap or chain.
4. Remove one socket head cap screw from underneath
fork at chassis end.
5. Remove snap ring from pivot pin in mounting block
of fork.

! CAUTION
The fork weighs approximately 114 pounds
(51 kg), use caution when it drops.

6. Drive out pivot pin. The fork washer(s) or shim(s)

will drop.
7. Replace damaged fork.

Install
1. Hold new fork in place underneath platform.
2. Install pivot pin through fork.
NOTE! Always use new snap rings when assem-
bling components.
3. Install new snap ring in pivot pin.

SM 844 11-2-2

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 Group 11, Attachment and Platform

Section 3

Platform Mounting

OzpT[`ZWXP

SM 844 11-3-1

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 Group 11, Attachment and Platform

Theory of Operation Troubleshooting

The operator platform attaches to the mast columns and Check fork frame mounting and inspect platform for dam-
chains. age and crack formation every six months.

Maintenance Repair and Rebuild

Replace bearings and chains on platform as necessary. The
Platform Shimming platform can not be rebuilt. Replace platform with new as
necessary.
! WARNING Removal
When blocking mast columns to reduce the
1. Reconnect battery connector to truck. Energize EPO
risk of lowering or when working on or near
switch and turn key switch ON.
mast, always block both sides of the column.
Otherwise, the truck could tip over on its side. 2. Attach pendant to steer/tractor manager card at pin
location.
1. Reconnect battery connector to truck. Energize EPO
3. Remove forks from platform.
switch and turn key switch ON.
4. Remove dash panel.
2. To use maintenance switch, lifting and lowering of
the mast assembly is working easily. 5. Remove the mast cable harness connectors from w/
harness platform.
3. Raise platform up inner column as far as it will go
under normal operation. Check bearing shimming as 6. Remove wire ties holding the mast cable harness to
the platform is lowered in six inch increments. With a the platform. Raise the mast assembly until the cable
0.030 inch (0.762 mm) feeler gauge, (a shim works clamp can be accessed at the base of the latform,
well), check bearing clearance between bearings and holding the mast cable harness to the platform. Block
the web of the column (as a pry bar is used to pry the mast assembly. Loosen the clamp and remove the har-
bearings plates of the platform side to side). Maxi- ness.
mum clearance must not exceed 0.030 inch (0.762 Sheave-Chain
mm).
4. Once the number of shims have been determined, Sheave

divide the shims equally as possible between the Anchor Bolt

upper bearings or the lower bearings as needed to
keep the platform centered in the mast. Cable

5. Remove the platform.

Inner Rail
6. Install shims behind bearings as needed.
Hose
7. Install platform into mast.
8. Remove hoist from platform and test operation of
platform in the mast. Check operation first with no
load, by checking the bearing clearance for tight
spots. If tight spots are encountered, shims will need
to be removed as required. If shimming is correct, test
operation of platform in the mast with a capacity rated
load.
9. Test truck for proper operation before returning to
service.

SM 844 11-3-2

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 Group 11, Attachment and Platform

7. Remove mast cable harness from the freelift sheave 13. Fully lower mast assembly.
and pull back towards the truck frame.
Hoist

Overhead
Guard
Bracket

Sheave

Chain

Assembly
1. Carefully raise mast assembly far enough to clear the
Anchor
Bolt
upper bearings on the platform.
2. Install platform into mast assembly.

Primary cylinder 3. Install primary chains on chain anchor bolts located

on either side of the primary cylinder. Adjust primary
chains.
8. Remove blocks from mast assembly. Fully lower
mast assembly, being careful not to pinch the recently 4. Install mast cable harness. Attach the harness cable
removed mast cable harness. clamp to the platform.

9. Attach a hoist to the platform overhead guard. Hoist 5. Install the mast cable harness connectors.
platform up far enough to release pressure on the 6. Lower platform until hoist chain is slack. Remove the
freelift chains. hoist chain.
10. Remove freelift chains from chain anchor bolts 7. Connect the mast cable harness connector to w/har-
located on either side of the freelift cylinder. ness platform.
11. Carefully raise mast assembly to clear the upper bear- 8. Install forks on platform.
ings on the platform.
9. Test truck for proper operation before returning to
12. Remove platform from mast assembly. service.
10. Reconnect battery connector to truck. Energize EPO
switch and turn key switch ON. Test truck for proper
operation before returning to service.

SM 844 11-3-3

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Intended for CLARK dealers only
Do not sell or distribute