CLARK FORKLIFT SM 649 CMP50607 SERVICE MANUAL – PDF DOWNLOAD
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CLARK FORKLIFT SM 649 CMP50607 SERVICE MANUAL – PDF DOWNLOAD
- The following instructions have been prepared from current industry and government safety standards applicable to industrial truck operation and maintenance. These recommended procedures specify conditions, methods, and accepted practices that aid in the safe maintenance of industrial trucks. They are listed here for the reference and safety of all workers during maintenance operations.
- Carefully read and understand these instructions and the specific maintenance procedures before attempting to do any repair work. When in doubt of any maintenance procedure, please contact your local Clark dealer. 1. IMPORTANT Powered industrial trucks can become hazardous if maintenance is neglected. Therefore, suitable maintenance facilities, trained personnel, and procedures must be provided. This message is used when special precautions should be taken to ensure a correct action or to avoid damage to, or malfunction of, the truck or a component.
- 2. Maintenance and inspection of all powered industrial trucks shall be done in conformance with the manufacturer’s recommendations. 3. A CAUTION This message is used as a reminder of safety hazards that can result in personal injury if proper precautions are not taken. A scheduled planned maintenance, lubrication, and inspection program shall be followed. 4. Only trained and authorized personnel shall be permitted to maintain, repair, adjust, and inspect industrial trucks. Work should be performed in accordance with the manufacturer’s specifications.
- A WARNING This message is used when a hazard exists that can result in injury or death if proper precautions are not taken. 5. Properly ventilate work area, vent exhaust fumes, and keep shop clean and floor dry. 6. A DANGER This message is used when an extreme hazard exists that can result in injury or death or serious injury if proper precautions are not taken. Avoid fire hazards and have fire protection equipment present in the work area. Do not use an open flame to check for level or leakage of fuel, electrolyte, or coolant.
- Do not use open pans of fuel or flammable cleaning fluids for cleaning parts. 7. Before starting work on truck: The above terms have been adopted by Clark Material Handling Company. The same terms may be used in different context in service literature supplied directly or indirectly by vendors of truck components. a. Raise drive wheels off of floor or disconnect power source and use blocks or other positive truck positioning devices.
- b. Disconnect battery before working on the electrical system. 8. Before working on engine fuel system of gasoline- or diesel-powered trucks, be sure the fuel shut-off valve is closed.
Table Of Contents:
CLARK FORKLIFT SM 649 CMP50607 SERVICE MANUAL – PDF DOWNLOAD
SM-649 CMP50/60/70............................................................................... 1 Use of this Manual............................................................................... 2 Contents......................................................................................... 3 GROUP SA SAFE MAINTENANCE........................................................................ 4 Section 1. Safety............................................................................ 5 Section 2. Lifting, Jacking, and Blocking.................................................... 7 Safe Parking............................................................................. 8 Lifting, Blocking, and Jacking Points.................................................... 8 Raising Drive Wheels Off Floor........................................................... 8 Raising Truck with a Hoist............................................................... 9 Blocking the Upright In Raised Position.................................................. 10 Raising Rear of Truck.................................................................... 10 Raising Entire Truck..................................................................... 11 Shipping Tie-Down Instructions........................................................... 12 Section 3. Towing............................................................................ 13 PERIODIC SERVICE................................................................................. 15 Section 1. Maintenance Schedules............................................................. 16 Service Chart/Lubrication Points......................................................... 17 Recommended Periodic Service Schedule.................................................... 18 Section 2. The Planned Maintenance Program................................................... 20 Introduction to Planned Maintenance...................................................... 21 The Basic PM Procedures.................................................................. 21 Visual Inspection........................................................................ 22 Functional Tests......................................................................... 23 Air Cleaning the Truck................................................................... 25 Truck Chassis Inspection and Lubrication................................................. 26 Upright and Tilt Cylinder Lubrication.................................................... 26 Lift Chain Lubrication................................................................... 26 Under-the-Hood Inspection................................................................ 26 Fluid Checks............................................................................. 26 Stall Test............................................................................... 27 Cranking Voltage Test.................................................................... 27 Critical Fastener Torque Checks.......................................................... 27 Section 3. The PM Form....................................................................... 28 GROUP 00 ENGINE.................................................................................. 30 Lubrication Diagrams......................................................................... 31 Perkins WORKSHOP MANUAL...................................................................... 33 Contents................................................................................. 34 General information...................................................................... 35 Introduction......................................................................... 36 Engine identification................................................................ 36 Safety precautions................................................................... 38 Asbestos joints...................................................................... 39 Specifications........................................................................... 40 Basic engine data.................................................................... 41 Recommended torque tensions.......................................................... 42 Data and dimensions.................................................................. 45 Introduction..................................................................... 46 Cylinder head assembly........................................................... 46 Pistons and connecting rods...................................................... 49 Crankshaft assembly.............................................................. 52 Timing case and drive assembly................................................... 55 Cylinder block assembly.......................................................... 56 Aspiration system................................................................ 57 Lubrication system............................................................... 57 Fuel system...................................................................... 59 Cooling system................................................................... 62 Flywheel and housing............................................................. 63 Electrical equipment............................................................. 63 Auxiliary equipment.............................................................. 64 Cylinder head assembly................................................................... 65 General description.................................................................. 66 Rocker cover......................................................................... 67 Rocker assembly...................................................................... 68 Valve tip clearances................................................................. 69 Valve springs........................................................................ 70 Cylinder head assembly............................................................... 71 Valves and valve springs............................................................. 74 Valve guides......................................................................... 76 Cylinder head........................................................................ 77 Piston and connecting rod assemblies..................................................... 79 General description.................................................................. 80 Big end bearing...................................................................... 81 Piston and connecting rod assembly................................................... 82 Piston rings......................................................................... 84 Piston and connecting rod assembly................................................... 85 Piston and rings..................................................................... 86 Connecting rod....................................................................... 86 Small end bush....................................................................... 87 Piston cooling jets.................................................................. 87 Crankshaft assembly...................................................................... 88 General description.................................................................. 89 Crankshaft pulley.................................................................... 90 Rear oil seal assembly - engines which have the standard seal........................ 91 Rear oil seal assembly - engines which have a flywheel housing that is oil filled.... 91 Thrust washers....................................................................... 94 Main bearing......................................................................... 95 Crankshaft........................................................................... 96 Balancer unit........................................................................ 98 To remove and to fit............................................................. 98 To dismantle..................................................................... 99 To assemble......................................................................100 To inspect.......................................................................101 To remove and to fit the needle roller bearings for the drive shaft..............102 To remove and to fit the bushes for the balance weights..........................102 Timing case and drive assembly...........................................................103 General description..................................................................104 Timing case cover....................................................................105 Front oil seal.......................................................................106 Idler gear and hub...................................................................107 Fuel pump gear.......................................................................108 Camshaft gear........................................................................109 Crankshaft gear......................................................................110 Timing case..........................................................................111 Camshaft and tappets.................................................................112 Cylinder block assembly..................................................................114 General description..................................................................115 Cylinder block.......................................................................116 Cylinder liner.......................................................................117 Engines fitted with CAV fuel injection pumps.............................................120 General description..................................................................121 To set number 1 piston to TDC on the compression stroke..............................122 An alternative method to set number 1 piston to TDC on the compression stroke........122 To check the valve timing............................................................123 To check the timing of the fuel iniection pump.......................................123 To check the timing mark of the fuel injection pump..................................124 To check the engine timing mark......................................................125 Lubrication system.......................................................................126 General description..................................................................127 Filter canister......................................................................128 Filter head..........................................................................128 Sump.................................................................................129 Oil strainer and suction pipe........................................................129 Lubricating oil pump.................................................................130 To remove and to fit.............................................................130 To renew the shaft for the idler gear............................................131 To inspect.......................................................................132 Relief valve.........................................................................133 Closed breather system...............................................................134 Engines fitted with a rotary fuel injection pump.........................................135 General description..................................................................136 Fuel filter element..................................................................137 Atomisers............................................................................138 Fuel lift pump.......................................................................139 Fuel injection pump..................................................................141 To remove and to fit - Bosch pump................................................141 To remove and to fit - CAV pump..................................................144 To adjust - Bosch pump...........................................................145 To adjust - CAV pump.............................................................145 To eliminate air from the fuel system - Bosch pump...............................146 To eliminate air from the fuel system - CAV pump.................................147 Cooling system...........................................................................149 General description..................................................................150 Thermostats..........................................................................151 Water pump...........................................................................152 Fan..................................................................................155 Fan drive............................................................................155 Lubricating oil cooler...............................................................156 Cooler by-pass valve.................................................................159 Flywheel and flywheel housing............................................................160 General description..................................................................161 Flywheel.............................................................................162 Ring gear............................................................................162 Flywheel housing.....................................................................163 Electrical equipment.....................................................................164 Alternators..........................................................................165 General description..............................................................166 Precautions......................................................................166 Drive belts......................................................................167 Alternator.......................................................................168 Fault diagnosis..................................................................169 Starter motors.......................................................................170 General description..............................................................171 Starter motor....................................................................172 Starting aid.........................................................................173 General description..............................................................174 Starting aid.....................................................................174 Power steering pump......................................................................175 Power steering pump..................................................................176 Adaptor for hydraulic pump/steering pump with splined drive..........................176 List of special tools....................................................................177 GROUP 01 COOLING SYSTEM..........................................................................183 Section 1. Cooling System Specifications and Description.....................................184 Section 2. Cooling System Troubleshooting....................................................186 GROUP 06 TRANSMISSION............................................................................187 DISASSEMBLY / REASSEMBLY.....................................................................188 DISASSEMBLY AND REASSEMBLY OF(IST) AND 2ND CLUTCH........................................200 DISASSEMBLY..........................................................................200 IST CLUTCH DISASSEMBLY...........................................................200 2nd CLUTCH ASSEMBLY..............................................................204 1ST CLUTCH REASSEMBLY............................................................208 2ND CLUTCH REASSEMBLY............................................................214 DISASSEMBLY AND REASSEMBLY OF 3RD CLUTCH.................................................220 DISASSEMBLY..........................................................................220 3RD CLUTCH REASSEMBLY................................................................223 DISASSEMBLY AND REASSEMBLY OF FORWARD AND REVERSE CLUTCHES...............................227 REVERSE CLUTCH DISASSEMBLY...........................................................227 FORWARD CLUTCH DISASSEMBLY...........................................................230 FORWARD CLUTCH REASSEMBLY............................................................233 REVERSE CLUTCH REASSEMBLY............................................................238 REGULATOR VALVE DISASSEMBLY AND REASSEMBLY...............................................244 DISASSEMBLY AND REASSEMBLY OF SPACER PLATE...............................................245 DISASSEMBLY..........................................................................245 SPACER PLATE REASSEMBLY..............................................................250 DISASSEMBLY AND REASSEMBLY OF CONVERTER HOUSING..........................................255 DISASSEMBLY..........................................................................255 CONVERTER HOUSING REASSEMBLY.........................................................258 OUTPUT FLANGE OIL SEAL SLEEVE DISASSEMBLY AND REASSEMBLY.................................261 OUTPUT FLANGE AND PARKING BRAKE DISC @...................................................262 REASSEMBLY OF TRANSMISSION...................................................................264 ELECTRIC CONTROL VALVE ASSEMBLY..........................................................271 DRIVE PLATE INSTALLATION.................................................................276 TRANSMISSION TO ENGINE INSTALLATION PROCEDURE............................................277 SPECIFICATIONS AND SERVICE DATA-POWER SHIFT TRANSMISSION AND TORQUE CONVERTER............278 LUBRICATION..............................................................................279 SERVICING MACHINE AFTER TRANSMISSION OVERHAUL................................................280 EXTERNAL PLUMBING AND PRESSURE CHECK POINTS..................................................281 CLEANING AND INSPECTION......................................................................283 PARKING BRAKE LINING AND PISTON REPLACEMENT PROCEDURE........................................285 TROUBLESHOOTING GUIDE FOR THE TRANSMISSION...................................................286 Stall Test...............................................................................287 Transmission Pressure Checks.............................................................287 Mechanical Checks........................................................................287 Hydraulic Check..........................................................................288 CONVERTER STALL PROCEDURE................................................................288 TROUBLESHOOTING GUIDE....................................................................289 3 SPEED ASSEMBLY INSTRUCTION.................................................................290 ASSEMBLY NOTES...............................................................................292 TORQUE SPECIFICATION FOR LUBRICATED OR PLATED SCREWS AND NUTS................................294 GROUP 14 ELECTRICAL..............................................................................295 Section 1. Electrical System Specifications and Circuit Diagram..............................296 Section 2. Instrument Pod....................................................................299 GROUP 20 DRIVE AXLE..............................................................................301 Section 1. Drive Axle Specifications and Description.........................................302 Section 2. Drive Axle Overhaul...............................................................304 Overhaul Specifications..................................................................305 Drive Axle Disassembly...................................................................305 Differential Disassembly.................................................................307 Drive Axle Cleaning......................................................................307 Drive Axle Inspection....................................................................307 Differential Reassembly..................................................................309 Drive Axe Reassembly.....................................................................311 GROUP 22 WHEELS AND TIRES........................................................................314 Section 1. Wheels and Tires Specifications and Description...................................315 Section 2. Pneumatic Wheels and Tires........................................................316 Pneumatic Tire Maintenance Precaution....................................................317 General Tire Maintenance, Inspection, and Repair.........................................318 Wheel Dismounting and Remounting.........................................................319 Drive and Steer Wheel Dismounting........................................................319 Drive and Steer Wheel Remounting.........................................................319 Dual-Drive Wheel Dismounting.............................................................320 Dual-Drive Wheel Remounting..............................................................320 Wheel Disassembly and Tire Removal.......................................................321 Tire Replacement and Wheel Reassembly....................................................323 Tire-to-Wheel Mounting...................................................................324 Filling Tires with Air...................................................................325 Filling Tires with Nitrogen..............................................................325 Checking and Adjusting Tire Pressure.....................................................326 GROUP 23 BRAKES..................................................................................327 Section 1. Brakes Specifications and Description.............................................328 Section 2. Service and Inching Brakes........................................................332 Pedals Adjustment........................................................................333 Brake Bleeding...........................................................................333 Removal/Installation of Master Cylinders and Pedal Arramgement...........................335 Brake Valve Overhaul.....................................................................336 Brake Shoe and Lining Replacement........................................................337 Wheel Cylinder Inspection................................................................337 Brake Drum Inspection....................................................................338 Automatic Adjuster.......................................................................338 Special Brake Tools......................................................................339 Section 3. Parking Brake.....................................................................340 Parking Brake Adjustment.................................................................341 Lever and Cable Installation.............................................................341 Parking Brake Lining and Piston Replacement..............................................342 Parking Brake Adjustment.................................................................343 GROUP 25/26 STEERING SYSTEM......................................................................344 Section 1. Steering System Specifications and Description....................................345 Specifications...........................................................................345 Description..............................................................................346 Schematic................................................................................346 Construction.............................................................................347 Rotary Valve Bank....................................................................348 Gerotor Set..........................................................................348 Operation................................................................................348 Section 2. Steering System Troubleshooting...................................................349 Section 3. Steering System Removals and Replacements.........................................351 Section 4. Steering System Pressure Check and Adjustment.....................................354 Section 5. Steering Unit Overhaul............................................................355 Section 6. Priority Valve Overhaul...........................................................359 Section 7. Steer Cylinder Overhaul...........................................................360 GROUP 29/30 HYDRAULIC SYSTEM.....................................................................361 Section 1. Hydraulic System Specifications & Schematic Diagram...............................362 Section 2. Hydraulic System Troubleshooting..................................................366 Pressure Check and Adjustment............................................................366 Control Valve Troubleshooting............................................................367 Section 3. Hydraulic Pump Overhaul...........................................................369 Main and Auxiliary Pumps Removal and Replacement.........................................370 Main and Auxiliary Pump Overhaul.........................................................371 Section 4. Hydraulic Valve Overhaul..........................................................374 Removal and Replacement..................................................................375 Description..............................................................................377 Disassembly..............................................................................378 Assembly.................................................................................378 Inspection and Assessment................................................................378 GROUP 34 UPRIGHT.................................................................................379 Section 1. Upright Specifications and Description............................................380 Section 2. Upright Checks and Adjustments....................................................382 Performing Visual Inspection.............................................................383 Checking and Adjusting Carriage Side Roller..............................................384 Checking Carriage and Mast Shim..........................................................385 Adjusting Standard Mast Shim.............................................................386 Adjusting Full Free Lift Two-Stage Mast Shim.............................................387 Adjusting Full Free Lift Three-Stage Mast Shim...........................................388 Checking and Adjusting Cylinder Racking..................................................389 Section 3. Lift Chain Service................................................................390 Section 4. Removals and Replacements.........................................................392 Removing and Installing Mast.............................................................393 Carriage Removal and Replacement.........................................................394 Forks....................................................................................395 Section 5. Lift and Tilt Cylinder Overhaul...................................................396 GROUP 38 COUNTERWEIGHT...........................................................................399 Section 1. Specifications....................................................................399 Section 2. Inspection........................................................................399 Section 3. Removal and Replacement...........................................................400 GROUP 40 SPECIFICATIONS..........................................................................401 Section 1. Specifications....................................................................402 Dimensions and Weight Specifications.....................................................403 Performance Specifications...............................................................404 Service Specifications by Group..........................................................405 Fluids Specifications....................................................................407 Critical Torque Specifications...........................................................408 Standard Tightening Torque...............................................................409 Metric Conversion Chart..................................................................410 Hydraulic Fitting Tightening Procedure...................................................411
Please Note:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.