Sm-575 C5Ooylso-200-225S-225L 25Os-25Ol-3Oos-3Ool-350

SM-575
C5OOYlSO-200-225S-225L
25OS-25OL-3OOS-3OOL-350
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Cl!!‘lRK
Service Manual
C500 Y 180-200-2252;-225L-250S-250L-300S-300L-350
LIFT TRUCK
Read and understand this manual before operating

truck. Pay attention to the safety instructions. Safe
operation is the responsibility of the operator.
File this manual for future use.
This manual covers machine
Serial No. Y2235-l-7056 & above

Serial No. Y2235HT-1-7061 & above
ALWAYS GIVE THE MACHINE SERIAL NUMBER

WHEN ORDERING PARTS.
Book No. SM 575 2nd Revision
333 West Vine Street

Lexington, Kentucky 40507
C500 Y2235 Series Pictorial Index
1
Group 30 Group 29 Group 32
Hydraulic Hydraulic Tilt Cylinders,
Valves, Sump, Filters Low-Tilt and
Hi-Tilt Mod-
Circuit Pres- els.
Tilt Cylinder
Adjustment
Tilt Cylinder Group 33
Lines; Drift Hydraulic
Test Relief Valve
(M arina
Models)
Tilt Lock
!2 Relief
Valves.
Group 34
Upright....
Carruage &
Forks. Lift
Circuit Pres-
sure Check.
Group 06
Transmission
Group 20
Drive Axle
Group 21
Univ. Joints
Group 39 Decal Replacement and Placement

Group 40 Truck and Engine Specifications. Lubrication Specifications and Grease Chart
PM Inspection and Drivers Daily Inspection Forms
SM575 Pictorial
Copyrighted Index
Material July 97
INDEX
GROUP SECTION DESCRIPTION
Forward
Introduction
PM Section
00 ENGINE
00 Engine Troubleshooting
00 Engine Removal
00 Ford Engine Specifications
00 Cummins Engine Specifications
01 COOLING SYSTEM
01 Troubleshooting
01 Radiator Removal
01 Testing and Maintenance
01 Radiator Repair
02 FUEL SYSTEM
02 Troubleshooting
02 Induction System
02 Accelerator Linkage
02 lmpco LPG Lock-off Valve
02 lmpco LPG Vaporizer-Regulator
06 TRANSMISSION
06 Troubleshooting
06 Transmission Stall Test
06 Transmission Removal
06 Transmission Clutch Modulation
06 Transmission Maintenance and Service
06 Linkage and Controls
14 ELECTRICAL
14 General Troubleshooting
14 Starter and Battery Troubleshooting
14 Alternator Troubleshooting
14 Wiring Diagram
14 Electrical Tools
20 DRIVE AXLE
20 Troubleshooting
20 Drive Axle Removal
20 Drive Axle Wheel Bearing Adjustment
20 Clark-Hurth and Rockwell Drive Axle Maintenance and
Service
0 Clark Material Handling Company 1997

Copyrighted1Material
INDEX
21 PROP SHAFT
21 1 Troubleshooting
21 2 Prop Shaft Removal
21 3 Prop Shaft Overhaul
22 WHEELS AND TIRES

22 1 Lifting, Jacking and Blocking
22 2 Wheel and Tire Mounting
22 3 Safe Handling of Split Rim Wheels
23 PARKING BRAKE
23 1 System Troubleshooting
23 2 Mechanical Release of Parking Brake
24 SERVICE BRAKE
24 Troubleshooting
24 Air Brake System
24 Air Brake Treadle Valve
24 Air Brake Chambers
24 Air Brake Compressor
24 Rockwell Cam Brakes
25 STEERING COLUMN AND STEERING

GEAR
25 2 Removing Steering Handwheel
25 3 Removing Column and Gear and Gear From
Column
25 4 Steering Pump Removal and Overhaul
26 STEER AXLE
26 2 Steer Axle Removal
26 3 Steer Axle Overhaul
2-Piece Kingpin Design-26-3-l
Single Piece Kingpin Design-26-3-l 1
26 4 Steer Cylinder Removal and Overhaul
26 5 Steer Cylinder Overhaul (Lot 7056 and above)
26 6 Steering System Pressure Check
2
INDEX
29 1 Hydraulic Filters (Prior to lot 8506)

29 2 Hydraulic Filters (Lot 8506 and above)
30 HYDRAULIC COMPONENTS
30 Troubleshooting
30 Hydraulic Pump-General
30 Tyrone Hydraulic Pump Overhaul
30 J. S. Barnes Hydraulic Pump Overhaul
30 Vickers Control Valve Overhaul
30 Lift & Tilt Control Valve Overhaul
30 Commercial Inter-tech Control Valve Overhaul
30 Hydraulic System Pressure Check
30 Hydraulic Diagrams
32 1 Tilt Cylinder Remove and Replace

32 2 Tilt Cylinder Service Procedures (Thru Lot 7045)
32 3 Tilt Cylinder Service Procedures (Lot 7055 & above)
32 4 Tilt Cylinder Drift Test
32 5 Tilt Cylinder Adjustment
33 1 Hydraulic Relief Valve

33 2 Hydraulic Tilt Lock Valve(s)
34 UPRIGHT-CARRIAGE-FORKS
34 2 Fork Removal and Inspection
37 COUNTERWEIGHTS
37 Counterweight Removal and Installation
39 DECAL REPLACEMENT AND PLACEMENT

39 Decal Replacement and Placement
40 SPECIFICATIONS
40 1 General Specifications
40 2 PM Inspection and Drivers Daily Inspection Forms
INTRODUCTION
SAFETY SIGNS AND MESSAGES USER SAFE MAINTENANCE PRACTICES
The following instructions have been prepared from

Safety signs and messages are placed in this manual current industry and government safety standards ap-
and also on the lift truck to provide instructions and to plicable to industrial truck operation and maintenance.
identify specific areas where potential hazards exist These recommended procedures specify conditions,
and special precautions should be taken. Be sure you methods, and accepted practices that aid in the safe
know and understand the meaning of these instruc- maintenance of industrial trucks. They are listed here
tions, signs and messages. Damage to the truck or for the reference and safety of all workers during
death or serious injury to you or other persons may maintenance operations. Carefully read and under-
result if these messages are not followed. stand these instructions and the specific maintenance
procedures before attempting to do any repair work.
NOTICE When in doubt of any maintenance procedure, please
This message is used when special information, contact your local Clark dealer.
instructions or identification is required relating to
procedures, equipment, tools, pressures, capaci-
ties and other special data. 1. Powered industrial trucks can become hazardous if
maintenance is neglected. Therefor, suitable mainte-
nance facilities, trained personnel and procedures
IMPORTANT must be provided.
This message is used when special precautions
should be taken to ensure a correct action or to 2. Maintenance and inspection of all powered indus-
avoid damage to or malfunction of the truck or a trial trucks shall be done in conformance with the
component. manufacturers recommendations.
3. A scheduled planned maintenance, lubrication and
A CAUTION
This message indicates a potentially hazardous
inspection program shall be followed.
4. Only trained and authorized personnel shall be

permitted to maintain, repair, adjust and inspect indus-
situation which, if not avoided, may result in minor trial trucks and in accordance with the manufacturer’s
or moderate injury. It may also be used to alert specifications.
against unsafe practices.
5. Properly ventilate work area, vent exhaust fumes
and keep shop clean and floor dry.
A WARNING 6. Avoid fire hazards and have fire protection equip-

ment present in the work area. Do not use an open
This message indicates a potentially hazardous flame to check for level or leakage of fuel, electrolyte or
situation which, if not avoided, could result in coolant. Do not use open pans of fuel or flammable
death or serious injury. cleaning fluids for cleaning parts.
7. Before Starting Work On Truck:
A DANGER
This message indicates an imminently hazardous
(a) Raise drive wheels off of floor or disconnect power
source and use blocks or other positive truck position-
ing devices.
situation which, if not avoided, will result in death (b) Disconnect battery before working on the electrical
or serious injury. This signal word is to be limited system.
to the most extreme situations. 8. Before working on engine fuel system of gasoline or
diesel powered trucks, be sure the fuel shut-off valve is
closed.
NOTE: The above terms have been adopted by Clark
9. Operation of the truck to check performance must be
Material Handling Company. The same terms may be
conducted in an authorized, safe, clear area.
used in different context in service literature supplied
directly or indirectly by vendors of truck components.
Copyrighted Material -1
INTRODUCTION-1 July 97
INTRODUCTION
10. Before Starting To Drive Truck: 20. Care must be taken to assure that all replacement
parts, including tires, are interchangeable with the
(a) Be in operating position. original parts and of a quality at least equal to that
(b) Be sure parking brake is engaged. provided in the original equipment. Parts, including
(c) Put direction control in neutral. tires, are to be installed per the manufacturer’s proce-
(d) Start engine. dures. Always use genuine CLARK or CLARK-ap-
(e) Check functioning of direction and speed controls, proved parts.
steering, brakes, warning devices and any load han-
dling attachments. 21. Use special care when removing heavy compo-
nentsfromthe truck, such ascounterweight, seatdeck,
Before Leaving The Truck upright, etc. Be sure that lifting and handling equip-
ment is of the correct capacity and in good condition.
Stop truck.
Put directional control in neutral. NOTICE -- You should also be familiar with additional
Apply the parking brake. operating and maintenance safety instructions con-
Stop the engine by turning off the ignition circuit. tained in the following publications:
Put blocks at the wheels if truck is on an incline.
ANSVASME B56.1 - Operator Control-Industrial Tow
Brakes, steering mechanisms, control mecha- Tractors (Safety Standard For Powered Industrial
nisms, warning devices, lights, governors, guards and Trucks). Published by: Society of Mechanical Engi-
safety devices and frame members must be carefully neers, United Engineering Center, 345 E. 47th Street,
and regularly inspected and maintained in a safe New York, N. Y. 10017.
operating condition.
NFPA 505-1982: Fire Safety Standard for Powered
13. Special trucks or devices designed and approved Industrial Trucks: Type Designations, Areas of Use,
for hazardous area operation must receive special Maintenance and Operation. Available from: National
attention to ensure that maintenance preserves the Fire Protection Assoc., Inc., Batterymarch Park, Quincy,
original approved safe operating features. Ma 02269.
14. Fuel systems must be checked for leaks and General Industrial Standards, OSHA 2206: OSHA
condition of parts. Extra special consideration must be Safety and Health Standards (29 CFR 1910), Subpart
given in the case of a leak in the fuel system. Action N-Materials Handling and Storage, Section 1910.178
must be taken to prevent the use of the truck until the Powered Industrial Trucks. For sale by: Superinten-
leak has been corrected. dent of Documents, U.S. Government Printing Office,
Washington, D. C. 20402.
15. The truck manufacturer’s capacity, operation and
maintenance instruction plates, tags or decals must be
maintained in legible condition.
16. Batteries, motors, controllers, limit switches, pro-

tective devices, electrical conductors and connections
must be inspected and maintained in conformance
with good practice. Special attention must be paid to
the condition of electrical insulation.
17. To avoid injury to personnel or damage to the

equipment, consult the manfacturer’s procedures in
replacing contacts on any battery connection.
18. Industrial trucks must be kept in a clean condition

to minimize fire hazards and help in the detection of
loose or defective parts.
19. Modifications and additions that affect capacity

and safe truck operation must not be done without the
manufacturer’s prior written approval. Capacity, op-
eration and maintenance instruction plates, tags or
decals must be changed accordingly.
July 97 INTRODUCTION-l-2
Copyrighted Material SM575
PM Section CLclRK
PM - PLANNED MAINTENANCE PROGRAM.
A planned maintenance program of regular, routine HOW TO PERFORM THE PM PERIODIC INSPEC-
inspections and lubrication is important for long life and TION AND MAINTENANCE
trouble-free operation of your lift truck. Make and keep
records of your inspections. Use these records to help Visual Inspection
establish the correct PM intervals for your application
and to indicate maintenance required to prevent major First, perform a visual inspection of the lift truck and its
problems from occurring during operation. components. Walk around the truck and take note of
any obvious damage and maintenance problems.
Check for loose fasteners and fittings.
PM Report Form
As an aid in performing and documenting your PM

inspections, Clark has prepared a “GAS, LPG OR
DIESEL PLANNED MAINTENANCE REPORT” form.
Copies of this form may be obtained from your author-
ized Clark dealer. We recommend that you use this
form as a checklist and to make a record of your
inspection and truck condition.
The periodic maintenance procedures outlined in this Check to be sure all capacity, safety and warning
manual are intended to be used with the PM report plates and decals are attached and legible.
form. They are arranged in groupings of maintenance
work that are done in a logical and efficient sequence. NOTICE: Do not operate a lift truck with damaged or
missing decals and nameplates. Replace them imme-
A check mark or entry is made on the PM Report Form diately. They contain important information.
when the PM is performed. Please note the special
coding system for indicating the importance of needed Inspect the truck, before and after starting engine, for
repairs and/or adjustments. any signs of external leakage: fuel, engine oil or cool-
ant, transmission fluid, etc.
When you have finished the PM inspections, be sure to
give a copy of the report to the designated authority or Check for hydraulic oil leaks and loose fittings. DO
the person responsible for lift truck maintenance. NOT USE BARE HANDS TO CHECK. Oil may be hot
or under pressure.
Do not make repairs or adjustments
unless authorized to do so.
Remove all jewelry (watch, rings, bracelets, etc.) before

working on the truck.
A CAUTION
HYDRAULIC FLUID PRESSURE
Do not use your hands to
Disconnect the batterygroundcable (-) fromthe engine check for hydraulic leakage.
or frame before working on electrical components. Fluid under pressure can
penetrate your skin and cause
Always wear safety glasses. Wear a safety (hard) hat
serious injury.
in industrial plants and in special areas where protec-
tion is necessary or required.
SM575 PM-l-ldealers only
Intended for CLARK July 97
CL’IRK PM Section
Be sure that the driver’s overhead guard and any other Forks
safety devices are in place, undamaged and attached Inspect the load forks for cracks, breaks, bending and
securely. wear. The fork top surface should be level and even
with each other. The height difference between both
fork tips should be no more that 3% of the fork length.
A WARNING
If the fork blade at the heel is worn
down more than 10 per cent, the
load capacity is reduced and the
fork must be replaced.
Inspect the forks for twists and bends. Put a 2” thick

Check the overhead guard for damage. Be sure that it metal block, at least 4” wide by 24” long on the blade of
is properly positioned and all mounting fasteners are in theforkwith the 4” surface against the blade. Put a24”
place and tight. carpenters square on the top of the block and against
the shank. Check the fork 20” above the blade to make
inspect the welds on the carriage and upright for sure it is not bent more than 1 inch maximum.
cracks. Report any cracks noted immediately. Be sure
that the mounting fasteners are in place and tight.
Inspect the upright assembly: rails, carriage rollers, lift

chains, lift and tilt cylinders. Lookforobvious wear and
maintenance problems, damaged or missing parts.
Check for any loose parts or fittings. Check for leaks,
any damaged or loose rollers and rail wear (metal
flaking). Carefully check the lift chains for wear, rust
and corrosion, cracked or broken links, stretching, etc.
Check that the lift and carriage chains are correctly
adjustedto have equal tension. Checkthatthe lift chain
anchor fasteners and locking means are in place and If the fork blades are obviously bent or damaged, have
tight. them inspected by a trained maintenance person be-
fore operating the truck.
Be sure all safety guards and chain retainers are in
place and not damaged. Inspect the carriage stops
and cylinder retainer bolts. Check all welded connec-
tions.
Inspect all lift line hydraulic connections for leaks.

Check the lift cylinder rods for wear marks, grooves
and scratches. Check the cylinder seals for leaks.
A CAUTION
Uprights and lift chains require
special attentionand maintenance
to maintain them in a safe operat-
ing condition. Refer to Lift Chain
Maintenance section for addition Inspect the fork locking pins for cracks or damage.
information. Reinsert them and note wherther they fit properly.
July 97 PM-1 -2 SM575
PM Section
Wheels and Tires Function Tests

Check the condition of the drive and steer wheels and
tires. Remove objects that are embedded in the tread. Now be sure that all controls and systems are
Inspect the tires for excessive wear or breaks or functioning correctly.
“chunking out”.
After checking that the parking brake is set, test horn,
lights and all other safety equipment and accessories.
Be sure they are properly mounted and working
correctly.
Press the horn button to check horn function. If the

horn or any other part does not operate, report the
.:::..
g:::
failure and have it repaired before the truck is put in
operation.
l!ciqpiB
Y:::..
..:? Y:.,
2 “$
.::,
Check all wheel lug nuts or bolts to be sure none are :“‘~::::i::i::i:,::,
‘ .,,,.:.:g$c?.‘..
:<A’
loose or missing. Have missing bolts or lug nuts

replaced and tightened to the the correct torque before
operating truck. Torque to 100-l 20 Ibf ft [135,6 - 162,7
f&m]. _ Check the operation of the neutral start switch by
placing direction control lever in forward or reverse and
turning key switch to START position. Starter must not
engage until direction control lever is moved to NEU-
TRAL position.
Water Oil Hour Brake Air

Temperature Pressure
_ Meter Pressure
A WARNING
Check tire pressure from a posi-
tion facing the tread of the tire, not
theside. Usea long handled gauge
to keep your body away from the
side. If tires are low, do not add air.
Check with a mechanic. The tire y Converter
may require removal and repair.
Incorrect (low) tire pressure can / Light
reduce stability of your lift truck. Key/Start
Proper cold inflation is 100 p.s.i. Switch
SM575 PM-l-3dealers only
Cl!“lRK= PM Section
Water Temperature Gauge Air Pressure Gauge

Indicates temperature of engine coolant water in de- Indicates brake system air pressure from 0 to 150 PSI
grees (F). 100 degrees F to 280 degrees F. Water and [0 to 1000 kPa]. Air pressure should register
temperature should be about 180 degrees F after 10 between1 10 and 130 PSI to assure proper operation of
minutes of operation. If the indicator registers in the the brakes and the parking brake. A warning buzzer is
“hot” zone, turn off engine until trouble is located and activated if pressure drops below 60 PSI.
corrected.
Oil Pressure Gauge Fuel Gauge

Indicates engine lubricating oil pressure in PSI. 0 - 100 Indicates quantity of fuel remaining in the tank in
PSI at maximum engine speed. Oil pressure should be fractionsof thewhole. Fuel level should be checked on
between 30 and 60 PSI on the oil pressure gauge at the
normal engine operating speeds. At idle, pressure fuel gauge at the beginning of each shift. Always start
should not fall below 15 PSI. If pressure is low or with a full tank.
erratic, shut down engine until trouble is located and
corrected.
Ammeter
Hour Meter Indicates rate of battery charge or discharge. With
Indicates total engine operating time in hours and engine running, should read slightly to the + side of
tenths. The indicated hours are used for planned “0”. If the ammeter shows a continuous high rate of
maintenance. The total hours should be recorded at charge or discharge, or reads erratically, report trouble
the beginning and end of each shift. to proper authority.
Copyrighted Material SM575
July 97 PM-l -4
PM Section
Checks with the engine running...

Be sure that:
lParking brake is applied.
lDirectional control is in “N” (neutral).
l Start the engine and let it warm up until it runs evenly
and accelerates smoothlywhen you push on the accel-
erator pedal.
l Check the hourmeter for operation with the engine
running. Report any malfunction or damage.
Key/Start Switch
A 3-position switch is standard equipment. To start
engine, rotate clockwise. Release to “run” position
when engine starts. The switch incorporates an “anti-
restart”feature which requires that the key be returned
to the “off” position before it can again be turned to
“start”. If engine does not start on the first attempt, do
not re-engage the starter until engine comes to a
complete stop (approximately 5 seconds).
Transmission Light
When illuminated, indicates inadequate converter oil
pressure. Light wilt be illuminated when key/start
switch is turned to “run” and "start" positions. It should Write the hour meter reading
go out shortly after engine starts. If light does not go on the PM report form.
out or if it comes on during truck operation you should
immediately shut down the engine until the cause is
located and corrected.
l Operate service and parking brakes, all hydraulic
controls: lift, tilt and auxiliary (if installed), accelerator,
Converter Light directional controls and steering system. Be sure all
Light will be illuminated when convener oil temperature controls operate freely and return to neutral properly.
is too high. Shift to a lower range. If light stays on, shut Checkthe service brake system. Push the brake pedal
truck down until trouble can be located and corrected. down fully and hold. The brakes should be applied
before the pedal reaches the floorplate. If the pedal
The gauges, lights and hour meter, conveniently continues to creep downwards report the failure imme-
grouped in the instrument panel, are designed to tell diately. DO NOTOPERATETHE TRUCK UNTILTHE
you at a glance many important things about the BRAKES ARE REPAIRED.
performance of your lift truck. Familiarize yourself with
their location and purpose and make it a practice to
scan the instrument panel as you start the engine, after
it starts and periodically as you drive. Report to the
designated authority if any gauge is not functioning
properly.
NOTE: The electrically operated gauges register cor-

rectly when the key switch is in the “on” position. When
the key switch is turned “off”, the indicator needle will
not necessarily return to any given position.
SM575 PM-l-5dealers only
PM Section
l Pull back on the lift control lever and raise the fork
Parking Brake Control carriage to full height. Watch the upright assembly as
it rises. All movements of the upright, fork carriage and
lift chains must be even and smooth, without binding or
jerking. Watch for chain wobble or looseness; the
chains should have equal tension and move smoothly
without noticeable wobble. Release the lever.
Service Brake Pedal
l Check the function of the parking brake. Release,

then reapply and then put truck in gear and acceler-
ate to insure that brake holds.
9 To check parking brake holding capability, park

the lift truck on a grade and apply the parking brake. If the maximum fork height is not reached, this indi-
The parking brake should hold a lift truck with rated cates there is an inadequate (low) oil level in the
load on a 15% grade. hydraulic sump tank or severe binding within the up-
right.
A CAUTION l Push forward on the lift control lever. Watch the

upright as it lowers. When the forks reach the floor,
Do not operate a lift truck if the
service or parking brakes are not release the lever.
operating properly
Auxilaty Controls...
Lift Mechanisms and Controls... If your lift truck is equipped with an attachment, test the
l Check the function of the lift system and controls with control leverforcorrectfunctionand brieflyoperatethe
the hydraulic pump (engine) running. attachment.
l Pull back on the tilt control lever and hold until the Auxiliary Valve Lever(s)
upright reaches the full back tilt position. Push forward
on the leverto return the upright to theverticalposition.
Release the lever.
A CAUTION
Be sure that there is adequate
overhead clearance before rais-
ing the upright.
July 97 Intended forPM-1
CLARK-6
dealers only SM575
PM Section
Steering System... When you have completed the operational tests,

NOTICE -- The steering system, steer axle and steer- park and leave truck according to standard shut
ing linkage on your truck should be inspected periodi- down procedures.
cally for abnormal looseness and damage, leaking Be sure to make a record of all maintenance and
seals, etc. Also, be alert for any changes in steering operating problems you find.
action. Hard steering, excessive freeplay (looseness)
or unusual sound when turning or maneuvering indi- Fluid and Filters
cates a need for inspection or servicing.
Check fluid levels and other components within
the engine compartment...
Unlatch and open the hood to access the engine

compartment.
A CAUTION
To avoid the possibility of per-
sonal injury, never work in engine
compartment with engine running
except when absolutely necessary
l Check the steering system by moving the steering to check or make adjustments.
handwheel in a full right turn and then in a full left turn. Take extreme care to keep hands,
Return the handwheel (steer wheels) to the straight- toolsand looseclothing,etc.,away
ahead position. The steering system components from gan and drive belts. Also,
should operate smoothly when the steering wheel is remove watches, bracelets and
turned. rings.
Never operate a truck which has a steering system
fault.
Engine Accessories
A WARNING
Fasten your seat belt before
Inspect the engine coolant hoses and fan belt(s). Look
for leaking and obvious damage, worn (frayed) condi-
tion, breaks, etc., which could cause failure during
driving the truck. operation.
Shift Control and Brakes
Check and make sure that the travel area is clear in Engine Air Cleaner
front of the truck. Check the engine air cleaner for damage and contami-
l Push firmly on the brake pedal. Release the parking nation (excessive dirt buildup and clogging). Check for
brake. Move the directional control lever from “N” correct mounting attachments of the air cleaner. Be
(neutral) to FORWARD travel position. sure that the air cleaner hose is securely connected
l Remove your right foot from the brake pedal and put (not loose or leaking). Fan or cone shaped dust
it on the accelerator pedal. Push down until the truck deposits on tube or hose surfaces indicate a leak.
moves slowly forward. Remove your foot from the
accelerator pedal and push down on the brake pedal to Change or service the air cleaner element every 50 to
stop the truck. The brakes should apply smoothly and 250 operating hours, depending uponyourapplication.
equally. Service intervals may also be determined by the air
restriction indicator.
Be sure the travel area is clear behind the truck.
Battery
l Put the directional control lever in the REVERSE Inspect the battery for any damage, cracks, leaking
travel position. Push down on the accelerator pedal condition, etc. If the terminals are corroded, clean and
until the truck moves slowly in the reverse direction. protect them with CLARK Battery Saver (available
Remove your foot from the accelerator pedal and push from your Clark dealer). If your battery has removable
down on the brake pedal to stop the truck. The brakes cell caps, check to be sure the cells are all filled. If
should apply smoothly and equally. possible, refill with distilled water.
PM-l-7dealers only
PM Section
Engine Cooling System l lnspectthecoolantforcondition. Lookforexcessive

l Check engine coolant level. The engine coolant contamination or rust or oil in the coolant solution.
level is checked by removing the radiator cap. Check the PM time interval for need to change coolant.
Remove the cap only when the engine is cold. First l Check condition of radiator cap rubber seal and
turn the cap slowly to release any pressure that may radiator filler neck for damage. Be sure they are clean.
be in the radiator. Then push the cap down fully Check overflow hose for clogging or damage.
and turn to release and remove the cap. NOTICE - Your lift truck cooling system is filled with a
factory-installed solution of 50% water and 50% per-
A
manent-type anti-freeze containing rust and corrosion
CAUTION inhibitors. You should leave it in year around. Plain
STEAM water may be used only in an emergency, but replace
it with the specified coolant as soon as possible to avoid
Do not remove the radiator cap damage to the system. With only water in the system,
when the radiator is hot. Steam do not let the engine run hot. Do not use alcohol or
from the radiator will cause se- methanol antifreeze.
vere burns.
Engine Oil
Check the engine oil level.
Never remove the radiator cap while the engine is
running. Stop the engine and wait until it has cooled.
Locate the engine oil dipstick (at left side of engine).
Even then, use extreme care when removing the cap
Pull the dipstickout, wipe it with a clean wiper and rein-
from the radiator. It is good safety practice to use a
sert it fully into the dipstick tube. Remove the dipstick
shop cloth to cover the radiator cap while it is being
and check oil level.
removed. Wrap the cloth around the cap and turn it
slowly to the first stop. Step back while the pressure is
It is normal to add some oil between oil changes. Keep
released from the cooling system. When you are sure
the oil level above the ADD mark on the dipstick by
all the pressure has been released, press down on the
adding oil as required. DO NOT OVERFILL. Use the
cap, with the cloth in place, turn and remove it. Stand
correct oil as specified under Lubricant Specifications.
clear of the radiator opening; hot coolant may splash
out. Failure to follow these instructions could result in
serious personal injury from hot coolant or steam
blowout and/or damage to the cooling system or en-
gine.
The correct FULL level is the top edge of the filler neck.
If level is low, add a 50/50 mixture of specified coolant
and water to the correct fill level. If you have to add
coolant more than once a month or if you have to add
more than one quart at a time, check the cooling
system for leaks.
FILLER NECK
PM-l-8 SM575
PM Section
Engine Oil and Filter Change Testing

It is recommended to:
A simple operation test to determine wherther the
Drain and replace the engine crankcase oil every 50 compressor unit is operating can be made as follows:
to 250 operating hours. See NOTICE below.
1. Start the engine and allow air to build up in the
Replace the engine oil filter every oil change. system and then shut the engine off.
Remove the oil pan drain plug to drain old oil, after 2. Depress the brake pedal to a given point several
truck has been inoperationand engine (oil) is hot (at times noting any increase in pedal pressure re-
operating temperature). quired to depress the pedal.
NOTICE -The time interval for changing engine oil will 3. If, however there is no change in the amount of
depend upon your application and operating condi- pedal pressure required between first and last test,
tions. To determine the correct schedule for your truck then the power system is not functioning, necessi
it is suggested that you periodically submit engine oil tating corrective action. Have the brakes checked
samples to a commercial laboratory for analysis of the by a mechanic before operating truck.
condition of the oil.
Hydraulic Sump Tank
OIL PERFORMANCE DESIGNATION -To helpachieve Checkthe hydraulic sump tank fluid level. Correct fluid
proper engine performance and durability, use only level is important for proper system operation. Low
engine lubricating oils of the proper quality. These oils fluid level can cause pump damage. Overfilling can
also help promote engine efficiency which results in cause loss of fluid or lift system malfunction.
improved fuel economy. A symbol has been devel-
oped by the API (American Petroleum Institute) to help Hydraulicfluid expands as its temperature rises. There-
you select the proper engine oil. It should be included fore, it is preferable to check the fluid level at operating
on the oil container you purchase. For diesel engines, temperature (after approximately 30 minutes of truck
CLARK recommends that you use motor oil that meets operation). To check the fluid level, first park the truck
API Service Classification CE/SF. CC/CD or CD/SF on a level surface and apply the parking brake. Put the
oils can be used in areas where CE oil is not available. upright in a vertical position and lower the fork carriage
fully down. Pull the dipstick out, (attached to the sump
breather) (later models have a sight guage instead of
a dipstick) wipe it with a clean wiper and reinsert it.
Remove dipstick and check oil level. Keep the oil level
Air Brakes above the LOW mark on the dipstick by adding recom-
mended hydraulic fluid only, as required. DO NOT
Adjustment OVERFILL.
l When the brake system is operating properly, the Check the condition of the hydraulic fluid (age, color or
cam like action of the reaction arm allows self-adjust- clarity, contamination). Change (replace) the oil as
ment for the total thickness of the brake linings. The necessary.
self-adjustmentfeatureeliminates the needfor manual
adjustment of the brakes. Hydraulic Fluid and Filter Change
Drain and replace the hydraulic sump fluid every 2000
l When the brake linings become worn beyond their operating hours.
designed limits, there will be a noticeable change in the (Severe service or adverse conditions may require
brake effort required to stop the truck or brakes will more frequent fluid change). Replace the hydraulic oil
become noisy during application. If either of these filters elements at every oil change. Remove, clean
conditions are noted, have the brakes checked by a and reinstall the hydraulic and steer system suction
mechanic before continuing to operate the truck. line screens at first PM and every 500 hours thereafter.
Check for leaks after installation of the filters. Also,
check that the hydraulic line connections at the filter
adapter are tightened correctly.
PM Section
Sump Tank Breather Maintenance and Inspection Differential Fluid and Breather Check
Remove the sump tankfiIIcap/breather and inspect for l Check the differential breather to be sure it is free of
excessive (obvious) contamination anddamage. Clean obstruction. Remove and clean in a Stoddard type
or replace the fill cap/breather, per recommended PM cleaning solvent if necessary. Dry breather with com-
schedule or as required by operating conditions. pressed air before replacing it on differential.
l Remove fill/level plug and verify differential lubricant
level. Level should be maintained to the height of the
Access to the Drive Axle plug opening.
The best method to use for reaching the drive axle
check points (oil level/filler plug and drain plug) is NOTICE: Check the planned maintenance interval
dependent upon the style of upright, carriage and (operating hours)ortheconditionoftheoiltodetermine
attachments on your truck. One method is to raise the if the drive axle fluid needs to be changed.
upright carriage to provide easy access to the drive
axle.
Apply the parking brake and block the wheels. Truck Chassis Inspection and Lubrication
Be sure to put blocking under the carriage and Lubrication and inspection of truck chassis compo-
upright rails. nents, including steerwheels, steeraxle linkage, steer-
A
ing cylinder and wheel bearings will be easier if the
WARNING truck is raised and blocked up under the frame. For
additional information refer to the Machine Blocking
An upright or carriage can move
and Jacking section.
unexpectedly. Chain or block the
Inspect the steering cylinder piston rods, seals and
carriage and rails. Failure to fol- fasteners for damage, leaks and looseness.
low this warning can result in se- Lubricate the steer axle lingage: rod ends and linkage
rious injury. pivot points. Be sure to clean the grease fittings before
lubricating and remove the excess grease from all
Refer to Machine Jacking and Blocking for further
points after lubricating.
information.
Lubricate miscellaneous linkage as needed.
Transmission Fluid Check
Before making check, run engine until unit is at
A
l
operating temperature. This is important as transmis-

sion oil temperature should be 200 degrees F and the WARNING
engine water iacket should be at operating tempera- Do not raise truck by lifting under
ture. Apply parking brake. the counterweight.
/I /
\ DIPSTICK 7
44
\4
Upright and Tilt Cylinder Lubrication
Clean the fittings and lubricate the tilt cylinder rod
end bushings (forward end).
\
Clean the fittings and lubricate the tilt cylinder base
rod end bushings (rear end).
Clean and lubricate the upright trunnion bushings.
-0
\ Lift Chains
\ - Lubricate the entire length of the upright rail lift and
carriage chains with Clark Chain and Cable Lube.
NOTE: Do not lubricate the carriage roller rails.
l With the engine operating at idle and the transmission
in NEUTRAL, check the fluid on the dipstick. Fill if
necessary to the FULL mark on the dipstick, using “C-
3 Dexron II D” or “Dexron”.
July 97 PM-l -10
PM Section
Air Cleaning Check Torque Of Critical Items, Including:

Always maintain a lift truck in a clean condition. Do not Drive axle mounting
allow dirt, dust, lint or ther contaminants to accumulate Drive & steer wheel mounting
on the truck. Keep the truck free from leaking oil and Counterweight mounting
grease. Wipe up all oil or fuel spills. Keep the controls Overheadguard mounting
and floorboards clean, dry and safe. A clean truck Tilt cylinder mounting & yokes
makes it easier to see leakage, loose, missing or Upright mounting & components
damaged parts and will help prevent fires. A clean
truck will run cooler.
The environment in which a lift truck operates will LIFT CHAIN MAINTENANCE
determine how often and to what extent cleaning is
necessary. For example, trucks operating in manufac- Lii chains are very important components of fork lift
turing plants which have a high level of dirt, dust or lint, trucks. The chain system on your upright was de-
(e.g. cotton fibers, paper dust, etc) in the air or on the signed for safe, efficient and reliable transmission of
floor or ground, will require more frequent cleaning. lifting force from hydraulic cylinder to the forks. Safe
The radiator, especially, may require daily air cleaning use of your truck with minimum down-time depends on
to ensure correct cooling. If air pressure does not the correct care and maintenance of the lift chains.
remove heavy deposits of grease, oil, etc., it may be Most complaints of unacceptable chain performance
necessary to use steam or liquid spray cleaner. are a resultof poor maintenance. Chains need periodic
maintenance to give maximum service life.
LIFT TRUCKS SHOULD BE AIR CLEANED, AS
NECESSARY, AT EVERY PM INTERVAL AND OTH-
ERWISE AS OFTEN AS NECESSARY. Lift Chain Adjustment Check
The lift chains are correctly adjusted if the lower fork
Air cleaning should be done using an air hose with carriage rollers reach their end (lowest) position ap-
special adapter or extension having a control valve and proximately [13 mm] 0.50 inch from the lower edge of
nozzle to direct the air properly. Use clean, dry, low the inner rail. This also positions the bottom of the forks
pressure compressed air. Restrict air pressure to [207 the same (equal) distance above the floor. To check
kPa] 30 psi, maximum. (OSHA requirement). this dimension, raise the carriage to a height that
exposes several inches of the inner rail at the roller
A
path. Apply a layer of grease to the roller path on the
CAUTION inner rail. Lower the carriage and pick up a rated
capacity load, (tilt the upright back slightly) and raise
Wear suitable eye protection and the load until the carriage rollers have passed overthe
protective clothing. greased area. Lower the load completely and remove
the load from the forks. Raise the carriage again to
expose the inner rail. You can now check the roller path
pattern in the grease and determine the correct adjust-
Air clean the: Upright assembly - Drive Axle - Radiator,
ment of the chains.
from both counterweight and engine side - Engine and
The lift chains can be adjusted by loosening or tighten-
accessories - Driveline and related components-Steer
ing of the chain anchor nuts.
axle and steer cylinder.
NOTICE: It is important to make the lift chain adjust-
ment check with a rated load to make sure that the
chains are stretched to their maximum length.
Critical Fastener Torque Checks
Fasteners in highly loaded (critical) components can
quickly fail if they become loosened; also, loosefasten-
ers can cause damage orfailure of the component. For A WARNING
safety it is important that the correct torque be main- Do not attempt to repair a worn
tained on all critical fasteners of components which chain. Replace worn or damaged
directly support, handle or control the load and protect chains.
the operator.
SM575 PM-l -11
Intended for CLARK dealers only July 97
CLSRK PM Section
Lift Chain Inspection and Measurement Lift Chain Replacement

Inspect and lubricate the lift chains every truck PM (50-
250 hours). When operating in corrosive environ- All chains must be replaced if any strand has wear of
ments, inspect the chains every 50 hours. During the 3% or more, or if any of the damaged conditions noted
inspection, check for the following conditions: are found during inspection.
l Rust and corrosion - Cracked plates - Raised or
turned pins - Tight joints - Wear, worn pins or holes. Order replacement chains from your CLARK dealer.
l When the pins or holes become worn, the chain
becomes longer. When a section of chain is 3% longer Replace all chains as a set.
that a section of new chain, the chain is worn and must
be discarded. Do not remove factory lubrication or paint new chains.
l Chain wear can be measured by using a chain scale
or a steel tape measure. When checking chain wear, Replace anchor pins and worn or broken anchors when
be sure to measure a segmentof chain that moves over installing new chains.
a sheave. Do not repair chains by cutting out the worn
section and joining in a new piece. If part of a chain is Adjust tension on new chains.
worn, replace all the chains on a truck.
Lubricate chains when they are installed on the upright.
Lift Chain Lubrication
Lift chain lubrication is an important part of your main-
tenance program. The lift chains operate under heavy
loadings and will function more safely and have longer
life if they are regularly and correctly lubricated. Clark
chain lubricant is recommended; it is easily sprayed on
and provides superior lubrication. Heavy motoroil may
also be used as a lubricant and corrosion inhibitor.
Lift Chain Inspection and Wear Criteria

1 - (NEW CHAIN LENGTH)
The distance from the first
pin counted to the last pin
counted in a span while the -
chains are lifting a small 0
load. 0
2 -(WORN CHAIN LENGTH) E

The distance from the first pin I--!
03
counted to the last pin count-
ed in a span while the chains
are lifting a small load.
3 - (SPAN) The number of

pins in the length (segment)
of chain to be measured.
0
4 - (PITCH) The distance
from the center of one pin 4
to the center of the next pin.
July 97 PM-l -12 SM575
GROUP 00
C500 Y 180-ZOO-225S-225L-250S-250L-300S-300L-350
GROUP OO-ENGINES
Troubleshooting .............................................................. Section 1
Engine Removal .............................................................. Section 2
Ford Engine Specifications ............................................ Section 3
Cummins Engine Specifications ......... .. .. ... .................... Section 4

NOTE: For parts and service information contact your local Cummins distributor.
SM 575, July 9
‘7 Copyrighted Material Engines
C5OOY2235 Grour>OO
SECTION I
ENGINE TROUBLESHOOTING
SM575 Copyrighted Material

Section Tile Page July 97
Troubleshooting GROUP 00
CONDITION POSSIBLE CAUSE SUGGESTED CORRECTION
1. Battery(ies) discharged. 1. Charge battery(ies). Perform

heavy load tests. If batt-
ery(ies) not defective, re-
charge battery( ies).
Engine will not crank or _
2. Battery and/or starter terminals 2. Clean and tighten.
cranks slowly.
loose or corroded. 3. Replace starter.
3. Starter defective. 4. Replace switch
4. Neutral start switch defective. 5. Replace defective section of
5. Wiring defective. wirina.
1. Engine out of fuel. 1. Check fuel level and fill as

required.
2. Incorrect type or grade of fuel. 2. Drain fuel system. Flush and
refill with correct fuel.
3. Air intake or exhaust plugged. 3. Visually check and remove
obstruction.
4. Fuel shutoff solenoid defective. Replace solenoid.
5. Water in fuel system. 2: Check fuel filter. Drain and
replace filter.
6. Air in fuel system. 6. Bleed fuel system. Locate
and correct cause of air in fuel
system.
7. Fuel filters clogged. 7. Replace fuel filter.
8. Damaged fuel line. 8. Repair or replace fuel line(s).
9. Camshaft timing incorrect. 9. Adjust camshaft timing.
10. Fuel transfer pump defective. 10. Remove outlet line from pump
and place in suitable con-
tainer. Crank engine and
check for fuel from hose. If no
fuel is observed, replace fuel
transfer pump.
11. Fuel injection pump defective. 11. Replace fuel injection pump.
12. Internal damage to engine. 12. Repair engine.
1. Low cranking speed. 1. Check battery(ies), electrical

wiring and connections, or
starter. Charge battery(ies)
and check electrical system
for shorts. Clean and tighten
connections and replace any
defective wiring. Replace
starter.
Engine hard to start or 2. Incorrect type or grade of fuel. 2. Drain fuel system. Flush and
will not start (smoke refill with correct fuel.
from exhaust). 3. Damaged fuel line(s). 3. Repair or replace fuel line(s).
transfer pump.
correct cause of air in fuel
system.
SM575 00-l-l July 97
GROUP00 Troubleshooting
6. Air filter clogged or air intake 6. Clean or replace air filter. Re-
system obstructed. move obstruction from air
intake system.
7. Fuel injection pump timing 7. Adjust injection pump timing.
incorrect.
9. Valves incorrectly adjusted. 9. Adjust valves.
10. Fuel injector(s) defective. 10. Replace defective injector(s).
11. Low Compression. 11. Perform compression check.
system restricted. move obstruction from air in-
take system.
system.
3. Fuel injector(s) plugged or de- 3. Clean or replace defective fuel
fective. injector(s).
4. Fuel filter(s) clogged. Replace fuel filter(s).
Engine starts but will not - 5. Fuel transfer pump defective. 2: Remove outlet line from pump
remain running. and place in suitable contain-
er. Crank engine and check
for fuel from hose. If no fuel is
observed, replace fuel transfer
pump.
7. Water in fuel system. 7. Check fuel filter and filter/
water separator. Drain water
and replace filter(s).
9. Internal damage to engine. 9. Repair engine.
1. High pressure fuel leak. 1. Check high pressure lines,

fuel injector sealing washers,
and delivery bypass valves for
leaks. Replace defective
Engine surges. I parts.
2. Fuel injector(s) defective. 2. Replace defective fuel injec-
tor(s).
3. Delivery bypass valve(s) de- 3. Replace defective delivery
fective. bypass valve(s).
1. Coolant temperature below 1. Replace thermostat.

Rough idle (engine normal due to incorrect or de-
misfiring). fective thermostat.
2. Idle speed to low. 2. Adjust idle speed.
3. High pressure fuel leak. 3. Check high pressure lines,
parts.
July 97 Copyrighted
00-l -2 Material SM575
Troubleshooting GROUP00
CONDITION . POSSIBLE CAUSE SUGGESTED CORRECTION

system.
Rough idle (engine
misfiring). - continued tor(s).
6. Delivery bypass valve(s) defec- 6. Replace defective delivery by-
tive. pass valve(s).
8. Low compression. 8. Perform compression check.
1. High pressure fuel leak. 1. Check high presssure lines,

2. Air in fuel system. leaks. Replace defective
parts.
2. Bleed fuel system. Locate
and correct cause of air in
3. Fuel filters clogged. fuel system.
4. Fuel transfer pump defective. 3. Replace fuel filter(s).
4. Remove outlet line from pump
Engine runs rough - tainer. Crank engine and
(misfiring). check for fuel from hose. If no
5. Damaged fuel line(s). transfer pump.
6. Fuel injection pump timing in- 5. Repair or replace fuel lines(s).
correct. Adjust injection pump timing.
7. Incorrect type or grade of fuel. 7”: Drain fuel system. Flush and
tors.
12. Camhaft timing incorrect. 12. Adjust camshaft timing.
13. Camshaft defective. 13. Replace camshaft.
14. Valve tapper(s) defective. 14. Replace defective valve
tappet(s).
1. Accelerator linkage worn or in- 1. Adjust or replace defective

correctly adjusted. linkage parts.
2. Fuel control lever on fuel injec- 2. Correct fuel control lever in-
tion pump incorrectly indexed. dexing.
3. High speed stop screw incor- 3. Adjust high speed stop screw.
rectly adjusted.
Engine rpm will not 4. Fuel filter(s) clogged. 4. Replace fuel filter(s).
reach rated speed. 5. Fuel transfer pump defective. 5. Remove outlet line from pump
transfer pump.
6. Damaged fuel lines(s). Repair or replace fuel line(s).
7. Fuel injection pump defective. ;: Replace fuel injection pump.
SM575 00-l-3 July 97
1. Accelerator linkage worn or 1. Adjust or replace defective

incorrectly adjusted. linkage parts.
2. Fuel control lever incorrectly 2. Adjust fuel control lever.
adjusted for full stop-on-top
travel.
3. Oil level too high. 3. Check and correct oil level.
incorrect.
take system.
6. High pressure fuel leak. 6. Check hight pressure lines,
fuel injector sealing washers
parts.
7. Fuel filter(s) clogged. 7. Replace fuel filter(s).
and place in suitable contain-
for fuel from hose. If no fuel is
pump.
3. Damaged fuel line(s). 3. Repair or replace fuel line(s).
Engine lacks power. 11. Incorrect type or grade of fuel. - 11. Drain fuel system. Flush and
refull with correct fuel.
12.Air leak between turbocharger 12.Check for loose connections
and intake manifold. or leak(s) in air inlet pipe,
hoses or through holes in in-
take manifold cover. Tighten
any loose connections. Re-
pair or replace defective parts.
13. Exhaust leak at manifold or 13.Check for leaks in manifold or
turbocharger. turbocharger gaskets. Check
for cracked exhaust manifold.
Repair or replace defective
parts.
14.Turbocharger defective. 14. Repair or replace turbo-
charger.
17.Air in fuel. 17. Bleed fuel system. Locate
system.
tor(s).
19. Restricted or damaged ex- 19. Check and repair exhaust
haust system. system.
20. Worn cyliner bores. 20. Measure bore diameter and if

oversize, machine cylinder
bores and install oversize pis-
ton and rings. If necessary,
machine bore and install
repair sleeves.
Copyrighted
00-l -4
Material SM575
July 97
21. Pitted valves and/or seats. 21. Repair or replace valves and/
Engine lacks power. or seats.
-continued 22. Broken, worn or sticking piston 22.Perform compression check.
ring(s). Low compression that can be
increased significantly by
squirting oil into cylinder indi-
cates inadequate piston ring
sealing. Replace defective
piston ring(s).
take system.
2. Air leak between turbocharger 2. Check for loose connections
and intake manifold. or leak(s) in air inlet pipe,
hoses or through holes in in-
take manifold cover. Tighten
any loose connections. Re-
pair or replace defective parts.
Excessive black 3. Exhaust leak at manifold or 3. Checks for leaks in manifold
exhaust smoke. turbocharger. or turbocharger gaskets.
Check for cracked exhaust
manifold. Repair or replace
defective parts.
4. Turbocharger defective. 4. Repair or replace turbo-
charger.
5. Fuel injector(s) installed with 5. Remove and correctly install
more than one sealing washer. fuel injector(s).
tors.
1. Coolant temperature below nor- 1. Replace thermostat.

mal due to incorrect or defec-
Excessive blue/white .
tive thermostat.
exhaust smoke.
2. Broken, worn or sticking piston 2. Perform compression check.
increased significiantly by
squirting oil into cylinder, indi-
piston ring(s).
1. Low coolant level. 1. Check coolant. Fill as requir-

ed. Check for leaks.
Engine overheating. 2. Radiator pressure cap defec- 2. Replace radiator pressure
tive. cap.
3. Oil level too high. t 3. Check and correct oil level.
I I L I
SM575 00-l-5 July 97
GROUP 00 Troubleshooting
4. Drive belt slipping. 4. Check operation of belt ten-

sioner. If defective, replace.
Check condition of drive belt.
5. Inadequate air flow to radiator. If worn or damaged, replace.
5. Check operation of fan. If
defective, replace fan.
6. Radiator fins plugged. 6. Blow debris from radiator fins.
7. Radiator clogged. 7. Drain and flush radiator.
8. Scale or deposits in cooling 8. Drain and flush cooling sy-
Engine overheating. , system. stem.
-continued- 9. Radiator defective. 9. Replace radiator.
10. Collapsed radiator hose(s). 10. Replace hoses.
11. Defective temperature sender 11 .Test gauge and temperature
or gauge. sender. Replace as neces-
sary.
12.Thermostat incorrect or defec- 12. Replace thermostat.
tive.
13. Cylinder head gasket leaking. 13. Replace cylinder head gasket.
14. Water pump defective. 14. Replace water pump.
15. Fuel injection pump timing in- 15. Adjust injection pump timing.
correct.
1. Low oil level. 1. Check and refil to correct oil

level.
2. Incorrect grade of lubricating 2. Drain oil. Refill with the cor-
oil. rect grade of oil.
3. Lubricating oil contaminated. 3. Refer to contaminated oil sec-
tion of engine troubleshooting.
4. Defective oil pressure sender 4. Test gauge and oil pressure
sary.
Low lubricating oil 5. Pressure relief valve stuck in 5. Replace pressure relief valve.
pressure. open position.
6. Oil filter clogged. 6. Replace oil filter.
7. Shipping plugs left in oil 7. Check and remove shipping
core replacement. plugs.
8. Loose or missing expansion 8. Check and replace any loose
plugs. or missing expansion plugs.
9. Lube oil suction tube loose or 9. Inspect and tighten. If defec-
gasket leaking. tive, replace gasket and/or
suction tube.
10. Lubricating pump defective. 10. Replace lubricating pump.
11. Main bearing(s) worn or main 11. Replace main bearing(s) and
bearing cap(s) loose. tighten main bearing cap(s).
12. Piston cooling nozzle(s) 12. Replace piston cooling
defective. nozzle(s).
July 97 Copyrighted
I
1. Incorrect grade of lubricating 1. Drain oil. Refill with correct
oil. grade of oil.
2. Pressure relief valve stuck in 2. Replace pressure relief valve.
IHigh lubricating oil
pressure.
closed position.
3. Coolant temperature too low
due to incorrect or defective
3. Replace thermostat.
thermostat.
4. Defective oil pressure sender 4. Test gauge and oil pressure
sary.
1. External leaks. 1. Visually inspect for leaks and

repair any found.
2. Crankcase overfilled. 2. Drain and refill crankcase to
correct level.
3. Incorrect grade of lubricating 3. Drain oil. Refill with correct
oil. grade of oil.
4. Oil cooler core leaking. 4. Check for oil in coolant. If
found, check and replace oil
1 Lubricating oil loss. I- cooler core.
5. Air compressor worn or defec- 5. Inspect air line from compres-
tive. sor to air tank. Carbon build-
up indicates compressor is
pumping oil. If found, replace
air compressor.
6. Worn or damaged seals in 6. Inspect air inlet pipe for signs
turbocharger. of oil. If found, repair turbo-
charger.
7. Worn valve stem seal(s). 7. Replace valve stem(s).
8. Broken, worn or sticking piston 8. Perform compression check.
rign(s). Low compression that can be
increased by squirting oil into
cylinder, indicates inadequate
piston ring sealing. Replace
defective piston ring(s).
t
1. Oil cooler core leaking. 1. Check for coolant in oil. If
found, check and replace oil
cooler core.
Oil contaminated with 2. Cylinder head gasket leaking. 2. Replace cylinder head gasket.
coolant. 3. Cracked or porous cylinder 3. Replace cylinder head.
head.
4. Leak in cylinder block coolant I 4. Replace cylinder block.
passages.
1. Fuel transfer pump seal 1. Replace fuel transfer pump.

Oil contaminated with
leaking.
fuel. 2. Replace defective fuel injec-
2. Fuel injector needle valve(s)
not sealing. tar(s).
1 J ,
SM575 00-l-7dealers only July 97
Intended for CLARK
take system.
2. Fuel injector needle valve(s) 2. Replace defective fuel injec-
Fuel or oil leaking form stuck in open position. tors.
exhaust manifold. 3. Restricted or damaged turbo- 3. Remove restriction and clean
charger drain line. turbocharger drain line. If
damaged, replace drain line.
4. Turbocharger exhaust restric- 4. Remove restriction.
tion.
5. Turbocharger seals defective. 5. Repair turbocharger.

fuel system.
incorrect.
tors.
take system.
2. Restricted or damaged ex- 2. Check and repair exhaust sy-
haust system. stem.
incorrect.
tar(s).
5. Valves not seating properly. 5. Check and repair valves and/
pq- or valve seats as required.
6. Low compression. Perform compression test.
7. Incorrect type or grade of fuel. ;: Drain fuel system. Flush and
8. Accelerator linkage sticking or 8. Remove restriction. Repair or
restricted. replace accelerator linkage.
11. Engine running too cool. 11. Replace thermostat.
12. Worn cylinder bores. 12. Measure bore diameter and if
bores and install oversized
piston and rings. If necessary,
machine bore and install re-
pair sleeves.
13. Broken, worn or sticking pis- 13. Perform compression check.
ton ring(s). Low compression that can be
increased significantly by
~ squirting oil into cylinder, indi-
piston ring(s).
July 97
Copyrighted
00-l-8
Material SM575
14. Perform visual inspection of

Excessive fuel con- fuel lines, fuel injection pump,
sumption - continued 14. Fuel Leakage. fuel transfer pump and fuel
t
tank. Repair or replace com-
ponents as necessary.
1
1. Worn cylinder bore(s). 1. Measure bore diameter and if

bores and install oversized
piston and rings. If neces-
sary, machine bore and install
repair sleeves.
2. Pitted valves and/or seats. 2. Repair or replace valves and/
or seats.
3. Worn valve stems and/or valve 3. Inspect and replace defective
seals. valves and/or valve seals.
Low compression. 4. Broken, worn or sticking piston 4. Perform compression check.
increased by squirting oil into
cylinder, indicates inadequate
piston ring sealing. Replace
defective piston ring(s).
5. Sticking valves. 5. Grind valves or replace as
required.
8. Weak or damaged valve 8. Inspect valve springs and re-
spring(s). place as required.
take system.
1. Engine not running smoothly. 1. Refer to “engine runs rough”

(misfiring) section of engine
troubleshooting.
2. Loose or broken engine mount- 2. Tighten or replace engine
ing components. mounting components.
3. Fan damaged. 3. Replace fan.
I Excessive vibration 4. Vibration dampener defective.
5. Fan pulley defective.
Replace vibration dampener.
2: Replace fan pulley.
6. Worn or damaged alternator 6. Repair alternator.
bearing. 7. Check and correct flywheel
7. Flywheel housing misaligned. housing alignment.
8. Crankshaft or connecting rods 8. Check and replace defective
defective. components.
9. Prop shaft defective. 9. Repair or replace prop shaft.
SM575 00-l-9dealers only
1. Drive belt slipping. 1. Check operation of belt ten-

If worn or damaged, replace.
2. Intake air or exhaust system 2. Check and repair intake air or
leaks. exhaust system.
3. Excessive valve lash. 3. Adjust valves. Check for bent
push rods or worn rocker
Excessive engine noise. levers. Replace any defective
components.
4. Turbocharger defective. 4. Check turbocharger for evi-
dence of impeller and/or shaft
and wheel to housing contact.
Repair turbocharger.
5. Excessive front gear backlash. 5. Check and measure gear
backlash. Adjust backlash.
Check and replace gears as
required.
6. Rod and/or main bearings 6. Replace rod and/or main
worn or damaged. bearings.
July 97 Copyrighted
C5OOY2235 Group 00
SECTION 2
ENGINE REMOVAL
Section Material
Copyrighted Tile Page
ClRRK Group 00, Engine Removal
ENGINE REMOVAL
1. Park truck on a level surface. Chock front and

back wheels. Lower forks to floor. Set parking
5. Disconnect air brake lines from air compressor

as shown.
2. Remove hood and counterweight grill.
3. Remove positive and negative battery cable from

engine and battery cables from battery. A DANGER
Depressurize air system by applying
A
brakes until gauge reads zero pres-
WARNING sure. Severe injury or death can result
if air system components are removed
Whenever disconnecting battery
while system is still pressurized.
cables, always disconnect negative
ground terminal first.
Typical Illustration 6. Disconnect transmission cooling lines at oil

cooler and radiator. Cap or plug exposed fittings or
4. Disconnect accelerator cable from engine fuel
ports. Remove cooling line supporting clip and lay
pump and from cable support bracket. Lay cable
hose back where they will not interfere with engine
back where it will be out of the way when engine is
lifted out. removal.
SM 575, July 97
‘ Engine Removal 9 00-2-l
Group 00, Engine Removal EIRRK
7. Remove radiator cap. Place a large drain pan

which has a minimum capacity of 27 quarts [25.5
liters] under the radiator and engine and drain
coolant from radiator and engine. Dispose of
coolant in prescribed manner. Do not reuse.
9. Disconnect exhaust system f&m engine turbo-

charger.
7. Disconnect engine coolant hoses. Remove rad-

ator and cooling fan. 10. Disconnect air intake assembly at engine turbo-
charger and at air cleaner and remove.
11. Disconnect all electrical wiring between engine

and truck. Tag each wiring terminal to assist in
reconnecting.
12. Drain oil from engine using a suitable container.

Dispose of used oil in approved manner. Do not
reuse.
8. Shut off fuel supply at fuel tank. Disconnect fuel

supply and return lines at engine. Use suitable
container to catch fuel drainage. Cap or plug
exposed fuel line fittings.
13. Remove capscrews holding transmission bell-

housing to engine bellhousing. Leave transmission
on cross member mounting bracket assembly.
00-2-2 l Engine Removal SM 575, July 97
‘
ElfIRK Group 00, Engine Removal
18.The special screw is to be used for ONE installa-

tion only. If the screw is removed for any reason it
MUST BE REPLACED. Obtain genuine replacement
parts from your Clark dealer. It is recommended that
the epoxy left in the flywheel hole be removed with
the proper tap and cleaned with solvent. Dry hole
thoroughly and use a NEW screw for re-installation.
Install backing ring and thirty-two (32) special screws

to approximately .06 inch [1,5 mm] of seated posi-
tion. It is permissible to use a power wrench for this
installation phase. With a calibrated torque wrench
tighten screws to 23 - 25 lb ft of torque [31,2 - 33,8
Nom].
NOTE: Assembly of the ring gear must be completed
within a fifteen minute period from start of screw
installation. The screws are prepared with an epoxy
coating which begins to harden after installation in
the flywheel mounting holes. If not tightened to
proper torque within the fifteen minute period
14. Remove engine mount to frame bolts, flat
insufficient screw clamping tension will result.
washers and nuts.
To obtain maximum effectiveness of the special
15Attach suitable lifting device to engine lifting eyes
screw’s locking feature, a minimum time period after
and remove engine from truck. It will be necessary
screw installation of twelve (12) hours is suggested
to move engine 4 to 5 inches towards counterweight
before engine start-up.
to disengage it from transmission. Place engine on
approved stand.
16. Service for the Cummins Diesel engine is pro-

vided only by Cummins. Consult your nearest
Cummins distributor for assistance. If necessary,
your Clark dealer can assist you with this.
..,-.’.I.. 1‘
19. Beginning with lot 8518, Clark changed the fiber

gear design shown above (17.) to a flex plate design
Special Screw - Backing as shown above. Refer to Group 06-Transmission
Ring and Ring Gear for details on mounting of flex plate.
to Engine Flywheel
32 Required 20. Reinstall engine in reverse order.
Torque front engine mount bolts to 60 - 65 Ibf-ft [81 -
17. If it is necessary to remove ring gear and backing 88 Nom].
ring from flywheel for engine repair it must be Torque flywheel housing bolts to 30 - 33 Ibf-ft [40 -45
reinstalled in the following manner. Nom].
SM 575, July 97
‘ Engine Removal l 00-2-3
C5OOY2235 Group00
SECTION 3
FORD ENGINE SPECIFICATIONS
SM575 Copyrighted
SectionMaterial
Title Page July 97
CUIRU Group 00, Engine
Section 3
Ford
Engine Specifications
Contents
Specifications . .. .. .. .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . . 00-3-l thru 7
SM 575, July 97
‘ Copyrighted Material Ford Engine Specifications l 00-3-l
Group 00, Engine CIRRK
ENGINE SPECIFICATIONS
l Ignition Timing -
ENGINE GASOLINE / LPG / CNG Gasoline Models: 10” BTCD

e Ford LSG-8751 V8-Block L.P.G. Models: 16” BTCD
. Weight (Dry): 731 lbs(323.4 kg) C.N.G. Models: 14” BTCD
. Engine Tvne: 90” Valve-in-Head l Spark Plums
.
dBore. 4.36 in. (110.7 mm) Type: Motorcraft ASF 42
. Stroke: 3.85 in (97.8 mm) Size: 14mrn
. Disnlacement: 460 CID (7.5 Litre) Description: Suppression Type

. Rotation (viewed from front): Clockwise Spark Plug Wiring: Resistance Type
* En urine Firing Order: l-5-4-2-6-3-7-8
Cooling System
. Comm-ession Ratio: 8.0 : 1
l Water Puma - Centrifugal Dual Outlet
. Cvlinder Block and Head Material: Cast Iron
Pump Drive: 36” V-Belt
. Engine Balance: Externally Balanced
Pump Capacity: 50 GPM @ 1600 RPM
. Flvwheel Bobweight: 24.0 oz.-in.
Pump Flow: 3.1 Liter/Second
. Vibration Damner Bobweight: 24 oz.-in
. Crankshaft Pullev: 2-Sheaves
. Governor True: Velocity
Pump Pulley: 3 Sheave
. Air Filter: Dry Type (replaceable element)
l Fan Drive Ratio: 1.15 x Eng. RPM
Performance
l Fan Snacer: l-inch thick
* Design Rated Power:
Radiator: Crossflow w/transmission
Continuous BHP: 120 @ 2600 RPM cooler in side tank.
l Design Rated Toraue : Capacity: 27 qts (25.5 L)
Continuous 263 lb.ft. (357 Nom) @ 1400 Radiator Cap: 7 PSI Nominal
RPM
Thermostat - Fully Opens
l Governor Speed Settings (+25. -25) -
GasolineKNG: 180” F (83“ C)
Gasoline Models:
L.P.G.: 160” F (72°C)
Full Load: 2500 RPM
No Load: 2600 RPM (High Idle) Fuel System
L.P.G. & C.N.G. Models: l Fuel Recommendations -
Full Load: 2500 RPM Gasoline: 87 Octane minimum (Mo-

tor Mathod)
No Load: 2650 RPM
LPG: HD-5 Propane
All Models:
l Fuel Pumu
Idle: 600 - 650 RPM
Type: Mechanical Diaphragm
00-3-2 l Ford Engine Specifications Copyrighted Material SM 575, July 97

‘
EMRU Group 00, Engine
Static Pressure @ Enrrine Idle

Electrical
5.5 / 7.5 PSI (0.39 / 0.53 kg)
12-Volt Negative Ground System
Puma Cauacitv:
40 GPH (151.4 L/HEQ @ 3600 RPM 55-Amp Alternator with Regulator
Puma Drive: Camshaft Eccentric Wire Harnes: Ignition Module & Patch. Refer
to Wire Schematic on following pages.
Puma Location: Lower Left Side of Front
Cover Fuses: 15 Amp
Fuel Filter
Camshaft and Related Parts
Type: Pleated Paper Replaceable Element
Crankshaft
Location: Integral with Fuel Pump
Type: 5 Bearing Shell Molded
Intake Manifold Heat Control
Material: Special Cast Iron Alloy,
Type: Exhaust Cross Over
Induction Hardened
Lubrication Journal Diameter:
l Lubrication Svstem 2.1238 / 2.1248 in. (53.945/53.97mm)
Type: Pressure to crankshaft main bear- Camlift -

ings, connecting rod bearings and Intake: 0.2526 in. (6.416 mm)
camshaft bearings.
Reduced pressure to rocker arms. Exhaust: 0.2780 in. (7.061 mm)
Oil mist to piston pins and cylinder Bearings
walls.
Indexed pressure to timing gear. Type: Replaceable Insert
l Oil Pumu: Material: S tee1 Backed Aluminum Lead

Over-plate
Type: Rotor
Total EffectiveLength: 2.90 in. (73.66 mm)
Location: Inside Oil Pan
Total Effective Area: 17.57 in. (113.36 cm*)
Intake: Non-Floading Shrouded Screen in
Camshaft Drive:
Sump.
Type: Silent Chain
Normal Oil Pressure:
Sprocket Material: Die Cast Alumninum
40 / 65 PSI @ 2000 RPM (2.8 / 4.6 kg/cm*)
with Nylon
l Oil Filter: Overlay
Type: Full Flow Disposable (Spin-On)
Crankshaft and Related Parts
Filter Attachment:
l Crankshaft
Base Mounted Left Side
Type: 5 Bearing Cast Nodular Iron
l Crankcase Cauacitv -
Length Overall: 29.146 in. (740.308 mm)
w/o Filter: 8.0 qts (7.6 L)
l Crankuin Journals -
with Filter: 9.0 qts (8.5L)
Diameter:
2.4992 / 2.5000 in. (63.480 / 63.500 mm)
SM 575, July 97
‘ Ford Engine Specifications 9 00-3-3
Group 00, Engine ElIIRK
Electrical Cranknin Journals -
12-Volt Negative Ground System Length:
55-Amp Alternator with Regulator 2.013 / 2.017 in. (51.130151.23mm)
Wire Harnes: Ignition Module &Patch. Refer Main Journals -

to Wire Schematic on following pages. Diameter:
Fuses: 15 Amp 2.9994 / 3.0002 in. (76.185/76.2Omn-i)
Length:
#l 1.132 / 1.172 in. (28.753/29.76rm-n)
l Crankshaft
#2&4 1.120 / 1.130 in. (28.448128.7Or1-m)
#3 1.124 / 1.126 in. (28.550/28.6Omm)
Material: Special Cast Iron Alloy,
#5 1.263 / 1.321 in. (32.80/33.553mm)
Induction Hardened
Journal Overlap: 0.824 in. (20.930 mm)
l Journal Diameter:
Crankshaft Snrocket:
2.1238 / 2.1248 in. (53.945/53.97mm)
Material: Sintered Iron
l Camlift -
Vibration Damner:
Intake: 0.2526 in. (6.416 mm)
Type: Rubber Floated
Exhaust: 0.2780 in. (7.061 mm)
Main Bearings
l Bearings
Type: Replaceable Insert Select Fit
Type: Replaceable Insert
Material: S tee1 Backed Overplated Copper
Material: S tee1 Backed Aluminum Lead
Lead
Over-plate
Effective Length:
Total Effective Length: 2.90 in. (73.66 mm)
#l, 2,4 & 5 0.746 in. (18.948 mm)
Total Effective Area: 17.57 in? (113.36 cm)
#3 0.66 in. (16.764
l Camshaft Drive:
mm)
Type: Silent Chain
Total Length: 3.644 in. (92.558 mm)
Sprocket Material: Die Cast Alumninum
Total Effective Surface Area:
with Nylon Overlay
34.34 in2 (220.916 mrr? )
Pistons, Rods and Bearings
l Crankshaft
l Connecting Rods
Type: I-Beam
Material: S tee1 Backed Overplated Copper
l Cranknin Journals -
Lead
Diameter:
l Length (Center-to-Center):
2.4992 / 2.5000 in. (63.480/63.5Omm)
6.6035 / 6.6065 in. (167.729/ 167.805 mm)
’ 00-3-4 . Ford Engine Specifications Copyrighted Material SM 575, July 97

‘
CUlRK Group 00, Engine
Pistons, Rods and Bearings- continued - l Length:
l Connecting Rod Bearings 3.29 / 3.31 in. (83.566 / 84.074 mm)

Type: Replaceable Insert Select Fit l Diameter:
Material: Steel Backed Copper Lead 1.0398 / 1.0403 in. (26.411 / 26.424
l Effective Length Each Bearing (Crank End): mm)
0.841 in. (21.361 mm) l Piston Fit:
l Total Effective Surface Area (Crank End): 0.0003 / 0.0006 in. (0.076 / 0.015 mm)
52.84 in.2 (340.924 rtKr? ) Valves and Valve Operating

l Pistons Mechanisms
Type: Autothermic .
pmessed Head
Material: Die Cast Aluminum Alloy
Material: Forged Silchrome #l
Finish: Tin Plate
. Head Diameter:
Length: 3.74 in. (95.00 mm)
2.075 / 2.090 in. (52.7 1 / 53.09 mm)
Piston Rings and Pins . Stem Diameter:
l Piston Riws 0.3416 / 0.3423 in. (8.677 / 8.694 mm)

. Stem Oil Control: Nylon Um-
Number: 3
brella Type
l TOD Comm-ession Ring
. Seat Material (Cvlinder Head):
Type: Inside Bevel Straight Face
Induction Hardened
Material: Cast Iron Alloy
. Seat Angle: 45”
Finish: Moly Filled Groove
. Totator TvDe: Ford Free Turn
l Second Compression Ring
. Sw-inrr Pressure - ODen:
Type: Tapered Face
229 lbs. @ 1.33 in. (103.9 kg @ 33.8 mm)
Material: Cast Iron . Snrinrr Pressure - Closed:
Finish: Phosphate Coated
80 lbs. @ 1.81 in. (36.3 kg @ 46.00 mm)
l Oil Control Ring . Exhaust Valve
Type: 3 Piece Segmented
Type: Recessed Head
Material: S tee1
Material: Forged 21-4N Steel, Tungsten Co-
Finish: Chrome Faced Rails, Oxide Coated balt Faced (Hardened)
Expander Rustless S tee1
. Head Diameter:
l Piston Pins
1.500/ 1.515 in. (38.100/ 38.481 mm)
Type: Press Fit in Rod, Tubular
. Stem Diameter:
Material: Heated Treated WE-5015 Steel
0.3416 / 09.3423 in. (8.677 / 8.694 mm)
Copyrighted Material Ford Engine Specifications 00-3-5

SM 575, July 97
‘ l
Group 00, Engine CMRU
Valves and Valve Operating Mechanisms - continued -
Exhaust Valve - continued -

Stem Oil Control: Nylon Umbrella
Type
Seat Insert Material:
Moly Tungsten Chrome Alloy
Seat Ancrle: 45”
Valve Lift: 0.481 in. (12.127 mm)
Rotator Tvne: Ford Free Turn
Snring Pressure - Onen:
229 lbs. @ 1.33 in. (103.9 kg @ 33.8 mm)
Spring Press - Closed:
80 lbs. @ 1.81 in. (36.3 kg @ 46.0
mm)
Valve ODerating Mechnism
Tappet Type: Hydraulic
Tappet Material: Hardened Alloy Cast Iron
Push Rod Material: Low Carbon Welded
S tee1 Tubing
Push Rod Length:
8.585 / 8.615 in (218.06 / 218.82 mm)
Rocker Arm Tvue: Pedestal Mounted
Cylindri- cal Pivot
Rocker Arm Material: Stamped SAE 1010
S tee1
00-3-6 l Ford Engine Specifications Copyrighted Material SM 575, July 97

‘
ClflRK Group 00, Engine
Alternator I-ord 460 CID

12 Volt Nregative Ground
10 Ga-wire limited to 60
Wire Harness
.a-___
Amp Alternator Maximum.

8 Ga-wire used for larger
alternators.
Schematic LSG8751-60
371
Alternator,
Starter and
Starter Relay
are grounded
by mounting
bolts to engine
block or to the Switchgage
system frame. System
inserted here
(when used)
voltmeter
730 2
1 1-
Z
E
Batterv
_ _.__- iin. 1
T71--
?Y 1 .. . I II T
B
1
7
Hour Meter and other

Accessories inserted @) 1 11 Lb7_ x 0 \ Distributor
here (when used).
IIr ._ 1
I
3 734
Circuit #16R shall
have a resistance of
I Ir48-
1.05to 1.15Ohms at
6 I I 75’ F as measured
from terminal to
Terminal
232A -1
t
Ground
/ r->Fpnition Coil
L
Tach Test
High,Tension
.._-_..i
Typical Illustration
Copyrighted Material Ford Engine Specifications 00-3-7

SM 575, July 97
‘ l

C5OOY2235 Group00
SECTION 4
CUMMINS ENGINE SPECIFICATIONS
SM575 Copyrighted
SectionMaterial
Tile Page July 97
CMRK Group 00, Engine
Section 4
Cummins
Engine Specifications
Contents
Specifications . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .... .. . ... .. .. .. .. .. . . .. .. .. .. .. .. .. .. .. .. .. .. .. .. 00-4-2
Copyrighted Material Cummins Engine Specifications 00-4-l

SM 575, July 97
‘ l

Group 00, Engine CMRU
ENGINE SPECIFICATIONS
DIESEL ENGINE Fuel System

Cummins 6BT 5.9
l Fuel Recommendations -
Weight (Dry): 880 lbs(400 kg)
D-2 with Cetane rating of 45 or higher
Bore.
A 4.02 in. (110.7 mm)
D- 1 & Jet A- 1 also acceptable
Stroke: 4.72 in (120 mm)
Disnlacement: 359 CID (5.88 Litre) Lubrication
Rotation (viewed from front): Clockwise Lubrication Svstem
Engine Firing Order: l-5-3-6-2-4 Type: Pressure to crankshaft main bear-

ings, connecting rod bearings and
Comuression Ratio: 17.5 : 1 camshaft bearings.
Air Filter: Dry Type (replaceable element)
Oil Pumtx
Performance Minimum Oil Pressure At:
l Design Rated Power: Rated Speed: 30 PSI (207 kPa)
Continuous BHP: 152 @ 2500 RPM At Idle: 10 PSI (69 kPa)
l Design Rated Toraue : Typical Oil Pressure At:
Continuous 414 lb.ft. (561 Nom) @ 1600 Rated Speed: 50 PSI (345 kPa)
RPM At Idle: 30 PSI (207 kPa)
l Governor Speed Settings (+25, -25) - Oil Filter:
Full Load: 2500 RPM Type: Full Flow Disposable (Spin-On)
No Load: 2650 RPM (High Idle)
Idle: 800 RPM (No Accessories) Crankcase Capacitv -
Cooling System with Filter: 17.3 qts (16.4 L)
l Water Pumu
Pump Capacity: 3 1 GPM @ 1600 RPM
00-4-2 l Cummins Engine Specifications Copyrighted Material SM 575, July 97

‘
GROUP 01
C500 Y 180-200-225S-225L-250S-250L-3OOS-3OOL=350
GROUP Ol-COOLING SYSTEM
Radiator Removal ........................................................... Section 2
Testing and Maintenance ............................................... Section 3
Radiator Repair ........ ...................................................... Section 4
SM 575, July 97
‘ Copyrighted Material Cooling System
C500 Y2235 Grow 01
SECTION I
TROUBLESHOOTING
SM575 SectionMaterial
Copyrighted Title Page July 97
1. Transmission cooler or lines 1. Check cooler and lines for

blocked. blockage. Flush cooler and
Temperature light lines. If problem not corrected,
comes on frequently. replace cooler or defective
lines.
2. Transmission cooler defective. 2. Replace transmission cooler.
Flush system.
1. Transmission oil cooler portion 1. Check engine coolant for

Transmission fluid loss - of radiator leaking into cooling - transmission fluid contamina-
(no signs). system. tion. Repair or replace cooler.
Rough idle (engine . 1. Coolant temperature below 1. Replace thermostat.

misfiring). normal due to incorrect or
defective thermostat.
Excessive blue/white . 1. Coolant temperature below 1. Replace thermostat.

exhaust smoke normal due to incorrect or
defective thermostat.
1. Low coolant level. 1. Check coolant. Fill as re-

quired. Check for leaks.
2. Radiator pressure cap defec- 2. Replace radiator pressure cap.
3. Check operation of fan. If de-
tive. fective, replace fan.
3. Inadequate air flow to radiator. 4. Blow debris from radiator fins.
Engine overheating. Radiator fins plugged. - 5. Drain and flush radiator.
z. Radiator clogged. 6. Drain and flush cooling sy-
6: Scale or deposits in cooling stem.
system. 7. Repair or replace radiator.
7. Radiator defective. 8. Replace thermostat.
8. Thermostat incorrect or de-
fective. 9. Replace hose(s).
9. Collapsed radiator hose(s). 10. Replace water pump.
Engine lubricating 1. Oil cooler core leaking. 1. Check for oil in coolant. If
oil loss. I found, check and replace oil
cooler core.

01-i-l July 97
C5OOY2235 Group01
SECTION 2
RADIATOR REMOVAL
SM575 Copyrighted
SectionMaterial
Tile Page July 97
C500 Y2235 Group 01
SECTION 3
TESTING AND MAINTENANCE
SM575 Copyrighted
SectionMaterial
Title Page July 97
C1RRK Group 01, Cooling System
COOLING SYSTEM - TESTING AND MAINTENANCE
Coolant Recommendations/Specifications Engine Coolant Check
Heavy duty diesel engines require a balanced coolant

mixture of water and antifreeze. Drain and replace the
mixture every 2 years, 320,000 KM [200,000 miles] or
6,000 hours of operation (whichever occurs first) to
eliminate buildup of harmful chemicals.
l Antifreeze is essential in any climate. It broad-

ens the operating temperature range by lowering
the coolant freezing point and by raising its
.‘ __
boiling point. Do not use more that 50 percent
antifreeze in the mixture unless additional freeze
.. _,..’
protection is required. Never use more than 68

percent antifreeze under any condition.
..’
l Use soft water in the coolant mixture. Contami- _. .’ .. ..
nants in hard water neutralize the corrosion in- NOTICE: Remove the radiator cap only when the
hibitor components. Water must not exceed 300 engine is cold to check the coolant level. It is a good
ppm hardness, or contain more than 100 ppm of practice to use a rag over the cap as shown if there is
either chloride or sulfate. any possibility of pressure being present. Turn cap to
the first stop and note if any steam is released.
l Specifications - Use low silicate antifreeze
which meetsASTM4985 test (GM6038Mspec.) Add coolant (50% water and 50% ethylene glycol
criteria. permanent type antifreeze solution containing rust and
corrosion inhibitors), as required. If frequent refilling or
9 Concentration -Antifreeze must be used in any as much as a quart is required at one time, inspect
climate for both freeze and boiling point protec- cooling system for leaks.
tion.Cumminsrecommendsa50percentcon-
centration level (40 percent to 60 percent NOTICE: The use of alcohol or methanol type anti-
range) of ethylene glycol or propylene glycol freeze is NOT RECOMMENDED.
in most climates. Antifreeze at 68 percent con-
A
centration provides the maximum freeze protec-
tion and must never be exceeded under any WARNING
condition. Antifreeze protectiondecreases above STEAM
68 percent. Do not remove the radiator cap when
the radiator is hot. Steam from the ra-
Ethylene Glycol Propylene Glycol diator will cause severe burns.
40% = -23°C [-1 O”F] 40% = -21 “C [-6’F’J
50% = -37°C [-34?=j 50% = -33°C [-27”F]
60% = -54°C [-65”F] 60% = -49°C [-56”F] Cooling System Inspection
68% = -71 “C [-9O”F] 68% = -63°C [-82”F] Inspectthe conditionofthecoolant. Lookforexcessive
contamination, rust or oiliness in the coolant solution.
Concentration Testing - Antifreeze concen- The coolant should have a clean appearance. Check
tration must be checked using a refractome- the planned maintenance time interval )operating
ter(such as Fleetguard Part No. CC2800). “Float- hours), or the condition of the coolant to determine if it
ing ball” type density testers or hydrometers are needs to be changed.
not accurate enough for use with heavy duty
diesel cooling systems.
SM 575, July 97
‘ Testing and Maintenance l 01-3-l
Group 01, Cooling System CUWK
NOTE: A coolant solution containing 50% ethylene

glycol provides freezing protection to -34” F [-37” Cl.
Refer to Service Information Bulletin, SI-01-207-78 for
more information on the use of antifreeze.
If the cooling system requires the addition of a large

quantity of coolant, and the engine has been overheat-
ing:
(a) Inspect radiator for blockage of air flow through
the fins. Air clean the radiator using an OSHA
approved air system of not more than 30 P.S.I.
(b) Check engine oil to see if it contains water.
(c) Pressure test the radiator cap. Replace if faulty.
(d) Pressure test the radiator and cooling system.
Repair air leaks or blockage.
Inspect the overflow tube and hose for clogging, dam- (e) Test the engine thermostat.
age orwear. Clean the overflow tube. Inspect the inlet
and out hoses for damage, cracks, wear or evidence of
collapsing. Inspect the radiator cap sealing surface COOLING SYSTEM PRESSURE TESTS
inside the filler neck. Lookfor nicks, deep scratches or If the need is indicated for further maintenance and
dents which may cause radiator cap leakage. testing of the cooling system, check for both external
and internal leaks in the cooling system with an accu-
rate pressure pump and gauge tester.
Testing the Radiator Cap
Inspect the radiator cap. Check the seal holder and

spring for correct movement and operation. The rub-
ber seal should be clean and undamaged. Look for
nicks or cracks. Replace the cap if the seal is defective.
Be sure the radiator cap has the correct pressure
rating. Refer to Group 40 - Specifications, for the
correct pressure rating of the radiator cap.
Pressure test the radiator cap to determine if it is

holding the correct pressure. Wash the cap in clean
water to remove any dirt or scale from the valve sealing
surfaces. Wetthe rubbersealingsurfaceand installthe
cap tightly on the tester. Presssurize the tester and
radiator cap.
Use a coolant tester to test the low temperature protec-
The gauge pressure reading should be within the
tion level (proportion of ethylene glycol to water) of the
specified limits of the cap relief pressure. If the test
coolant solution. Add coolant solution (antifreeze or
relief pressure either exceeds or is below the specified
water) to provide maximum cooling system protection
limints, replace the cap with a new Clark part. Refer to
(50/50 mixture).
Group 40, Specifications for cap relief pressure rating.
01-3-2 l Testing and Maintenance Intended for CLARK dealers only SM 575, July 97
‘
CMRK Group 01, Cooling System
Replace the thermostat if even a slight opening of the

valve at normal temperature is found or if its appear-
ance shows any breakage. If the sensing part is
damaged, the thermostat valve will remain closed.
COOLING SYSTEM DRAIN AND REFILL
Draining the Radiator and Cooling System

Place a large drain pan which has a minimum capacity
of 27 quarts [25.5 liters] under the radiator and engine
and remove radiator cap.
A STEAM
WARNING
Pressure test the radiator and cooling system to deter-
Do not remove radiator cap when the
mine if it will hold the correct pressure without leaks or
radiator is hot. Steam from the radiator
failure. Wet the rubber sealing surfaces and install the
will cause severe burns.
tester cap tightly on the radiator filler neck. Apply
pressure to the cooling system equal to the radiatorcap
specified relief pressure.
Observe the gauge reading for approximately two

minutes. The pressure should not drop during this
time. If pressure drops, check for leaks in the radiator,
hoses, connections and the engine components.
Testing the Thermostat

Remove and test the engine thermostat to determine if
it closes correctly and opens at the correct tempera-
ture. Referto Group40 - Specifications, forthe correct
opening temperature of the thermostat. /
_,r.r_r x........_...............
_.__ ................ . .........
:\
COOLANT DRAIN PLUG
Remove the coolant drain plug from the engine block
as shown and open drain cock on radiator.
Inspect the coolant hoses and clamps to determine if

they need to be replaced.
Flushing the Cooling System

If the condition of the used coolant indicates severe
contamination, rust deposits, scale or oil in the cooling
system, it may be necessary to clean and flush the
cooling system with a commercial cleaner. Choose a
product from a reliable manufacturer and follow the
Place the thermostat fully immersed in a pan of water.
manufacturer’s recommendations in its use.
Heat the pan slowly while stirring the water to produce
an even temperature. Use a thermometer to measure
Reinstall the engine coolant drain plug and close the
the temperature at which the thermostat valve cracks
radiator drain cock.
(starts to open) and when it is fully open. Measure the
valve lift distance of the fully opened valve. If the test
results are not to specification, replace the thermostat.
SM 575, July 9 ‘7 Intended for CLARK dealers only Testing and Maintenance 01-3-3 l

Group 01, Cooling System C1RRK
Fill the cooling system and perform the cleaning and

flushing operation in accordance with the manufac-
turer’s recommended procedure.
Again drain the cooling system by removing the engine

coolant drain plug and opening the radiator drain cock.
Reinstall the engine coolant drain plug, close the radia-
tor cock and remove the drain pan. Dispose of both
used coolant and flushing fluid in the proscribed man-
ner.
Fill the radiator to the bottom of the filler neck opening

with the recommended 50/50 coolant mixture.
Start the engine and allow it to run for 2-3 minutes to

circulate coolant through the cooling system. Acceler-
ate the engine to a moderate speed several times for
brief periods. Then, stop engine. Using shop cloth as shown, remove radiator cap. Turn
cap only to the first stop and allow any residual steam
Check the coolant level and add coolant as required to to escape. Then remove cap and top off coolant as
the correct fill level. necessary with recommended 50/50 solution.
Reinstall radiator cap and again start engine. Run at Again inspect cooling system hoses, connections and
fast idle and observe temperature gauge until operating components for any leaks that may have developed
temperature has been reached and the thermostat has when system was pressurized.
opened. Shut engine down and allow to cool.
01-3-4 l Testing and Maintenance Intended for CLARK dealers only SM 575, July 97
‘
C500 Y2235 Group 01
SECTION 4
RADIATOR REPAIR
Copyrighted
SectionMaterial
Title Page July 97
GROUP 02
C500 Y 18092009225S-225L-250S-250L-3OOS-3OOL-350
GROUP 02-FUEL SYSTEM
Induction System ............................................................ Section 2
Accelerator Linkage ....................................................... Section 3
Impco LPG Lock-Off Valve ........................................... Section 4
Impco LPG Vaporizer-Regulator .................................. Section 5
SM 575, July 97
‘ Copyrighted Material Fuel System
C500 Y2235 Group 02
SECTION I
TROUBLESHOOTING
Section
Material
1. Engine out of fuel. 1. Check fuel level and fill as

required.
3. Water in fuel system. 3. Check fuel filter and fuel filter/
water separater. Drain water
Engine cranks but will and replace filters.
not start (no smoke from 4. Air in fuel system. 4. Bleed fuel system. Locate
exhaust). and correct cause of air in
fuel system.
5. Fuel filters clogged. 5. Replace fuel filters.
and place in suitable container.
Crank engine and check for
fuel from hose. If no fuel is
pump.

3. Fuel transfer pump defective. 3. Check per (7) above.
Engine hard to start or 4. Air in fuel system. 4. Bleed fuel system. Locate
will not start (smoke
from exhaust).
fuel system.
correct.
take system.
2. Air in fuel system. 2. Bleed fuel system. Locate and
system.
I
Engine starts but will
not remain running. t- 3. Fuel injector(s) plugged or
defective.
- 3. Clean or replace defective
injector.
5. Fuel transfer pump defective. 5. Check per (7) above.
7. Water in fuel system. 7. Check fuel filter and fuel filter/
water separator. Drain water
and replace filters.
SM575 02-l Material

Copyrighted -1 July 97
1. High pressure leak. 1. Check high pressure lines, fuel

injector sealing washers and
delivery bypass valves for
Engine surges
leaks. Replace defective parts.
2. Fuel injector(s) defective. 2. Replace defective fuel in-
jectors.
1. High pressure fuel leak. 1. Same as (1) above.

Rough idle (engine correct cause of air in fuel sy-
misfiring). stem.
3. Fuel injector(s) defective. 3. Replace defective fuel in-
jector(s).
4. Delivery bypass valve(s) de- 4. Replace defective delivery by-
fective. pass valve(s).
1. High pressure fuel leak. Same as (1) above.

2. Air in fuel system. :: Bleed fuel system. Locate and
system.
and place in suitable contain-
Engine runs rough for fuel from hose. If no fuel is
(misfiring). observed, replace fuel transfer
pump.
5. Damaged fuel line. 5. Repair or replace fuel line(s).
correct.
7. incorrect type or grade of fuel. 7. Drain fuel system. Flush and
tar(s).
1. Adjust or replace defective
t
1. Accelerator linkage worn or
2. Fuel control lever on fuel injec- 2. Correct fuel control lever
tion pump incorrectly indexed. indexing.
Engine rpm will not 3. High speed stop screw incor- - 3. Adjust high speed stop screw.
reach rated sbeed. rectly adjusted.
5. Fuel transfer pump defective. 5. Same as (4) above.
July 97 02-l -2 Material

Copyrighted SM575
1. Accelerator linkage worn or 1. Adiust or reolace defective

2. Fuel control lever incorrectly 2. Adjust fuel control.
adjusted for full stop-to-stop
travel.
incorrect.
4. Air filter clogged or air intake 4. Clean or replace air filter.
system restricted. Remove obstruction from air
intake system.
5. High pressure fuel leak. 5. Check high pressure lines, fuel
injector sealing washers and
delivery bypass valves for
Engine lacks power. -
parts.
6. Fuel filters clogged. Replace fuel filters.
7. Fuel transfer pump defective. ;: Remove outlet line from pump
transfer pump.
8. Damaged fuel line(s). Repair or replace fuel line(s).
9. Fuel injection pump defective. !: Replace fuel injection pump.
11 .Air in fuel system. 11. Bleed fuel system. Locate and
system.
tor(s).
1. Air filter clogged or air intake 1. Clean or replace air filter.
I
system restricted. Remove obstruction from air
intake system.
2. Fuel injector(s) installed with 2. Remove and correctly install
-
more than one sealing washer. fuel injector(s).
tors.
2. Fuel injection pump defective.
Engine oil contaminated _ 1. Fuel transfer pump seal 1. Replace fuel transfer pump.
with fuel. leaking.
Fuel or oil leaking from 1. Air filter clogged or air intake 1. Clean or replace air filter. Re-
exhaust manifold. system restricted. move restriction from air
intake system.
I I
SM575 02-l-3
Copyrighted Material July 97

system.
Engine knocking. 2. Incorrect type or grade of fuel. 2. Drain fuel system. Flush and
correct.
4. Fuel injector(s) defective. 4. Replace defective fuel
injector(s).
take system.
incorrect.
Excessive fuel 3. Replace defective fuel injec-
3. Fuel injector(s) defective.
consumption. tar(s).
5. Accelerator linkage sticking or 5. Remove restriction. Repair or
restricted. replace accelerator linkage.
7. Fuel leakage.
Low compression. 1. Air filter clogged or air intake _ 1. Clean or replace air filter. Re-
take system.

Copyrighted SM575
C500 Y2235 Group 02
SECTION 2
INDUCTION SYSTEM
SM575 Copyrighted
SectionMaterial
Title Page July 97
ElfIRK Group 02, Fuel System
AIR INDUCTION SYSTEM
1. Your lift truck is equipped with a heavy duty “Cyclo-

pat” air cleaner for maximum protection of the engine.
Air enters through the weather cap at the top of the
truck and is conducted to the engine by way of a stack
WEATHER CAP
and connecting tubing and hoses.
I AIR RESTRICTION INDICATOR

/
AIR CLEANER
3. The air cleaner is equipped with an Air Restriction

Indicator. It is recommended that the element be
serviced only when this is indicated by the red dial
becoming visible. This is because every time the air
cleaner cap and the element are removed, there is
danger of some dust getting into the engine. This
should therefore be done only when necessary.
IMPORTANT
iR
The life of the engine is dependant
2. The cyclonic action of the Cyclopac air cleaner upon the integrity of the air induction
spins out much of the dirt and dust in the incoming air. system. Check the hose clamps for
It is then automatically dumped by the Vacuator Valve. tightness regularly. At ever PM, look all
This greatly increases the intervals for element serv- around each connection for fan shaped
ice. dust deposites that indicate a possible
leak. Check hose elbows and bushings
for cracks or damage.
SM 575, July 9
‘7 Copyrighted Material Air Induction System l 02-2-l
C5OOY2235 Group02
SECTION 3
ACCELERATOR LINKAGE
Copyrighted
SectionMaterial
Tile Page
CmK Group 02, Fuel System
ACCELERATOR LINKAGE
ACCELERfTOR PEDAL
ACCELERATOR ROD AND
CABLE ANCHOR BRACKET
RETURN SPRING
1. The accelerator system consists of a pedal, pedal 3. The accelerator cable has inner and outer covers
stop bolt, pivot rod, cable with clevises on each end and and is protected from contamination with dust shields.
a return spring. It requires no lubrication and is designed to provide
long, trouble-free life. Because of the importance of
2. The cable length should be adjusted by means of quick acting acceleration/deceleration, the condition of
the clevis ends so that the pedal contacts the stop bolt the cable should be checked regularly. Insure that
as soon as the lever on the engine fuel control is fully there is no contact between the return spring, linkage,
opened. The stop bolt may also be adjusted. This is brackets or other vehicle components and the cable
important to keep undue force being applied to the that could cause binding, wear or damage to the cable
accelerator system after full open throttle has been housing. Inspect the cable assembly to insure that it
achieved. operates smoothly, without binding. Inspect the ex-
posed portion of the cable for fraying. Replace cable
immediately if binding or fraying is noted.
SM 575, July 97
‘ Copyrighted Material Accelerator Linkage l 02-3-I
C500 Y2235 Group 02
SECTION 4
IMPCO LPG LOCK-OFF VALVE
MODEL VFF30
SM575 Copyrighted
SectionMaterial
Tile Page July 97
EUIRK Group 02, Fuel System
LPG LOCK-OFF VALVE
Diaphragm Cover Screw
-!?
-Diaphragm Cover (N)
Valve Lever FulcrumScrew
Operating Lever Fulcrum
Operating Lever
,-Repair Kit
I=&zI
BodyN
4 Marked!?._..I
Capscrew
Lockwasher Spring
f _-- Lockwasher
, Aalve Spring Screw
Filter Element & Screen (R)
#
Filter Cover Gasket (R)
e--
(u
c,
Filter Cover (N)
-Lockwasher
Non Serviceable Items Marked (N) -X Filter Cover Screw
SM 575, July 9
‘7 Copyrighted Material lmpco LPG Lock-off Valve l 02-4-I
Group 02, Fuel System
Removal
l/4” NPT
A CAUTION
Wear safety glasses at all times to pro-
l/8” NPT
Vacuum Inlet Port
Fuel Outlet
tect your eyes.
1. Close manual shut-off valve at LPG tank.
2. Start engine. Allow to run until engine stops. Turn

off ignition switch.
A WARNING
Do not smoke while removing any as-
semblies from the LPG system. Dis-
connect the grounded cable (-) at the
battery to prevent accidental sparking.
LPG is high inflammable. Tap 1/4”-20 x l/2” (2 places)
Mounting Bosses
3. Disconnect vacuum and fuel lines from lock-off 2 Screws Provided
valve. Plug or cap the end of the lines. FILTER COVER
4. Remove bolts securing lock-off valve to mounting

bracket.
1. Remove filter cover and gasket.
.I. -.. .
*. .‘--‘
Disassembly .-
,
\-.
Disassemble lock-off valve on a clean work bench.
For purpose of identification, the “Model Number”

side is the diaphragm cover; the “Fuel In” side is
the filter cover as shown.
2. Remove filter element and screen.
1A by 20 Thread
DIAPHRAGM COVER
02-4-2 l lmpco LPG Lock-off Valve Copyrighted Material SM 575, July 97

‘
Grow 02, Fuel System
Remove valve spring.
CUTAWAY VIEW
7. With paper clip or wire, fashion a hook. Insert

hook in fuel outlet port and remove seal retaining
4. Remove valve seat.
washer.
5. Remove valve operating pin.

8. Insert hook through valve jet and pick out O-ring
6. Cutaway assembly show:

9. Turn lock-off valve assembly over. Remove cover
and diaphragm assembly.
1. Valve spring
2. Valve seat . ”
3. Valve operating pin

4. Seal retaining washer
5. O-Ring seal
Removal of the valve pin allows retaining washer to
be removed through fuel outlet port.
SM 575, July 9
‘7 Copyrighted Material lmpco LPG Lock-off Valve l 02-4-3
10. Loosen fulcrum screws. Tip out fulcrum and 2. Inspect valve jet for defects which would affect
valve operating lever. sealing.
Check for cracks especially at valve body ports and

cover flanges.
If damaged, replace valve body or covers.
Cleaning and Inspection
Pick up repair kit, part number905054, from your Parts

Department. Discard old parts which will be replaced
3. Check body and cover sealing surfaces against
by the kit.
gasket or diaphragm. Dress burrs and nicks with
hard stone where required.
Repair Kit Includes:
1 - Fuel Cover Gasket
1 - Filter
1 - Screen
1 - Diaphragm Assembly
1 - Valve Seat (Viton Bonded to Aluminum)
1 - Valve Operating Pin
1 - O-Ring Seal
1. Wash all parts clean, particularly valve jet pas-

sages and outlet port. Dry with compressed air.
NOTICE
4. Check for damaged threads. Rethread holes with
Use kerosene or equivalent petroleum
proper size tap, or replace screws.
solvent. Do not use carburetor cleaner
or lacquer thinner as they will attack
special coatings or synthetic rubber
seals after assembling.
I
02-4-4
. lmpco LPG Lock-off Valve SM 575, July 97
‘
Reassembly
1. To reassemble valve parts, place new O-ring seal 4. Install new valve seat with viton (rubber) side down
on valve jet as shown. Coat O-ring with silicone on valve jet.
grease or equivalent to prevent friction against
valve pin.
Use afiltercover screwto press O-ring down into its

recess. Rotate screw while pressing down to ease
O-ring into position.
5. Install valve spring. In tightening screws (8-32 x 5/

16), hold tip of spring on valve, centered between
the three (3) guide fins.
After installing, lift spring slightly to assure freedom

of travel.
2. Using needle nose pliers, insert seal retainerwasher
in slot inside the outlet port to hold O-ring in place.
3. Lubricate valve operating pin with silicone grease. 6. Insert new screen and filter.
Rotate pin gently to ease it into place through
washer, O-ring seal and body housing.
SM 575, July 97
‘ Copyrighted Material lmpco LPG Lock-off Valve 9 02-4-5
7. Align new cover gasket. With two opposite screws 10. Check valve operating lever for free travel and that
in filtercover, start screws in theirthreads. All holes operating pin follows lever travel.
are equally spaced.
6. Insert remaining screws. Tighten screws in rotation

alternately across the cover until all are solidly set. 11. Install new diaphragm assembly with plate marked
“inside” or “this side down” toward the lever. There
is only one position in which the holes will line up.
9. Hook valve operating lever into lugs on fulcrum.

Place in position over valve operating pin and
tighten screws. 12. Install diaphragm cover. Tighten screws in rotation
alternately across cover until all are solidly fas-
tened.
NOTICE
Tip of lever must bend downward into
housing. Also, when assembling you
will notice a wear point on lever where
it contacts pin.
02-4-6 . lmpco LPG Lock-off Valve SM 575, July 9
‘7
Grow 02. Fuel System
Bench Tests Installation
Before installing lock-off valve on machine, pressure All port openings in the valve body are NPT. Standard
test for leakage, using soap suds or testing solution. torque specifications are not applicable to pipe threads.
1. Install fitting and hose on vacuum port. Draw or When installing hoses or fittings, use a stick-type pipe
suck on hose to create a vacuum, and listen for joint compound.
diaphragm to operate.
a. Hand tighten.
b. Wrench tighten 1-l/2 to a maximumof three
turns.
1. Place lock-off valve in position, and tighten mount-

ing bolts securely.
2. Connect fuel and vacuum lines. Connect battery

ground cable.
2. Pressurize the “fuel-in” port with air. Check fuel

A WARNING
Do not smoke while removing any as-
outlet port and filter cover gasket for leakage. semblies from the LPG system. Dis-
connect the grounded cable (-) at the
LPG is high inflammable.
3. Open shut-off valve on LPG tank. Start engine.
4. Check installation for leaks with soap suds or

testing solution.
3. Install a O-200 PSI gauge in fuel outlet port. Apply

and hold vacuum with thumb or by crimping hose.
Gauge will register line pressure. Release vacuum
and if gauge slowly drops to zero, it indicates a
cracked outlet port or porous casting.
. -2. ..--w,
SM 575, July 9
‘7 Copyrighted Material lmpco LPG Lock-off Valve l 02-4-7
C500 Y2235 Group 02
SECTION 5
IMPCO LPG VAPORIZER-REGULATOR
MODEL EB

Section Tiile Page July 97
ElfIRK Group 02, Fuel System
VAPORIZER REGULATOR
- Primary Regulator Diaphragm Cover Screw

- Lockwasher
Secondary Regulator Cover (N)
Primary Regulator
Diaphragm Cover Screw Lo&washer Primary Diaphragm Cover Screw (R)
Secondary Regulator Lever Pivot
Primary Regulator Cover (N)
-Primary Diaphragm Spring

Primary Diaphragm Spring
- Vaporizer-Regulator Body (N)
LP Gas Test Plug
Heat Exchanger Body (N)
Water Jacket Drain Plug
Vaporizer-Regulator Body Cover (N)

- Lockwasher
Non Serviceable Items Marked (N) Body Cover Screw
SM 575, July 97
‘ Copyrighted Material lmpco LPG Vaporizer-Regulator l 02-5-l
Group 02, Fuel System CUIRK
Removal
A A WARNING
CAUTION Do not smoke while removing any as-
Wear safety glasses at all times to pro- semblies from the LPG system. Dis-
tect your eyes. connect the grounded cable (-) at the
1. Close manual shut-off valve at LPG tank. LPG is high inflammable.
2. Start engine. Allow to run until engine stops. Turn 4. Disconnect fuel and water lines from the vaporizer-
off ignition switch. regulator. Plug or cap the end of the lines.
3. Drain radiator. 5. Remove mounting bolts and the vaporizer-regula-

tor.
Water in-Out
LPG Inlet
Letter
Water
Bleed
Port
SECONDARY COVER HEAT EXCHANGER COVER
02-5-2 lmpco LPG Vaporizer-Regulator

l SM 575, July 97
‘
Disassembly
This section covers the Model EB Vaporizer-Regu- Screw holesarespaced so that covers, diaphragms
lator. See Table 1. and gaskets line up in only one position.
For purpose of identification, the “Model Number” Disassemble the vaporizer-regulator on a clean
side is the secondary (low pressure) cover. The work bench.
reverse side or back cover is the heat exchanger
cover as shown on the previous page.
TABLE 1
MODEL CLARK LETTER SECONDARY VAPOR OUTLET (1) CHECK

P/N STICKER SPRING PRESSURE VALVE
COLOR
C%ER
EB 2360142 B BLUE - l-1/2” NO
(1) Negative pressure (vacuum) measured by water column manometer.
1. Remove secondary cover assembly. If necessary, 3. Remove screw blocking secondary fulcrum pin.
break cover loose by tapping it with screw driver Remove pin, secondary regulator lever (containing
handle. seat) and spring.
2. Remove secondary diaphragm. Disengage dia- NOTICE

phragm link from the secondary regulator lever by Color of secondary spring must agree
moving it away from the vapor outlet port. with letter sticker on secondary cover.
Refer to Table 1.
4. Primary diaphragm cover is under spring tension.

Hold down while removing pan head screws last,
Link and remove cover.
SM 575, July 9
‘7 Copyrighted Material lmpco LPG Vaporizer-Regulator l 02-5-3
2. Inspect primary and secondary valve jets for proper 6. Check threads for damage and that blind holes are
sealing surface. If damaged, replace vaporizer- clean full depth. Restore threads with proper side
regulator. tap. Replace damaged screws.
3. Checkforcracks especially at body ports and cover

flanges. If damaged, replace vaporizer-regulator.
7. Clean coolant passages to assure good heat trans-

fer. Wire brush to remove heavy scale. After as-
sembly, clean and flush cooling system.
4. Be sure gas inlet and vaporizing ports (2) in laby-

rinth are open. Checkwith penlight size flashlight or
small diameter screwdriver.
Reassembly
During reassembly do not use a sealer on gasket or

diaphragm surfaces.
1. Install heat exchanger cover and gasket using 1O-

24 x 5/8 screws. Tighten mounting boss screws first
5. Draw a straight edge across sealing surfaces of
(A); then remaining screws alternately across cover
each body and cover.
until firmly set.
Dress burrs or nicks with hard stone where re-
quired.
SM 575, July 97
‘ Copyrighted Material lmpco LPG Vaporizer-Regulator l 02-5-5
2. Install primary seat with viton (rubber) against the 6. Hold primary cover down and install (2) 1O-24 x 3/8
jet. Fit new sponge into cast recess in heat ex- pan head cover screws.
changer
3. Place a new gasket over locating pins on regulator

body and install on heat exchanger. Screw holes 7. Install remaining 12-24 x 7/8 cover screws except
align in only one position. one blocking fulcrum pin. Tighten diagonally oppo-
site screws in sequence until firmly set.
Install (2) screws 12-24 x 7/8 to hold units in place.
Tighten securely.
4. Install primary valve pin. 8. Assemble a new seat and pin on secondary lever.
Pull seat tight but allow to tilt for alignment with
secondary jet. Bend pin as shown to retain seat in
place. Clip off excess length.
5. Align primary diaphragm over locating bosses and

install springs. ...
02-5-6 l lmpco LPG Vaporizer-Regulator SM 575, July 9
‘7
ClmK Group 02, Fuel System
9. Locate secondary spring in tabs of lever assembly. 12.Align secondary cover. Install screws finger tight;
Push down and insert fulcrum pin. Install the last then tighten in rotation alternately across cover until
12-24 x 7/8 cover screw. Press and release lever firmly set.
several times to insure proper operation.
10. Using lever gauge, Part No. 1801833, across face

of body, check that slot in gauge slides freely over Bench Tests
pin at end of lever. Remove and bend end of lever
with pliers until proper fit is obtained. Before installing vaporizer-regulatoron machine, pres-
sure test for leakage, using soap suds or testing
solution.
1. Pressurize the “LPG In” port with air. Check for

leakage at body center gasket and in outlet port
past secondary seat.
11. Engage locating slots of secondary diaphragm link

with lever pin.
2. Plug LPG outlet port. While pressurizing the “LPG

In” port, push down on hand primer button. Check
for leakage at secondary diaphragm.
SM 575, July 97
‘ Copyrighted Material lmpco LPG Vaporizer-Regulator l 02-5-7
Installation
All port openings in the vaporizer-regulator are NPT.

Standard torque specifications are not applicable to
pipe threads.
When installing hoses or fittings, use a stick-type pipe

joint compound.
a. Hand tighten.
b. Wrench tighten l-1 /2 to a maximumof three
turns.
1. Position vaporizer-regulator. Securely tighten

mounting bolts.
2. Connect fuel and water lines. Fill cooling system.

Connect battery ground cable.
A WARNING
Do not smoke while installing and
checking LPG assemblies. LPG is
highly inflammable.
3. Open shut-off valve on LPG tank. Start engine.
4. Check installation for leaks with soap suds or

testing solution.
5. Bleed air from water lines.
Copyrighted Material SM 575, July 9

‘7
02-S-8 l lmpco LPG Vaporizer-Regulator
GROUP 06
C500 Y 180-200-225S-225L-25OS-25OL-3OOS-3OOL-350
GROUP 06-TRANSMISSION
Transmission Stall Test ................................................... Section 2
Transmission Removal ................................................... Section 3
Transmission Clutch Modulation .................................. Section 4
Transmission Maintenance and Service ....................... Section 5
Linkage and Controls ..................................................... Section 6
SM 575, July 9
‘7 Copyrighted Material Transmission
C500 Y2235 Group 06
SECTION I
TROUBLESHOOTING
SM575 Copyrighted
SectionMaterial
Tile Page July 97
1. Transmission fluid low. Check fluid level. Fill as re-

Truck will not move 2. Directional control linkage Repair or replace linkage.
when shifted into gear defective.
with engine running. 3. Transmission defective. Troubleshoot transmission
using the following guides.
4. Drive axle defective. Refer to Group 20, Section l-
L
i
Drive Axle Troubleshooting.
1. Transmission fluid low. 1. Check transmission fluid. Fill

as required. Check for leaks.
2. Transmission fluid burnt 2. Drain, flush and fill with new
(overheated). transmission fluid.
3. Transmission cooler or lines 3. Check cooler lines for block-
blocked. age. Flush cooler and lines.
If problem not corrected, re-
place cooler or defective lines.
4. Transmission cooler defective. 4. Replace transmission cooler.
Flush system.
5. Control cover assembly de- 5. Repair or replace control
fective. cover assembly.
6. Screen assembly clogged. 6. Remove screen assembly and
clean.
7. Low directional pressure. Repair transmission.
8. Regulator valve assembly 8’: Repair or replace regulator
defective. valve assembly.
9. lnsuff icient fluid to impeller 9. Repair transmission.
and turbine and transmission
cooler.
10. Shaft seal of converter pump 10. Repair converter pump
assembly worn and allowing assembly.
fluid leakage.
11. Brakes dragging. 11. Refer to Group 23, Section l-
Parking Brake Trouble-
shooting.
1. Transmission oil caller portion 1. Check engine coolant for

Transmission fluid loss _ of radiator leaking into cooling - transmission fluid contamina-
(no signs). system. tion. Repair or replace cooler.
1. Transmission fluid low. 1. Check fluid level. Fill as re-

2. Transmission fluid burnt 2. Drain, flush and fill with new
I
Transmission shifts
slow.
(overheated).
3. Control cover assembly
defective.
transmission fluid.
3. Repair or replace control
cover assembly.
4. Internal damage. 4. Repair transmission.
1. Control cover assembly de- 1. Repair or replace control

cover assembly.
2. Repair or replace directional
control linkage.
3. Repair transmission.
1. Transmission fluid low. 1. Check fluid level. Fill as re-

2. Screen assembly clogged. 2. Remove screen assembly and
clean.
Transmission is noisy 3. Converter pump assembly 3. Repair or replace converter
-
when selecting direction defective. pump assembly.
4. Defective transmission impeller 4. Repair or replace transmission
and turbine installation. impeller and turbine installa-
tion.
5. Restricted flow in transmission 5. Remove obstruction or re-
cooler. place transmission cooler.
1. Parking brake not released. 1. Release brake.

2. Directional control linkage 2. Repair or replace directional
I
Transmission will not
pull in either direction. t- defective.
3. Transmission fluid low.
4. Converter pump assembly
control linkage.
3. Check fluid level. Fill as re-
defective. 4. Converter pump assembly
defective.
1. Directional control linkage 1. Repair or replace directional

defective. control linkage.
I
Transmission pulls in
one direction only. l-
2. Control cover assembly
defective.
3. Defective discs in clutch packs. t
2. Repair or replace control
cover assembly.
3. Replace discs in clutch packs.
July 97 Copyrighted
C500 Y2235 Group 06
SECTION 2
TRANSMISSION STALL TEST

Section Title Page July 97
ClflRK Group 06, Transmission
TRANSMISSION STALL TEST
In any situation involving truck power loss or low power

condition, it is necessary to determine if the fault is in
the transmission or engine. Unless the problem is
obvious, i.e. blue or black exhaust smoke or a highly
A WARNING
Make sure that all other personnel are
overheated transmission; a transmission stall test will clear of truck. If parking brake should
indicate the probable cause. Generally, a higher than not hold, injury to personnel could re-
normal stall speed indicates a transmission problem sult. If possible, conduct test before
such as low fluid pressure or clutch pack slippage. post or other immovable barrier.
Lowerthan normal stall speed indicates that the engine
A
is operating below it’s rated output. Normal stall speed
for C500 Y 180-350 lift trucks equipped with Cummins CAUTION
6BT diesel engine and Clark 18000 transmission is
Prolonged stalling of the converter can
1,900 to 2,000 rpm. cause serious internal damage. Stall
converter only long enough to read
Improper running of this test could result in injury to the
engine rpm. Do not exceed 30 seconds.
operator or bystanders and damage to the vehicle.
Therefore, it should be conducted exactly in accor-
10. Place transmission gear lever in third gear and the
dance with the following procedures.
direction control lever in Forward (F). Accelerate
engine to full throttle and observe stall rpm.
1. Ensure that radiator is clean so that proper cooling
NOTE: Do not operate inching pedal during test as this
action prevents engine and transmission from over-
will cause false readings.
heating during stall test. If radiator requires cleaning
refer to Section 01 - Cooling System.
If low stall reading is obtained, consult your nearest
Cummins Engine Distributor for assistance. If neces-
2. Check transmission fluid and fill with transmission
sary, you Clark dealer can assist you with this.
fluid as necessary. Refer to Group 40 - Specifications
for amount and type of fluid.
If high stall readings are obtained, proceed to test the
transmission further and repair if necessary. Refer to
3. Verify that emergency brake is operating properly
Group 06, Section 3 -Transmission Clutch Modulation
and apply brake.
and Section 4 - Transmission Maintenance and
Service.
4. Connect tachometer to engine.
5. Start truck and allow transmission to reach stan-

dard operating temperature of 180 - 200” F (82 - 90” C).
Transmission fluid must be at operating temperature in
order to obtain proper readings.
6. With transmission in NEUTRAL (N) position, check

that full throttle governed speed is 2750 rpm. Adjust
engine to obtain this speed if necessary.
7. With engine at full throttle, hold tilt lever fully back

and check loaded rpm. Indicated rpm should be 2500
rpm.
8. Lower forks or attachments to the ground.
9. Securely block wheels.
SM 575, July 9
‘7 Copyrighted Material Transmission Stall Test l 06-2-l
C500 Y2235 Group 06
SECTION 3
TRANSMISSION REMOVAL
Copyrighted Tile Page July 97
CIRRK Group 06, Transmission
Transmission Removal
1. Remove floorplates. 4. Remove dipstick from transmission and cap or

plug exposed hydraulic fitting ends.
2. Place suitable container under transmission and
drain fluid. Dispose of fluid in approved manner. Do 5. Tag and disconnect electrical connections at
not reuse. power steering pump, transmission temperature
A
sensor, air brake pressure switch, stop light switch
and transmission pressure sender.
Warning
Hydraulic fluid is toxic to skin, eyes
and respiratory tract. Avoid skin and
eye contact. Good general ventilation
is normally adequate.
6. Disconnect direction and shift control cables

from the transmission and lay them out of the way.
Note: If necessary, secure cables so that they will
remain out of the way when truck is lifted from the
rear to remove transmission.
A@’
3. Remove transmission cooling lines from trans-
.5-
.I
mission and cap or plug exposed ports and hydraulic
fitting ends. 7. Unbolt and remove U-Joint.
SM 575, July 9
‘7 Copyrighted Material Transmission Removal l 06-3-l
Group 06, Transmission ElfIRK
8. It is necessary to support engine by chaining to 12. Raise rear of truck with hoist until steer tires are
upper truck frame members or to a bar secured approximately thirty inches above floor and place
across the top of the engine compartment. Chain as suitable stands under wheels.
shown or to engine lifting eye.
13. Pull transmission out from under side of truck.
9. Tilt upright back and chock front and back of Pulling out on a rearward angle works best.
drive wheels.
14. Reverse procedure to reinstall transmission.
10. Position a suitable, portable or overhead hoist Torque mount to frame bolts to 35 - 40 Ibf - ft [47 -
and nylon web lifting sling thru floor plate area. 54 N=m]. Torque transmission to engine bellhousing
Place sling under transmission converter pump bolts to 30 - 33 Ibf-ft [40 - 45 Nom].
assembly and regulator valve assembly. Lift on
transmission so that it is supported. Tighten chain
supporting engine.
11. Remove bolts, washers, nuts and vibration

isolaters fastening transmission mount to truck
frame. Leave mounting bracket assembly on
ttransmission. Remove transmission bellhousing
bolts and move transmission five inches towards
upright to clear engine. Lower transmission to floor
or suitable dolly.
06-3-2 l Transmission Removal SM 575, July 9
‘7
C500 Y2235 Group 06
SECTION 4
TRANSMISSION CLUTCH MODULATION
The”Transmission Clutch ModulatiorYvendor

literature inserted afterthis page illustrates the
“Fiber Gear” used prior to lot 8518. This was
then replaced with a “Flex Plate” which is
illustrated per Picture Page 06-631 which is
included on the back of this page.
SM575 Copyrighted
SectionMaterial
Title Page July 97
C5OOY2235 Group 06
I Transmission
Assembly Complete I-
06.200
! \
i
I
05.021
W.UlZ \
. ..-_ 05.019 _..- /. ...:
05.006
,_ ?\
‘ ~f??+j ,?,, 3& 6 ,,_,, .~~~~C~“
;C
‘ ~
..d
i 05.015 .
05.014 _...-..“”
..’
TORQUE CONVERTER & FLEX DRIVE PLATES 06-631
06.200 Transmission Assembly (continued) 05.026 Seal, Converter Oil Baffle

05.003 Plate, Converter Drive & Reinforcing 05.027 Baffle, Torque Converter Oil
05.006 Cover, Converter Impeller 05.028 Seal, Converter Oil Baffle
05.008 Fastener, Impeller Cover 05.030 Gear, Impeller Hub
05.009 Seal, Impeller Cover 05.031 Ring-Retainer, Impeller Hub Gear
05.010 Bearing, Impeller Cover 05.033 Stator Support Assembly, Converter
05.011 Ring-Retaining, Cover Bearing 05.034 Fastener, Stator Support
05.012 Fastener, Turbine To Hub 05.035 Shaft, Converter Turbine
05.013 Hub, Converter Turbine 05.036 Seal, Turbine Shaft
05.014 Turbine, Torque Converter 05.037 Bearing, Turbine Shaft
05.015 Ring-Retainer, Turbine Hub 05.039 Gear, Turbine Shaft
05.016 Ring-Retainer, Reaction Member 05.040 Ring-Retaining, Turbine Shaft Gear
05.017 Reaction Member, Torque Converter 05.169 Ring-Retaining, Converter Oil Baffle
05.019 Spacer, Reaction Member 05.221 Expander, Stator Support Seal
05.020 Ring-Retainer, Impeller Hub Bearing 05.234 Plates, Flex Drive Assembly
05.021 Bearing, Impeller Hub 05.235 Ring, Flex Drive Plate Backing
05.022 Hub, Converter Impeller 05.236 Fastener, Flex Drive Plate Backing
05.023 Seal, Converter Impeller Hub 05.237 Ring, Hub To Impeller Backing
05.024 Impeller, Torque Converter 91.302 Lockwasher, Stator Support Fastener
05.025 Fastener, Impeller To Hub
July 97 Copyrighted
Section Title PageMaterial SM575
TRANSMISSION
CLUTCH MODULATION
OPERATION
and
TROUBLE SHOOTING GUIDE
COMPONENTS
Mod SUP- Rev.3-89

Service Publications
l-77 at I-40, Rt. 18, Box 38
Statesville, NC 28677
0 Copyright Clark Equipment Company, 1999.1999

Unpublished material -all rights reserved
Limited Distribution
No part of this work may be reproduced in any form under
any means without direct written permission of Clark
Equipment Company.
TRANSMISSION CLUTCH MODULATION
TRANSMISSION MODULATOR VALVE OPERATIONAL DESCRIPTION
Both directional clutch assemblies are contolled by individual modulator valves. The pressure rise at side “A” of the regulator
spool is the same as that applying the clutch piston. Supply flow to the clutch and modulator is limited by a flow limiting orifice.
From this limited flow the regulator spool drains flow to the vent port. The regulator spool restricts flow through the vent port to
build clutch pressure at a predetermined rate. Once the vent flow is shut off, only minimal flow passes through the flow limiting
orifice to make up for normal spool and clutch leakages. Pressure on either side of the orifice is virtually identical and full
regulated system pressure is applied at the clutch piston.
When forward direction is selected the oil under pressure enters the port on the “A” side of the regulator spool. This passes
through the quick release ball check. The pressure force on the spool area shifts the spool to the right exposing the vent port.
The time required to shift the regulator spool over to expose the vent port shows up as a pressure spike at the beginning of the
pressure versus time chart.
The movement of the regulator spool is opposed by the regulator and accumulator springs. This provides an initial low pressure
head of approximately 20 psi [137,9 Kpal on the “A” side of the spool. This 20 psi [137,9 Kpal is represented as a horizontal line
on the pressure versus time chart immediately following the spike. Oil flows through the regulator spool orifice due to a pressure
imbalance. Pressure at the side “A” is constantly higher than side “B” as a result of the added force of the side “B” spring.
The pressure differential of side “A” to side “B” across the regulator spool orifice gives a controlled flow rate. This controlled
flow establishes the time it takes to fill the accumulated cavity.
As the accumulator cavity is filled, the accumulator spool is forced against the accumulator springs. As the springs compress
their force increases causing the hydraulic pressure in the accumulator cavity and “B” side of the regulator spool to increase.
Pressure on the “A” side of the regulator spool increases with the opposing force on the “B” side.
This causes the rising slope in the clutch pressure versus time chart. The rate of this rise is controlled by the accumulator spring
force. Once the accumulator spool is stroked to its limit, pressure on “A” and “B” side of the regulator spool is balanced since
no flow passes through the regulator spool orifice. The clutch and modulator pressure rapidly rise to the system regulated clutch
supply pressure setting. This is the vertical line on the clutch pressure versus time chart.
The entire modulator sequence of events occurs in less than two seconds. The steady rise of clutch pressure increases the clutch
driving torque which results in a smooth clutch application.
When forward direction is selected the reverse clutch and modulator are vented through the control valve to the transmission
sump. The reverse accumulator cavity is vented back through the regulator spool orifice and the quick release ball check. To
hasten the reset time of the accumulator, immediately preparing the transmission for a directional shift, full system regulated
clutch supply pressure from the forward control valve is directed to the spring cavity of the reverse accumulator.
When reverse direction is selected the reverse clutch and modulator function through the same sequence of events as the
forward clutch and modulator.
The lock-up modulator system works on the same hydraulic principles. (See pages 16, 17, 18 Et 20 for the modulated lock-up
plumbing diagram).
-l-
CLSRK
28000 AND 32000 SERIES MODULATION

SIDE 1
MODULATED FORWARD c-----

CLUTCH PRESSURE
CHECK PORT
/
I I
r----7
TRANSMlSSiON I 6 PLATE
FORWARD I M03L’LATION
--&!I- !\
0
UPPLY
j REGULATOR
/j FRo SIDE B SPRING
SIDE B
REGULZTOR SPOO
ORIF!CE
FLOW LiMlTlNG
I / SUPPLY ORIFICE / SIDE A
A AI
UUIGK Ht!-tASt
MODULATED SALL CHECK
REVERSE
CHECK PORT ”
TO FORWARD /
CLUTCH SYSTEM REGULATED
CLUTCH PRESSURE
i- MODULATED
This pressure spike is time required for spools to react.

The spike pressure is used to quickly fill the clutch pressure supply
passages with oil.
I 1
ACCUMULATOR :----’
I fI
_-____ SPOOLS I
-ACCUMULATOR
SPRINGS
ACCUMULATOR
MODULATOR
nC”Cnat
MODULATOK W”I”T\ IIILLC\.JL
BALL CHECK
PRESSURE PORT
CLLlTCH
REG”l_AT&-
SPOOLS
-2-
CLSRK
FORWARD & 1st (LOW)
LOW SPEED CLUTCH

PRESSURE TUBE
CONVERTER TO COOLER4
COOLER TO LUB
OIL DlSTRiBUTOR
Y HIGH PRESSURE
i
[T LOW PRESSURE
v SUCTION. DRAIN & LUBE
28000 Et 32000 SERIES TRANSMISSION

PLUMBING DIAGRAM
-3-
Trouble Shooting Guide - Modulated Transmissions
I Introduction
Standard Clark Service manual pressure and flow check procedures must be supplemented with this guide for modulated
transmission assemblies. However, relatively simple procedures may be employed to assist in trouble shooting these
transmissions. These procedures are written to assist in leakage checks and to enable isolation of problem areas.
II Modulated Transmission Design

A. Modulated Transmission Concepts
1. A complete modulation circuit is provided for each clutch being modulated. Included are.a differential
pressure regulator and a spring loaded accumulator. Such a valve circuit is shown schematically on page 6.
2. All modulator circuits are in hydrualic parallel to clutch supply lines. They do not interrupt the circuit at any
time. A flow limiting orifice is designed into each modulation valve assembly. Consequently conventional
regulated pressure ports, often noted as clutch pressure ports no longer indicate actual clutch pressure for
forward and reverse clutches. (See B 2 & 3 below).
3. All current modulated transmission directional clutch pistons employ a fixed bleed orifice. Due to the com-
bination of clutch leakage, piston bleed orifice flow rate, and flow limited orifices, directional clutch pressure
will be slightly lower than regulated pressure.
B. Pressure Gauge Ports

1. Refer to pages 7 & 8 for locations of directional clutch pressure check ports.
2. Note that the control valve forward and reverse check ports of 18000, 24000, 28000, 32000 & 34000
transmissions cannot be used to check actual clutch pressures of modulated units.
3. The 1000 series transmission control valve ports can be used to check directional clutch pressure.
C. Pre-Test Study
1. Proper transmission identification is required prior to test. For example the 28000 transmission check out pro-
cedures are different for an R model and HR model.
2. Modulated transmission charging pump size should be determined prior to test.
Ill Transmission Leakage Studies

A. Clutch Pressure Study
1. Locate gauge ports for regulated, forward clutch, and reverse clutch pressures. A 400 PSI [2758,0 Kpal
gauge is recommended for use at these ports.
2. Warm system up to operating temperature (I 80 to 200° F [82,2 - 93,3O Cl at converter outlet). Always use
parking brake when making pressure checks.
3. At idle (assumed to be 650800 RPM) measure and record directional clutch pressures in forward and reverse
(use 3rd or 4th range). At idle, with the direction control in neutral, measure and record system regulated
clutch pressure, in all ranges, 1, 2, 3, 4.
-4-
CLRRK
4. Use following table to evaluate data. Note that data indicates 2nd clutch repair is required.
Example:
Clutch System Regulated Clutch Pressure Mod. Clutch Pressure
Dir.-Range PSI Kpa Fwd. PSI Kpa Rev. PSI Kpa
Fwd.-4th 255 [I 758,l I 240 [1654,71 0

Rev. -4th 255 [1758,11 0 225 [1551,21
Neut.-I 255 [1758,11 0 0
Neut.-2 235 [I 620,21 0 0
Neut.-3 255 [1758,11 0 0
Neut. -4 255 [1758,11 0 0
Table No. 1
Clutch Pressure Study at Idle
Do to the combination of clutch leakage, piston bleed orifice flow rate, and flow limiting orifices, direc-
tional (fwd. and rev.) clutch pressure can be as much as 30 psi [206,8 Kpal, lower than the system
regulated clutch pressure.
Maximum
Range Clutch
Trans. Reg. Pressure
Model System Regulated Clutch Pressure Difference
PSI Kpa PSI KPa

18000 180-220 [I 241 ,l - 1516,81 5 [34,41
24000 240 - 280 [I 654.7 - 1930,51 5 [34,41
28000 240 - 280 [I 654,7 - 1930,51 5 [34,41
32000 240 - 280 [I 654,7 - 1930,51 5 134.41
34000 240 - 280 [1654,7 - 1930,51 5 [34,41
4000 240 - 280 [I 654,7 - 1930,51 5 w,41
5000 180 - 220 11241.1 - 1516,81 5 [34,41
6000 180-220 [I 241 ,I - 1516,81 5 [34,41
8000 180-220 [I 241 ,I - 1516,81 5 [34,41
16000 180-220 [1241 ,l - 1516,81 5 [34,41
IV Techniques for Problem Isolation
A. Transmission Malfunctions
1. Low Clutch Pressure
Assume an operation malfunction that results in lack,of propulsion due to little or no pressure in forward or
reverse clutches.
The lack of acceptable directional clutch pressure may be due to clutch leakage or due to modulator malfunc-
tion. To isolate proceed as follows.
a. Install .375 dia. x 1.125 [9,525 x 28,565 mm] pin inside modulator
regulator spool. This blocks valve shut.
,.375 DIA X 1.125 PIN
-5-
b. If pressure at clutch increases to acceptable level, assume clutch is good.
Assume modulator malfunction.
c. If pressure remains low, assume clutch is leaking.
ALWAYS REMOVE PIN AFTER TEST. DO NOT Al-TEMPT TO ELIMINATE MODULATION BY

BLOCKING REGULATOR SHUT. CLUTCHES OF DIFFERENT DESIGN ARE REQUIRED TO
ELIMINATE MODULATION SAFELY.
2. Harsh Shift or Excessively Delayed Shift
If modulation is ineffective, problem could be associated with modulator or with clutch. If problem is in
modulator, a regulator or accumulator spool may be bound up. Accumulator spring breakage is also possible.
To study, observe action of a directional clutch pressure gauge. On a modulated clutch you should note a
distinct pause in application of pressure. If clutch pressure remains at a low level with the engine at idle and
doesn’t rise, repair of the modulator valve or clutch pack is indicated.
B. Modulation Valve Service
1. The modulation valve assemblies can be cleaned. The regulator spool orifice (approximately .030 [0.76mml
diameter) and spool ball check should be checked for dirt. Spools should all be free to move in their respec-
tive bores.
MODULATION VALVE SCHEMATIC
REGULATOR SPOOL ORIFICE
20 PSI
DIFFERENTIAL PRESSURE REGULATOR
SPRING LOADED ACCUMULATOR 1 1
PISTON
BLEED
ORIFICE
-
CHARGE PUMP c
Q
REGULATED QUICK RELEASE
PRESSURE BALL CHECK
FLOW LIMITING
SUPPLY ORIFICE
FROM CONTROL VALVE
I -
PRESSURE ON THIS SIDE OF THE FLOW
LIMITING SUPPLY ORIFICE COULD BE AS MUCH
AS 30 PSI LOWER THAN THE CHARGE PUMP
REGULATED PRESSURE.
CLUTCH PISTON
DIRECTIONAL
CLUTCH
*VENTTO TRANSMISSION SUMP OR, ON SOME MODELS, TOTHETRANSMISSION LUBE. PRESSURE
-6-
ELqRK
4000-5000-6000-8000-1 SO00 CHECK PORTS
LUBE PRESSURE
PORT
MODULATED 28000AND 32000 TRANSMISSION
FORWARD CLUTCH
PRESSURE PORT
NOTE: DO NOT USE 28000

CONTROL VALVE PORTS FOR
MODULATED TRANSMISSION
DIRECTIONAL CLUTCH PRESSURES
REVERSE CLUTCH
PRESSURE PORT PORT 7”
‘
FORWARD CONTROL
VALVE PRESSURE
PORT 3”
‘
REVERSE CONTROL
VALVE PRESSURE
-7-
18000 MODULATED TRANSMISSION CMRK
CHECK PORTS
REVERSE CLUTCH PRESSURE PORT

-SEE MODULATOR BELOW
NOTE: DO NOT USE CONTROL

VALVE TEST PORTS FOR
DIRECTIONAL CLUTCH PRESSURES
MODULATED
REVERSE CLUTCH
PRESSURE PORT
MODULATOR
LUBE PRESSURE
PORT
-8-
CLSRK 18000 & 34000 SERIES MODULATION
(See Page 19 for 34000 Check Ports)
FLOW LIMITING
FORWARD ACCUMULATOR -/
FORWARD REGULATOR
,REGULATOR
SPOOL
ORIFICE
REVERSE REGULATOR p
CHECK PORT
MODULATED
CLUTCH PRESSURE

The spike pressure is used to quickly fill the clutch pressure
supply passages with oil.
REVERSE ACCUMULATOR
FLOW LIMITING
ORIFICE
FORWARD ACCUMULAT
FORWARD REGULATOR
-4 SPOOL
REGULATOF
ORIFICE
I
REVERSE REGULATOR
&- MODULATED
CLUTCH PRESSI JRE

CHECK PORT
-9-
18000 Et 34000 SERIES MODULATION
(See Page 19 for 34000 Check Ports)
EL9RK
TRANSMISSION
REVERSE ACCUMULATOR
FORWARD ACCUMULATOR
FORWARD REGULATOR
- REGULATOR
SPOOL
REVERSE REGULATOR ORIFICE
.,
FLOW
LIMITING
ORIFICE MODULATED
REVERSE
CLUTCH PRESSURE
CHECK PORT
MODULATED
, PRESSURE CLUTCH PRESSURE

The spike pressure is used to quit
REVERSE +$-
REVERSE ACCUMULATOR
FORWARD ACCUMULATOR
FORWARD REGULATOR
REGULATOR
REVERSE REGULATOR
FLOW
LIMITING
ORIFICE CHECK PORT
-lO-
I
MODULATED FORWARD CLUTCH 1 1
PRESSURE CHECK PORT I
r----y
TRANSMLSSION
FORWARD .- -.
FROM SUPPLY
QUICK RELEASE
BALL CHECK
REGULATOR
TO FORWARD
CLUTCH PRESSURE
MODULATED
This pressure spike is iime required for spools to react.

The spike pressure is used to quickly fill the clutch pressu
MODULATED FORWARD CLUTCH

PRESSURE CHECK PORT 1
,------l
I
FROM SUPPLY
SUPPLY ORIF
TO FORWARD
CLUTCH
SPOOLS
OVER FOR REVERSE

MODULATION
EMRU
f
TRANSMISSION
REVERSE
FLOW LIKITING
SUPPLY ORIF’CE
QU!CK RELEASE
TG REVERSE
CLU;CJ+
-
REVERSE J /
REGULATOR
CLiiTCH PRESSWE
This pressure spike iS tin%? retjuire:: %I: SpOO!S t3 XaCt.

The Spike pre$Sure is used to quickly iiii the ziu:C
supply passages witI4 oii.
- REGULATOR
4 CHECK PORT SPOOL
$
ORIFICE
TC REVERSE
_, . *7-n, _ QUICK RELEASE
BALL CHECK
-12-
CLqRK

(See Page 7 for Check Port Location)

The spike pressure is used to quickly fill the clutch pressure
CHARGING PUMP
FLOW FROM
I
MODULATED
CONTROL
COVER $
2
w”
::
FLOW LIMITJNG
TO CLUTCH
TO MODULATOR VALVE
FROM CONTROL VALVE FROM CONTROL VALVE

QUICK RELEASE I I
BALL CHECK
\ I
REGULATOR
SPOOL
_--
I-
I
t
L ---
Acc”M”-+g
SPOOL
/L?A3TRk START OF SHIFT SHIFT COMPLETE
2
-13-
CMRK
li lb \
9
-14-
CLqRK 4000-5000-6000 SERIES MODULATION
(See Page 7 for Check Port Location)
4000-5000AND 6000 SERIES

CONTROL COVER
REGULATOR / ull-
\ FORWARD
/
REVERSE REGULATOR
FORWARD
ACCUMULATOR
\ ACCUMULATOR I /
-15-
-16-
r
-17-
SUPPLY
SUPPLY 1
4 --
OIL CIRCUIT 81 PLUMBING DIAGRAM
FOR LOCK-UP MODULATOR VALVE
SUPPLY
--
LOCK-UP SOLENOID SUPPLY FROM MODULATOR VALVE

VALVE OPTION
REMOTE MOIJ
bmT.?;P MODULATOR TO LOCK-UP
t DRAIN
CL-27O/CL-32O/CL-5000 8, CL-8000 TORQUE CONVERTER

81 R-28000 / R-32000 TRANSMISSION
n
x
CLclRW
\ i IA.
I
\
L------__-
L--------------e
/
I
-lS-
ELSRK
18000 AND 24000 SERIES
Supply to Lock-up and

Modulator Valve.
Supply from Modulator

Valve to Lock-up.
I
Remote Mounted
Lock-up Valve
*
and Modulator Assembly.
1
-2o-
C500 Y2235 Group 06
SECTION 5
TRANSMISSION MAINTENANCE
AND SERVICE
The “28000 Powershift Transmission” vendor
literature inserted afterthis page illustrates the
“Fiber Gear” used prior to lot 8518. This was
then replaced with a “Flex Plate” which is
illustrated per Picture Page 06-631 on the
back of Section 4 Title page and on the back of
this page showing the engine to transmission
installation including the flex plate.
Also, Figure H of this Vendor Literature illus-
trates a shoe and drum type of parking brake
which is not used. See Groups 23 and 24 for
information on the truck parking brake.
A WARNING A CAUTION
Hydraulic fluid is toxic to skin, Do not reuse old transmission
eyes and respiratory tract. Avoid fluid. Refill with Clark transmis-
skin and eye contact. Good gen- sion fluid, part number 2776236.
eral ventilation is normally ad- This fluid contains additives that
equate. condition clutch friction discsand
extend their life.
A WARNING
Gasoline is not an acceptable
cleaning solvent because of its
extreme combustibility. It is
undafe in the workshop environ-
ment.
SM575 Copyrighted
SectionMaterial
Title Page July 97
C500 Y2235 Group 06
July 97 Copyrighted
Section Title PageMaterial SM575
28000
I
I w
I
I
Powershift
Transmission
HR MODEL 3SPEED SHORTDROP
CLARKkHURTHB
COMPONENTS
SM HR-28310(Rev.l0-94)
Do not sell or distribute I
1293 Glenway Dr.
TOWING OR PUSH STARTING
Before towing the vehicle, be sure to lift the NOTE: If the transmission has 4 wheel drive,
rear wheels off the ground or disconnect the disconnect both front and rear drivelines.
driveline to avoid damage to the transmission Because of the design of the hydraulic system,
during towing. the engine cannot be started by pushing or
towing.
0 Copyright Clark Equipment Company, 1992,1994

Unpublished material All rights reserved
No part of this work may be reproduced in any form
under any means without direct written permission of
Clark Equipment Company.
FOREWORD
This manual has been prepared to provide the customer and the
maintenance personnel with information and instructions on the mainten-
ance and repair of the CLARK-HURTH COMPONENTS product.
Extreme care has been exercised in the design, selection of materials and
manufacturing of these units. The slight outlay in personal attention and
cost required to provide regular and proper lubrication, inspection at
stated intervals, and such adjustments as may be indicated will be
reimbursed many times in low cost operation and trouble free service.
In order to become familiar with the various parts of the product, its
principle of operation, trouble shooting and adjustments, it is urged that
the mechanic study the instructions in this manual carefully and use it as a
reference when performing maintenance and repair operations.
Whenever repair or replacement of component parts is required, only Clark-

Hurth Components-approved parts as listed in the applicable parts
manual should be used. Use of “will-fit” or non-approved parts may
endanger proper operation and performance of the equipment. Clark-
Hurth Components does not warrant repair or replacement parts, nor
failures resulting from the use of parts which are not supplied by or
approved by Clark-Hurth Components. IMPORTANT: Always furnish the
Distributor with the serial and model number when ordering parts.
TABLE OF CONTENTS
HOW THE UNITS OPERATE
SECTIONAL VIEWS AND PARTS IDENTIFICATION
Basic Design Silhouette ............................... Fig. A
ConverterGroup ................................... ..Fig .B
Converter and Transmission Case Group .................. Fig. C
3 Speed Clutch and Gear Group ......................... Fig. D
Clutch Group ........................................ Fig. E
Regulating Valve, Charging Pump and Filter Group .......... Fig. F
Control Valve Assembly ............................... Fig. G
Mechanical Parking Brake .............................. Fig. H
Assembly Instruction Drawing .......................... Fig. I
External Plumbing Diagram ............................ Fig. J
DISASSEMBLY OF TRANSMISSION ............................. 1
CLEANING AND INSPECTION .................................. 12
REASSEMBLY OF TRANSMISSION ............................. 13
SERVICING MACHINE AFTER TRANSMISSION OVERHAUL ......... .26
SPECIFICATION AND SERVICE DATA ........................... .27
LUBRICATION ............................................. .27
TROUBLE SHOOTING GUIDE ................................. .28
HR MODEL TYPICAL THREE SPEED POWER FLOW ................ .29
CLUTCH AND GEAR ARRANGEMENT .......................... .30
SHIELDED BEARING INSTALLATION ........................... .32
RING GEAR INSTALLATION ........................... .34-35-36-37
SPEED SENSOR BUSHING INSTALLATION ...................... .38
DRIVE PLATE INSTALLATION ............................... .40-41
NOTE: Metric Dimensions Shown in Brackets 1 I.
TRANSMISSION ASSEMBLY
The transmission and hydraulic torque portion of the power train enacts an important role in transmitting engine power to
the driving wheels. In order to properly maintain and service these units it is important to first understand their function and
how they operate.
The transmission and torque converter function together and operate through a common hydraulic system. It is necessary to
consider both units in the study of their function and operation.
To supplement the text below, and for reference use therewith, the following illustrationsare provided:
Basic Design Silhouette
Converter Assembly
Converter and Transmission Case Group
Three-Speed Case and Clutch Group
Clutch Group
Regulating Valve, Charging Pump and Filter Group
Control Valve
Mechanical Parking Brake
Typical 28000 Cross Section
External Plumbing Diagram
Typical Three-Speed Power Flow
Clutch and Gear Arrangement
Ring Gear Installation
Shielded Bearing Installation
The R, HR, and MHR Model Transmissions are of three basic designs.
The R Model consists of a separate torque converter, mounted to the engine with the powershift transmission remotely
mounted and connected to the torque converter with a drive shaft.
The HR Model consists of a torque converter and powershifted transmission in one package mounted directly to the engine.
The MHR version is a mid-mount torque converter and transmission assembly connected to the engine by means of a drive
shaft. (See Fig. A for basic design silhouette.)
The shift control valve assembly may be mounted directly on the side of the converter housing or front transmission cover, or
remote mounted and connected to the transmission by means of flexible hoses. The function of the control valve assembly is
to direct oil under pressure to the desired directional and speed clutch. A provision is made on certain models to neutralize
the transmission when the brakes are applied. This is accomplished through use of a brake actuated shutoff valve. The speed
and direction clutch assemblies are mounted inside the transmission case and are connected to the output shaft of the
converter either by direct gearing or drive shaft. The purpose of the speed or directional clutches is to direct the power flow
through the gear train to provide the desired speed range and direction.
HOW THE UNITS OPERATE
With the engine running, the converter charging pump draws oil from the transmission sump through the removable oil
suction screen and directs it through the pressure regulating valve and oil filter.
The pressure regulating valve maintains pressure to the transmission control cover for actuating the direction and speed
clutches. This requires a small portion of the total volume of oil used in the system. The remaining volume of oil is directed
through the torque converter circuit to the oil cooler and returns to the transmission for positive lubrication. This regulator
valve consists of a hardened valve spool operating in a closely fitted bore. The valve spool is spring loaded to hold the valve in
a closed position. When a specific pressure is achieved, the valve spool works against the spring until a port is exposed along
the side of the bore. This sequence of events provides the proper system pressure.
After entering the converter housing the oil is directed through the stator support to the converter blade cavity and exits in
the passage between the turbine shaft and converter support. The oil then flows out of the converter to the oil cooler. After
leaving the cooler, the oil is directed to a fitting on the transmission. Then through a series of tubes and passageslubricates
the transmission bearings and clutches. The oil then gravity drains to the transmission sump.
The hydraulic torque converter consists basically of three elements and their related parts to multiply engine torque. The
engine power is transmitted from the engine flywheel to the impeller element through the impeller cover. This element is the
pump portion of the hydraulic torque converter and is the primary component which starts the oil flowing to the other
components which results in torque multiplication. This element can be compared to a centrifugal pump in that it picks up
fluid at its center and discharges at its outer diameter.
The torque converter turbine is mounted opposite the impeller and is connected to the output shaft of the torque converter.
This element receives fluid at its outer diameter and discharges at its center. Fluid directed by the impeller out into the
particular design of blading in the turbine and reaction member is the means by which the hydraulic torque converter
multiplies torque.
The reaction member of the torque converter is located between and at the center or inner diameters of the impeller and
turbine elements. Its function is to take the fluid which is exhausting from the inner portion of the turbine and change its
direction to allow correct entry for recirculation into the impeller element.
The torque converter will multiply engine torque to its designed maximum multiplication ratio when the output shaft is at
zero RPM. Therefore, we can say that as the output shaft is decreasing in speed the torque multiplication is increasing.
The shift control valve assembly consists of a valve body with selector valve spools. A detent ball and spring in the selector
spool provides one position for each speed range. A detent ball and spring in the direction spool provides three positions, one
each for forward, neutral and reverse.
With the engine running and the directional control lever in neutral position, oil pressure from the regulating valve is blocked
at the control valve, and the transmission is in neutral. Movement of the forward and reverse spool will direct oil, under
pressure to either the forward or reverse direction clutch as desired.
When either directional clutch is selected the opposite clutch is relieved of pressure and vents back through the direction
selector spool. The same procedure is used in the speed selector.
The direction or speed clutch assembly consists of a drum with internal splines and a bore to receive a hydraulically actuated
piston. The piston is “oil tight” by the use of sealing rings. A steel disc with external splines is inserted into the drum and
rests against the piston. Next, a friction disc with splines at the inner diameter is inserted. Discs are alternated until the
required total is achieved. A heavy back-up plate is then inserted and secured with a snap ring. A hub with O.D. splines is
inserted into the splines of discs with teeth on the inner diameter. The discs and hub are free to increase in speed or rotate in
the opposite direction as long as no pressure is present in that specific clutch.
To engage the clutch, as previously stated, the control valve is placed in the desired position. This allows oil under pressure to
flow from the control valve, through a tube, to a chosen clutch shaft. This shaft has a drilled passageway for oil under
pressure to enter the shaft. Oil pressure sealing rings are located on the clutch shaft. These rings direct oil under pressure to a
desired clutch. Pressure of the oil forces the piston and discs against the heavy back-up plate. The discs, with teeth on the
outer diameter, clamping against discs with teeth on the inner diameter, enables the hub and clutch shaft to be locked
together and allows them to drive as a unit.
There are bleed balls in the clutch piston which allow quick escape for oil when the pressure to the piston is released.
HR 28000
(SHORT DROP)
(OUTPUT)
HR 28000 MHR 28000
Copyrighted
FIGURE Material
A
HR 28000 CONVERTER GROUP
Item Description sty. item Description Qty.
Bearing Support Screw . . . . . . 32 Impeller Hub. ................ ....... 1
Bearing Support Screw Lockwasher . . 33 Impeller Hub O-Ring ........... ....... 1
Driving Gear Snap Ring . . . . . . . . . .. 34 Impeller- ................... . . . . . . .1
Drive Gear Bearing . . . . . . . . . . 35 Oil Baffle Retainer Ring ......... . . . 1
Drive Gear Bearing Support .. . . . . . . 36 Oil Baffle ................... . . . . . . .1
Drive Gear . . . . . . . . . . . . . . 37 Oil Baffle Seal Ring ............ ....... 1
Snap Ring (Internal - See item 8) . . . . 38 Detent Spring ................ ....... 2
Drive Gear Hub Sleeve and Snap Ring 39 Detent Ball .................. ....... 2
Assembly - Inc. items 7 and 9. . . .
40 Valve to Converter Gasket . . . ....... 1
9 Snap Ring (External) - See item 8 . . . .
41 Control Valve Housing Assembly . ....... 1
IO Valve Body to Converter Housing Gasket.
42 Valve to Converter Housing Screw
11 Valve Body to Converter Housing O-Ring . Lockwasher .. . . . .. . .. . . . ....... 9
12 Valve Body to Converter Housing O-Ring . . 43 Valve to Converter Housing Screw . ....... 9
13 Valve Body to Converter Housing O-Ring . 44 Turbine Hub Screw Washer . . . . . ....... 8
14 Regulator Valve, Charging Pump and 45 Turbine Hub Screw . . . . . . . ....... 8

Filter Assembly . . . . . .. . . . . . .I
46 Ring Gear Screw . . . . . . . . . . ...... 16
15 Oil Seal . . . . . . . . . . . . . . .. . . .I
47 Ring Gear Screw Plain Washer . .. . ...... 16
16 Impeller Hub Gear . . . . . . .. . . .I
48 Flywheel Ring Gear . . . . . . . ....... 1
17 Impeller Hub Gear Snap Ring . . . .I
49 Impeller Cover Sleeve . . . . .. . . . ....... 1
18 Stator Support Oil Sealing Ring . . .I
50 Impeller Cover to Impeller Screw and
19 Sealing Ring Expander Spring . .. . .I Lockwasher . . . . . .. . . . . . . . . . 24
20 Stator Support . . . .. . . . . . . .I 51 Impeller Cover . . . . . . . .. . ....... 1
21 Turbine Shaft . . . . . . . .. . .I 52 Impeller Cover Bearing . . . . . . ....... 1
22 Turbine Shaft Gear . . . . . . . .I 53 Impeller Cover Bearing Retainer Ring ....... 1
23 Turbine Shaft Gear Retainer Ring .I 54 Impeller Cover O-Ring . . . . . . . . . . . . .1
24 Converter Housing and Tube Assembly .I 55 Turbine Retainer Ring . . . . . . . . . . . .1
25 Turbine Shaft Bearing . . .. . . . .. . . . .I 56 Turbine . . . . . .. . . .. . . . . . ....... 1
26 Turbine Shaft Oil Sealing Ring . . . . .I 57 Turbine Hub . . . . . .. . . . . ....... 1
27 Stator Support Screw Lockwasher .. . . .6 58 Turbine Locating Ring . . . . . . . ....... 1
28 Stator Support Screw . . . . . . .. . . . . .6 59 Reaction Member Retainer Ring . . . . . . .1
29 Hub to Impeller Screw . . . . . . .. . . .8 60 Reaction Member . . . . . . . . .. . . . . . ..1
30 Hub to Impeller Screw Washer . .8 61 Reaction Member Spacer .. . . .. . . ....... 1
31 Impeller Hub Bearing . . . .. . . . .I 62 Impeller Hub Bearing Retainer Ring . ....... 1
2
I 3
43
Copyrighted
FIGURE C Material
HR 28000 CONVERTER AND TRANSMISSION CASE GROUP
Item Description City. Item Description Qty.
1 Suction Tube Assembly ................. .I 37 Tube Clip Screw ...................... .I
2 Converter Housing & Tube Assembly ....... .I 38 Suction Tub O-Ring .................... .I
3 Tube Sleeve ......................... .I 39 Suction Tube Spacer Ring ................ 1

4 Tube Sleeve ......................... .I ..... 1
40 Suction Tube Retainer Screw Lockwasher
5 Converter Housing Sleeve ................ 1 1
41 Suction Tube Retainer Screw ..............
6 Converter Housing Sleeve Lock. ........... .I
42 Tube Sleeve ......................... .I
7 Converter Housing Sleeve Screw Lockwasher . . 1
43 Pressure Tube O-Ring .................. .I
8 Converter Housing Sleeve Screw ........... 1
44 Converter Housing to Transmission
9 Converter Housing Sleeve Screw ........... 1 Case Gasket ...................... .I
10 Converter Housing Sleeve Screw Lockwasher . . 1
11 Converter Housing Sleeve Lock. ............ 1 Case Dowel Pin .................... .2
12 Converter Housing Sleeve ................ 1 46 Low Speed Clutch Pressure Tube ........... 1
13 Breather. ........................... .I 47 Transmission Case to Converter Housing

14 Street Eli ........................... .I Screw Lockwasher. ................. 10
15 Street Eli Reducing Bushing .............. .I 48 Transmission Case to Converter

Housing Screw ................... .I0
16 Tube Sleeve ......................... .3
49 Transmission Case Assembly ............. .I
17 Pipe Plug ........................... .I

50 Transmission Case to Rear Cover Dowel Pin .. .2
Housing Screw Lockwasher. ........... .4 51 Transmission Case to Rear Cover Gasket ...... 1
19 Converter Housing to Transmission 52 Transmission Case Rear Cover ............. 1

Housing Screw .................... .4
53 Rear Cover to Case Screw Lockwasher ..... .I3
Housing Lockwasher ................ .4 54 Rear Cover to Case Screw ............... 13
21 Converter Housing to Transmission 55 Rear Cover Pipe Plug .................... 1

Housing Screw .................... .4
56 Rear Cover to Transmission Case Stud Nut ... .2
22 Lube Tube Retaining Screw ............... 1
57 Rear Cover to Transmission
23 Lube Tube Retaining Screw Lockwasher ..... .I Case Lockwasher. .................. .2
24 Valve Oil Supply Tube .................. .I 58 Tube Sleeve O-Ring ..................... 1
25 3rd Speed Tube O-Ring .................. 1 ......................... .I
59 Tube Sleeve
26 3rd Speed Tube Assembly ................ 1
60 Transmission Case to Rear Cover Stud ...... .2
27 Tube Clip.. .......................... .
61 Drain Plug .......................... .I
28 Tube Clip Screw Lockwasher ............. .I
62 Oil Level Plug ........................ .I
29 Tube Clip Screw ...................... .I
63 Screen Assembly Gasket ................ .I
30 Lube Tube Assembly .................... 1
64 Screen Assembly ..................... .I
31 Lube Tube Retainer Screw Lockwasher ....... 1
65 Suction Tube Assembly ................. .I
32 Lube Tube Retainer Screw ................ 1
33 Reverse Tube O-Ring .................... 1 66 Pipe Plug ........................... .2
34 Reverse Tube Assembly. ................. 1 67 Suction Tube O-Ring .................... 1
35 Tube Clip ........................... .I 68 Suction Tube Retainer Washer ............. 1
36 Tube Clip Screw Lockwasher .............. 1 69 Suction Tube Retainer Washer Screw ....... .2
I 93
94
Copyrighted
FIGUREMaterial
D
28000 THREE-SPEED CASE AND CLUTCH GROUP
(Short Drop Output)
Item Description Qty. Item Description Qty.
1 Reverse & 3rd Clutch, Shaft Piston Ring ..... .3 53 Front Bearing Retainer Ring .............. 1
IA Piston Ring Expander Spring ............... .3 54 Forward & 2nd Shaft Piston .........
Ring .3
2 Front Bearing Retainer Ring ............... 1 54A Piston Ring Expander Spring .............. 3
3 Reverse & 3rd Shaft Front Bearing .......... 1 55 Low Speed Clutch Shaft Pilot Bearing ....... 1
4 Front Bearing Retainer Ring ............... 1 56 2nd Gear Bearing ..................... 1
5 Shielded Driven Gear Bearing-Shield Out ...... 1 57 Low Gear Bearing Retainer Ring ........... 1
6 Clutch Driven Gear Bearing Snap Ring ........ 1 58 Low Gear Bearing ..................... 1
7 Clutch Driven Gear .................... .1 59 Low Gear Bearing Locating Ring ........... 1
8 Clutch Hub Oil Baffle Ring ................ 1 60 Low Gear ......................... ..l
9 Clutch Driven Gear Bearing Snap Ring ........ 1 61 Low Gear Oil Baffle Ring ................ 1
10 Clutch Driven Gear Bearing ............... 1 62 Low Gear Bearing Locating Ring ........... 1
11 Return Spring Retainer Snap Ring ........... 1 63 Low Gear Bearing ..................... 1
12 Spring Retainer Snap Ring Retainer .......... 1 64 Low Gear Bearing Retaining Ring .......... 1
13 Spring Retainer ........................ 1 65 Return Spring Retainer Snap Ring .......... 1
14 Piston Return Spring .................... 1 66 Spring Retainer Snap Rrng Retainer ......... 1
15 Spring Retainer ........................ 1 67 Return Spring Retainer .................. 1
16 Reverse & 3rd Clutch Shaft & Drum ......... 1 ........................ 1
68 Return Spring
17 Spring Retainer ........................ 1 69 Return Spring Retainer .................. 1
18 Piston Return Spring .................... 1 .......... 1
70 Low Speed Clutch Shaft & Drum
19 Spring Retainer ........................ 1 71 ................... .5
Bearing Cap Screw
20 Spring Retainer Snap Ring Retainer .......... 1
72 Bearing Cap Screw Lockwasher .......... .5
21 Return Spring Retainer Snap Ring ........... 1
73 Rear Cover Bore Plug. .................. 1
22 3rd Gear Bearing. ...................... 1 ................ 1
74 Drive Gear Retainer Ring
23 3rd Gear Bearing Snap Ring ............... 1
75 Low Speed Drive Gear. ................. 1
24 Clutch Hub Oil Baffle Ring ................ 1
76 Output Rear Bearing Lock Ball ............ 1
25 3rd Gear ........................... .I
77 Low Shaft Rear Bearing ................. 1
26 3rd Gear Bearing Spacer ................. 1
78 Low Shaft Rear Bearing Retainer Ring ....... 1
27 3rd Gear Bearing Snap Ring ............... 1
79 Low Shaft Piston Ring .................. 1
28 3rd Gear Bearing - Shield Out. ............ 1
80 Low Shaft Piston Ring .................. 1
29 Reverse & 3rd Shaft Rear Bearing ........... 1
81 Rear Bearing Cap Gasket ................ 1
30 2nd Gear ............................ 1
82 Rear Bearing Cap O-Ring ................ 1
31 Clutch Hub Oil Baffle Ring ................ 1
83 Low Shaft Rear Bearing Cap. ............. 1
32 2nd Gear Retainer Ring .................. 1
84 Low Shaft Rear Bearing Cap Plug .......... 1
33 Return Spring Retainer Snap Ring ........... 1
85 Rear Bearing Cap Oil Seal ............... 1
34 Spring Retainer Snap Ring Retainer .......... 1
86 Rear Bearing Cap Screw ............... .4
35 Spring Retainer ....................... .I
87 Rear Bearing Cap Screw Lockwasher. ...... .4
36 Piston Retainer ........................ 1
88 Output Shaft Bearing Cap ............... 1
37 Spring Retainer ........................ 1
89 Output Shaft Bearing Cap Gasket .......... 1
38 Forward & 2nd Clutch Shaft & Drum ........ 1
90 Rear Bearing Spacer ................... 1
39 Spring Retainer ........................ 1
91 Rear Bearing Locating Ring. .............. 1
40 Piston Return Spring .................... 1
92 Output Shaft Rear Bearing ............... 1
41 Spring Retainer ........................ 1
.......... 1 93 Output Shaft Gear. .................... 1
42 Spring Retainer Snap Ring Retainer
........... 1 94 Output Shaft Gear Retaining Ring .......... 1
43 Return Spring Retainer Snap Ring
44 Clutch Driven Gear Bearing ............... 1 95 Output Shaft ........................ 1
Clutch Driven Gear Bearing Snap Ring ........ 1 96 Output Shaft Front Bearing .............. 1
45
Clutch Hub Oil Baffle Ring ................ 1 97 Bearing Locating Ring .................. 1
46
47 Clutch Driven Gear ..................... 1 98 Bearing Retaining Ring .................. 1
48 Clutch Driven Gear Bearing Snap Ring ........ 1 99 Transmission Case Assembly ............. 1
49 Shielded Driven Gear Bearing-Shield Out ...... 1 100 Output Companion Flange ............... 1
50 Front Bearing Retainer Ring ............... 1 101 Flange O-Ring ........................ 1
51 Front Bearing Locating Ring ............... 1 102 Flange Nut Washer .................... 1
52 Forward & 2nd Shaft Front Bearing .......... 1 103 Flange Nut .......................... 1
LOW CLUTCH GROUP
,---’ 2 3 4 5 6 7
________________
REVERSE & 3RD CLUTCH GROUP
--_.__
__
01
7
,___________________--______________________--________------------__
7 8
1
FORWARD & 2ND CLUTCH GROUP
FIGURE E Material
Copyrighted
LOW CLUTCH GROUP
Itern Description Qty.
1 End Plate Retainer Ring ............ _ ..................................................... 1
2 EndPlate ............................................................................... 1
3 ClutchlnnerDisc ......................................................................... 9
4 Clutch Outer Disc ........................................................................ 9
5 Clutch Piston ............................................................................ 1
6 Clutch Piston Outer Seal Ring ............................................................... 1
7 Clutch Piston Inner Seal Ring ............................................................... 1
8 Low Speed Clutch Drum and Shaft ........................................................... 1
REVERSE AND 3rd CLUTCH GROUP
Item Description Qty.
1 EndPlateRetainer Ring ................................................................... 2
2 EndPlate ............................................................................... 2
3 Clutch Inner Disc ........................................................................ 12
4 ClutchOuterDisc ....................................................................... 12
5 ClutchPiston ............................................................................ 2
6 Clutch Piston Outer Seal Ring ............................................................... 2
7 Clutch Piston Inner Seal Ring ............................................................... 2
8 Reverse and 3rd Clutch Drum andShaft ....................................................... 1
FORWARD AND 2nd CLUTCH GROUP
item Description Qty.
End Plate Retainer Ring.. .................................................................. 2
EndPlate .............................. ..‘..........................................._ . ..2
Clutch Inner Disc ........................................................................ 12
ClutchOuter Disc ....................................................................... 12
ClutchPiston ............................................................................ 2
Clutch Piston Outer Seal Ring ............................................................... 2
Clutch Piston Inner Seal Ring ............................................................... 2
Forward and 2nd Clutch Drum and Shaft ...................................................... 1
CHARGING PUMP
I
PUMP DRIVE SLEEVE
POSITION
Copyrighted
FIGURE Material
F
PRESSURE REGULATOR VALVE, CHARGING PUMP & OIL FILTER GROUP
Item Description Qty. Item Description Qty.
Charging Pump Drive Sleeve. . .. . . . .1 26 Valve to Housing Stud Lockwasher ......... .4
Pump Sleeve Snap Ring . . . . . . . . . .1 27 Valve to Housing Stud Nut. .............. .4
Valve to Housing Gasket . . . . . .. . . . 1 28 Thrust Plate & Bearing Assembly .......... .2
4 Valve Body O-Ring . . . . . . . . 1 29 Wave Spring. ........................ .2
5 Valve Body O-Ring . . . . . ....... . 1 30 Pump Shaft Seal ...................... .2
6 Pipe Plug . . . . . . . .. . . . ....... . .1 31 Pump to Filter Adaptor Screw Lockwasher. ... .4
7 Safety Valve Seat . . . . .. . . . ....... . .1 32 Pump to Filter Adaptor Screw. ............ .4
8 Safety Valve Spacer . . .. . . . ....... . .1 33 Pump Drive Shaft Assembly .............. .I
9 Safety Valve Plunger . . .. . .1 34 Pump Drive Shaft Oil Seal ................ 1
10 Safety Valve Spring. . .. . . 1 35 Pressure Regulator Valve ................. 1
11 Valve Stop O-Ring. .......... . . .. . 36 Valve Body Roll Pin .................... .3
12 Valve stop ................ . . . 37 Valve Body O-Ring ..................... 1
13 Valve Stop Roll Pin .......... . . . 38 Pump to Filter Gasket ................... 1
14 Valve Stop Roll Pin .......... . . . 39 Filter Adaptor ........................ .I
15 Valve stop ................ . . . 40 Filter Adaptor Plug ..................... 1
16 Valve Stop O-Ring. .......... 41 By-Pass Filter Disc Spring ................ 1
17 Valve Piston ............... 42 By-Pass Filter Disc ..................... 1
18 Valve Spring - Inner. ........ 43 By-Pass Filter Disc Seat .................. 1
19 Valve Spring - Outer ........ 44 Filter Seat Retainer Ring. ................. 1
20 Valve to Converter Housing Stud 45 Filter Housing O-Ring. ................... 1
21 Valve Body to Pump Gasket .... 46 Oil Filter Element Assembly ............... 1
22 Pump Body Snap Ring _ ....... 47 Oil Filter Element Spring. ................. 1
23 Thrust Plate & Bearing Assembly 48 Filter Housing ........................ .I
24 Pump Driven Shaft Assembly . . . 49 Pipe Plug ........................... .I
25 Charging Pump Housing. . . . _. . 50 Optional Adaptor for Remote Filter .......... 1
DECLUTCH DECLUTCH DECLUTCH
FDRWARD6REVERSE REVERSE ONLY FORWARD ONLY INCHING
a 22- e
-22 22- =
@ @
%a
a-23 23-a a-23
23-a
e-24 24- 8 8 -24
24-8
e-25 25-8 e-25
25-
26-
8 u -26
21- 26-
28- e
29-a
30-o 29-Q
30-
-32
-32
1G.A IG.8 1G.C

32-
I
L______________L__ _____L__--
33-t3
B-20
34-B
35-e
a--19
a-18
36-
@ -17
l-
0 Q
2- 0
3-a
F IG. D
4-
LESS
DECLUTCH
5-
24-
:IG.E ,
HYDRAULICALLY OPERATED CONTROL VALVE
Copyrighted
FIGURE G Material
CONTROL VALVE ASSEMBLY
Item Description city.
1 ValveSpool OilSeal .................................................................... 1
2 Valve Spool Oil Seal Retainer Ring ......................................................... 1
3 Valve Spool Oil Seal Washer .............................................................. 1
4 Forward and Reverse Valve Spool .......................................................... 1
5 Control Valve Assembly - Incl. items 1 thru 9,15,16 and 18 thru 20 .............................. 1
6 Neutral Switch Detent Ball ............................................................... 1
7 Neutral Switch ........................................................................ 1
8 Valve HousingPlug.. ................................................................... 1
9 Valve Housing Plug “0” Ring ............................................................. 1
IO OvershiftSpacer ....................................................................... 1
11 Detent Spring Plug (Optional) ............................................................. 1
12 Detent Spring Plug Washer (Optional) ....................................................... 1
13 DetentSpring(Optional) ................................................................ 1
14 DetentBail(Optional) .................................................................. 1
15 Speed Selector Spool Pipe Plug ............................................................ 1
16 SpeedSelector ........................................................................ 1
17 OvershiftSpacer ....................................................................... 1
18 ValveSpool Oil Seal Washer .............................................................. 1
19 Valve Spool Oil Seal Retainer Ring ......................................................... 1
20 ValveSpool Oil Seal .................................................................... 1
21 Hydraulic Piston Housing Assembly ........................................................ 1
NOTE: Items 22 thru 25,32,33 and 37 are various declutch options.
38 Adaptor to Converter Housing Screw ....................................................... 4
39 Adaptor to Converter Housing Screw Lockwasher ............................................. 4
40 Valve Adaptor Housing .................................................................. 1
41 Converter Housing to Valve Adaptor Housing Gasket ........................................... 1
42 Adaptor Housing to Converter Housing Screw ................................................ 5
43 Adaptor Housing to Adaptor Plate Gasket ................................................... 1
44 Valve Adaptor Plate .................................................................... 1
NOTES
MECHANICAL PARKING BRAKE
Item Description Qty.
1 Backing Plate Assembly .................................................................... 1
2 Actuating Lever .......................................................................... 1
3 BrakeShoe,and Lining ..................................................................... 2
4 BrakeFlange ............................................................................ 1
5 BrakeDrum.............................................................‘................ 1
6 Brake Drum to Flange Screw Lo&washer ...................................................... 6
7 BrakeDrumtoFlangeScrew ................................................................ 6
8 ReturnSpring ........................................................................... 2
9 BrakeShoe(Seeitem 3) ................................................................... -
10 BrakeLining ............................................................................ 2
11 Rivet ................................................................................. 20
12 Backing PlateScrew ....................................................................... 4
13 Backing Plate Screw Lockwasher ............................................................. 4
FIGURE H
USE PERMATEX & CRANE SEALER ONLY WHERE SPECIFIED.
ALL LEAD IN CHAMFERS FOR OIL SEALS, PISTON RINGS & 0’

‘ RINGS
MUST BE SMOOTH & FREE FROM BURRS. INSPECT AT ASSEMBLY.
LUBRICATE ALL PISTON RING GROOVES & 0” RINGS WITH OIL

BEFORE ASSEMBLY.
APPLY VERY LIGHT COAT OF PERMATEX NO. 2 TO O.D. OF ALL OIL

SEALS BEFORE ASSEMBLY.
AFTER ASSEMBLY OF PARTS USING PERMATEX OR CRANE SEALER,
THERE MUST NOT BE ANY FREE OR EXCESS MATERIAL THAT COULD
ENTER THE OIL CIRCUIT.
APPLY LIGHT COAT OF CRANE SEALER TO ALL PIPE PLUGS.

APPLY A THIN COATING OF GREASE BETWEEN SEAL LIPS ON LIP
TYPE SEALS PRIOR TO ASSEMBLY.
APPLY A LIGHT COAT OF PERMATEX NO. 2 TO ALL THRU HOLE STUD

THREADS.
BEFORE ASSEMBLY OF BVSHING TO COVER
-( NOTE POSITION OF SEAL
TIGHTEN
3. _TURBINE
35 Lb_FTBOLTS /
GEAR TOWARD RETAINER RING
\ [40,7 - 47,4 N.m]
MUST SE LOOSE/INTERNAL FIT BRG.
SEE ELASTIC STOP NUT

/ / TORQUE CHART
a/f _$PPLY
OF PLUG
PERMATEX
BEFORE
NO. 2 TO 0.0.
ASSEMBLY.
LOW CLVTCH
S-OUTER STEEL PLATES
9 INNER FRICTION PLATES
ASSEMBLE ALTERNATELY STARTING
WITH OUTER STEEL PLATE.
OUTPUT II
k- SEE ELASTIC STOP NUT
7. TORQUE CHART
“~ 1-I -;3K$LM~“‘CAL
/ 1
TIGHTEN OIL SCREEN ASSY.

10 - 15 Lb-FT
[13,6 - 20.3 N-m] NOTE METRIC DIMENSIONS
SHOWN !N BRACKETS [ 1
28310 SERIES POWER SHIFT TRANSMISSION WITH VARIOUS OPTIONS
FIGURE
Copyrighted I
Material
COOLER
INSTALL GAUGE IN THIS LINE

FOR CONVERTER “OUT” PRESSURE*
CLUTCH PRESSURE
ii CHECK POINT**
OIL LEVEL
FROM COOLER TO / CHECK POINT
TRANSMISSION LUBE
DISTRIBUTOR
CHARGING PUMP
OIL SUCTION SCREEN
28000 SERIES PLUMBING DIAGRAM
FROM CONVERTER
TYPE “A” FILTER

USE REPLACEMENT
ELEMENT 215502
INSTALL GAUGE IN THIS DO NOT SUBSTITUTE
LINE FOR CONVERTER
“OUT” PRESSURE*
CLUTCH PRESSURE
CHECK POINT**
FROM COOLER TO CHECK POINT

TRANSMISSION
LUBE DISTRIBUTOR
NOTE: ALL TYPE “A” FILTERS
w USE CLARK FILTER REPLACEMENT
ELEMENT PART NO. 215502.
CHARGING PUMP OIL
SUCTION SCREEN DO NOT SUBSTITUTE.
28000 SERIES PLUMBING DIAGRAM

(WITH REMOTE FILTER)
*CONVERTER OUT CONVERTER OUTLET OIL TEMP. 160°-2OO=‘F [82,3°-93,30C1TRANSMlSS10N IN NEUTRAL

PRESSURE
OPERATING SPECIFICATIONS:
25 P.S.I. [172,4 kPa] MINIMUM PRESSURE AT 2000 R.P.M. ENGINE SPEED
AND A MAXIMUM OF 70 P.S.I. L482.6 kPa1 OUTLET PRESSURE
WITH ENGINE OPERATING AT NO-LOAD GOVERNED SPEED.
**CLUTCH PRESSURE 240-280 PSI [I 654,8 - 1930,5 kPa1 WITH PARKING BRAKE SET (SEE NOTE). OIL TEMPERATURE
180-200” F. [82,2 - 93,3 o C.], ENGINE AT IDLE (400 TO 600 RPM). SHIFT THRU DIRECTION AND
SPEED CLUTCHES. ALL CLUTCH PRESSURE MUST BE EQUAL WITHIN 5 PSI. [34,5 kPa] IF CLUTCH
PRESSURE VARIES IN ANY ONE CLUTCH MORE THAN 5 PSI. [34,5 kPa1 REPAIR CLUTCH.
NOTE: NEVER USE SERVICE BRAKES WHILE MAKING CLUTCH PRESSURE CHECKS. UNITS
HAVING BRAKE ACTUATED DECLUTCHING IN FORWARD AND/OR REVERSE WILL NOT GIVE A
TRUE READING.
ALWAYS USE PARKING BRAKE WHEN MAKING CLUTCH PRESSURE CHECKS.
FIGURE J Material
Copyrighted
MAINTENANCE AND SERVICE
The instructions contained herein cover the disassembly CAUTION: Cleanliness is of extreme importance and an
and reassembly of the transmission in a sequence that absolute must in the repair and overhaul of this unit. Before
would normally be followed after the unit has been attempting any repairs, the exterior of the unit must be
removed from the machine and is to be completely thoroughly cleaned to prevent the possibility of dirt and
overhauled. It must also be understood that this is a basic foreign matter entering the mechanism.
28000 transmission with many options. Companion flanges
and output shafts with and without disconnect assemblies
may vary on specific models. The units are very similar to
trouble shoot, disassemble, repair, and reassemble.
DISASSEMBLY
Figure 1 Figure 3
Side view of 3-speed short drop output power shift Remove charging pump to regulating valve stud nuts.
Transmission. Remove pump and filter adaptor.
Figure 2 Figure 4
Remove filter housing and filter element. Remove pressure regulating valve assembly.
NOTE: See lubrication section for filter cartridge change interval.
Copyrighted 1Material
Figure 5 Figure 8
Remove pump drive sleeves. Install two bolts in threaded holes 180’ apart to remove cover
from impeller. NOTE: Some units may have pry slots instead
of threaded holes.
Figure 6
Remove control valve bolts and washers. Remove control
valve. Use caution as not to lose detent springs and balls. Figure 9
Remove impeller cover.
Figure 7
Figure IO
Remove impeller cover bolts. If impeller cover bearing is to be replaced, remove retainer
ring. Pry bearing from pocket.
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2
Material
Figure 11 Figure 14
Remove turbine retaining ring. Remove reaction member retainer ring.
Figure 12 Figure 15
Remove turbine and hub assembly. NOTE: For special turbine Remove reaction member and spacer.
to hub assemblv see Daae 33.
Figure 13 Figure 16
Remove turbine locating ring. Remove oil baffle retainer ring.
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Figure 20
Remove pump drive gear bearing support bolts.
Figure 17
Using pry slots in converter housing, pry oil baffle and
impeller from housing.
NOTE: Impeller, oil baffle and impeller hub gear are

removed as an assembly.
Figure 21
Move center gear toward the rear of converter housing.
Remove pump drive gear on the right.
Figure 18
Remove stator support to housing bolts.
Figure 19
Remove stator support.
Figure 22
NOTE: Support must be turned to clear pump drive gear. Remove pump drive gear on the left.
4
Figure 26
Figure 23 Figure 26 shows forward & 2nd clutch locating ring with
Remove center pump drive gear. forward and 2nd clutch in position.
Figure 27
Figure 24 Figure 27 shows forward and 2nd clutch in converter
Remove bolts securing converter housing to transmission housing. If clutch remained in converter housing, spread
housing. ears on snap ring as explained in Figure 25 and remove
clutch. If clutch assembly remained in transmission case
remove same by pulling straight out.
Figure 25
Support converter housing with a chain fall. Using
spreading type snap ring pliers, spread ears on forward
clutch front bearing retaining ring. Holding snap ring open Figure 28
pry converter housing from transmission housing. Remove turbine shaft gear retainer ring and gear.
Figure 29
Figure 32
From rear of converter housing tap turbine shaft and
Remove impeller hub gear.
bearing from housing.
Figure 30 Figure 33
Remove turbine shaft and bearing from converter housing. Lift oil baffle and oil seal assembly from impeller.
Figure 31 Figure 34
Remove impeller hub gear retainer ring. Remove impeller to hub bolts.
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6 Material
Figure 35
Remove impeller hub O-Ring. Figure 38
Remove output flange nut, washer and O-Ring.
Figure 39
Remove output flange.
Figure 36
Remove 2nd gear retaining ring and 2nd gear.
NOTE: If parking brake is used, remove brake drum and
flange, upper and lower brake shoe return springs, brake
shoes, and actuator arm. Remove brake backing plate bolts
and backing plate.
Figure 37 Figure 40
Remove 2nd speed clutch shaft pilot bearing. Remove low shaft bearing cap bolts and bearing cap.
Figure 44
Remove rear cover bolts. Using pry slots provided, pry
Figure 41
cover from transmission housing tapping on low clutch and
Remove output shaft bearing cap bolts and bearing cap. output shaft to allow cover to be removed without shaft
binding.
CAUTION: Do not lose output shaft rear bearing lock ball.
Figure 42
Remove low shaft rear bearing locating ring.
Figure 45
Remove low shaft rear bearing retainer ring.
Figure 43 Figure 46
Remove output shaft rear bearing locating ring. Remove low clutch rear bearing.
6
F iaure 50
Remove output shaft assembly from housing.
Figure 47
Remove low speed drive gear snap ring and drive gear.
Figure 51
Remove low clutch assembly from housing.
CLUTCH DISASSEMBLY
NOTE: Two clutches are shown being disassembled. The low
clutch, and the forward and second. All clutches are disassem-
Figure 48 bled in a similar manner. The quantity of clutch discs will differ
Remove reverse and 3rd clutch assembly. between the low clutch and the forward, reverse, second and
third. Do not mix the friction discs in the low clutch with the fric-
tion discs of any of the other clutches. (See note, Figure 86.)
LOW CLUTCH DISASSEMBLY
Figure 49
From the front of the transmission housing, tap the output Figure 52
shaft, gear and bearing from pilot location in case. Remove low clutch shaft rear bearing.
Figure 56
Figure 53 Remove clutch end plate and inner and outer clutch disc.
Remove low speed gear retainer ring. See Note Figure 86.
Figure 54
Remove low speed gear and outer bearing. Figure 57
Remove low gear inner bearing.
Figure 58
Remove clutch piston return spring. A sleeve with a portion
removed is recommended for removing the clutch piston
return spring, washer, and retainer ring. Sleeve shown is a
common pipe, with a l-1/2” . wide x 1” high
(39,Ox26,0mm) opening. The pipe is 6” long, 3-l/4” O.D.,
2-314” I.D. (155,Ox85,0x78,0mm). Compress spring
retainer washer. Through opening remove spring retainer
Figure 55 snap ring. Release tension on spring retainer. Remove spring
Remove clutch end plate retainer ring. retainer and spring. Turn clutch over and tap clutch shaft
on a block of wood to remove clutch piston.
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10 Material
FORWARD & 2ND CLUTCH DISASSEMBLY
Figure 62
Remove front bearing locating ring.
Figure 59
Remove clutch shaft piston rings and expander springs.
Figure 63
Figure 60 Remove clutch driven gear and outer bearing.
Remove front bearing retainer ring.
Figure 61 Figure 64
Remove front bearing. Remove inner bearing.
11
Figure 65
Remove end plate retainer ring.
Figure 66
Relieve spring compression. Remove retainer ring, retainer
and spring.
Figure 66
Remove end plate.
Figure 69
Remove inner and outer clutch discs. Turn clutch over and
tap clutch shaft on a block of wood to remove clutch
piston.
CLEANING AND INSPECTION
CLEANING
Clean all parts thoroughly using solvent type cleaning fluid.

It is recommended that parts be immersed in cleaning fluid
and moved up and down slowly until all old lubricant and
foreign material is dissolved and parts are thoroughly
cleaned.
CAUTION: Care should be exercised to avoid inhalation of

vapors and skin rashes when using alkali cleaners.
Figure 67 Bearings
Compress return spring retainer. Remove retainer ring from Remove bearings from cleaning fluid and strike flat against
groove. a block of wood to dislodge solidified particles of lubricant. _‘
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12 Material
Immerse again in cleaning fluid to flush out particles. recommended type Automatic Transmission Fluid before
Repeat above operation until bearings are thoroughly clean. assembly.
Dry bearings using moisture-free compressed air. Be careful
to direct air stream across bearing to avoid spinning. Do not Gears and Shafts
spin bearings when drying. Bearings may be rotated slowly If magna-flux process is available, use process to check
by hand to facilitate drying process. parts. Examine teeth on all gears carefully for wear, pitting,
chipping, nicks, cracks or scores. If gear teeth show spots
Suction Screen: where case hardening is worn through or cracked, replace
Remove suction screen located at the lower left hand side with new gear. Small nicks may be removed with suitable
of the transmission housing. Clean screen thoroughly or hone. Inspect shafts and quills to make certain they are not
replace if necessary. AFTER housing is cleaned, reinstall sprung, bent, or splines twisted, and that shafts are true.
screen and gasket.
Housing, Covers, Etc.
Housings: Inspect housings, covers and bearing caps to be certain they
Clean interior and exterior of housings, bearing caps, etc., are thoroughly cleaned and that mating surfaces, bearing
thoroughly. Cast parts may be cleaned in hot solution tanks bores, etc., are free from nicks or burrs. Check all parts
with mild alkali solutions providing these parts do not have carefully for evidence of cracks or condition which would
ground or polished surfaces. Parts should remain in solution cause subsequent oil leaks or failures.
long enough to be thoroughly cleaned and heated. This will
aid the evaporation of the cleaning solution and rinse water.
REASSEMBLY
Parts cleaned in solution tanks must be thoroughly rinsed
with clean water to remove all traces of alkali. Cast parts
FORWARD & 2ND CLUTCH REASSEMBLY
may also be cleaned with steam cleaner.
CAUTION: Care should be exercised to avoid inhalation of

vapors and skin rashes when using alkali cleaners.
All parts cleaned must be thoroughly dried immediately by

using moisture-free compressed air or soft, lintless absor-
bent wiping rags free of abrasive materials such as metal
filings, contaminated oil or lapping compound.
INSPECTION
The importance of careful and thorough inspection of all

parts cannot be overstressed. Replacement of all parts
showing indication of wear or stress will eliminate costly
and avoidable failures at a later date.
Bearings
Carefully inspect all rollers, cages and cups for wear,
chipping or nicks to determine fitness of bearings for
further use. Do not replace a bearing cone or cup Figure 70
individually without replacing the mating cup or cone at Install new clutch piston inner and outer sealing rings.
the same time. After inspection dip bearings in recom-
mended type Automatic Transmission Fluid and wrap in
clean lintless cloth or paper to protect them until installed.
Oil Seals, Gaskets, Etc.

Replacement of spring load oil seals, O-Rings, metal sealing
rings, gaskets and snap rings is more economical when unit
is disassembled than premature overhaul to replace these
parts at a future time. Further loss of lubricant through a
worn seal may result in failure of other more expensive
parts of the assembly. Sealing members should be handled
carefully, particularly when being installed. Cutting,
scratching, or curling under of lip of seal seriously impairs
its efficiency. Apply a thin coat of Permatex No. 2 on the
outer diameter of the oil seal to assure an oil tight fit into
the retainer. When assembling new metal type sealing rings,
same should be lubricated with coat of chassis grease to Figure 71
stabilize rings in their grooves for ease of assembly of Insert clutch piston in clutch drum. Use Caution as not to
mating members. Lubricate all O-Rings and seals with damage sealing rings.
13
Figure 72
Install clutch piston return spring, spring retainer and Figure 75
retainer snap ring. Insert one steel disc. Install end plate retainer ring.
Figure 73
Install clutch piston return spring, spring retainer and retainer
snap ring. Insert one steel disc. NOTE: If forward and reverse
clutches are modulated, assemble piston return disc springs as Figure 76
shown in Figure A on page 31. Install clutch driven gear inner Bearing.
Figure 77
Install clutch driven gear into clutch drum. Align splines on
clutch gear with internal teeth of friction disc. Tap gear into
Figure 74 position. Do not force this operation. Gear splines must be
Install end Plate. in full position with internal teeth of all friction disc.
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14 Material
Figure 81
Install front bearing retainer ring.
Figure 78
Install driven gear outer bearing. (See page 32 for proper
Shielded Bearing Installation.)
Figure 82
Figure 79 Install clutch shaft oil sealing rings and expander springs
Install front bearing locating ring. per instructions on page 39.
LOW CLUTCH REASSEMBLY
Figure 83
Install new clutch piston inner and outer sealing ring. Insert
Figure 80 piston into clutch drum using caution as not to damage
Install front bearing. seals. Position piston return spring, spring retainer and
retainer snap ring. Compress spring and retainer and install
NOTE: Snap ring groove in front bearing must be down. snap ring.
Figure 87
install end plate and retainer ring.
Figure 84
Install low gear inner bearing.
Figure 88
Install low gear into clutch drum. Align splines on low gear
with internal teeth of friction discs. Tap gear into position.
Do not force this operation. Gear splines must be in full
position with internal teeth of all friction discs.
Figure 85
Install one steel disc.
Figure 86
Install one friction disc.
NOTE: The friction discs in the low clutch has a h&her Figure 89
co-efficient rating than the friction discs in the other Install low gear outer bearing.
clutches, therefore the discs must not be mixed. Alternate
steel and friction discs until the proper amount of discs are NOTE: When installing the 3rd gear in the 3rd speed clutch
installed. First disc next to the piston is steel, last disc a bearing spacer is used between the inner and outer 3rd
installed is friction. gear bearing.
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16 Material
Figure 90 Figure 93
Install low gear retainer ring. Install output shaft, gear and bearing assembly in housing.
Figure 91 Figure 94
Install low clutch shaft rear bearing. From the front of the transmission housing install the
reverse and 3rd clutch assembly.
Figure 92 Figure 95
Install low clutch assembly in transmission housing. Install low drive gear and retainer ring.
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17 Material
Figure 96
Figure 99
Install low clutch rear bearing with bearing ring groove to
Tighten rear cover bolts to specified torque.
the rear.
Figure 100
Figure 97 From front of transmission case tap low clutch and output
Install low clutch rear bearing retainer ring. shaft to rear. This will allow clearance to install rear bearing
snap ring. Install low clutch rear bearing locating ring.
Figure 98
Position a new gasket on rear transmission case. Align lock
ball in output shaft rear bearing with notch in rear
transmission cover. Tap cover in place and secure with bolts Figure 101
and lockwashers. Install output shaft rear bearing locating ring.
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18 Material
Figure 105
If mechanical parking brake is used, install output bearing
cap and brake backing plate. Install bolts and washers and
Figure 102 tighten to specified torque. Position actuating arm and
Install output shaft rear bearing spacer or speedometer locate brake shoes. Install upper and lower brake shoe
drive gear on output shaft. Position new gasket on rear return springs. Install brake drum and flange. If parking
cover. Oil hole in gasket must align with oil return hole in brake is not used install companion flange.
rear cover. Install output bearing cap and secure with bolts
and washers.
NOTE: If mechanical parking brake is used refer to Figures

105 and 106 before installing output bearing cap.
Figure 106
Secure flange with new O-Ring, washer and flange nut. Tighten
nut 200 to 250 ft. Ibs. torque. (271,2-338,9 Nom.)
Figure 103
Install low clutch shaft piston rings. Install new gasket and
O-Ring on low shaft bearing cap.
Figure 104 Figure 107

Install bearing cap and secure with lockwashers and bolts. Position 2nd speed clutch shaft pilot bearing in low speed
Tighten to specified torque. clutch shaft.
h-c2&j rDRIVE GEAR
wr RETAINER RING
TURB INE
‘ SHAFT
I‘II II NOTE: LONG HUB OF

DRIVE GEAR TOWARD
RETAINER RING
Figure 111
At the rear of the converter housing install turbine shaft
Figure 108 gear and retainer ring as shown.
Install 2nd speed gear on low clutch shaft and secure with
retainer ring.
Figure 112
From the front of the transmission case, install the forward
Figure 108
and 2nd clutch assembly. Inner discs in clutch must be fully
Position new turbine shaft piston ring on shaft.
engaged with splines on 2nd gear.
Figure 113
Spread forward clutch front bearing retainer ring. Position
converter housing to transmission case assembly. Use a
heavy coat of grease to center clutch shaft sealing rings. Tap
Figure 110 housing into place using caution as not to damage any of
Tap turbine shaft and bearing in converter housing. the sealing rings.
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20 Material
Figure 114
Secure converter housing to transmission case with bolts
and washers. Tighten to specified torque.
Figure 117
Install right pump drive gear.
Figure 118
Align holes in pump drive gear bearing supports with holes
Figure 115 in converter housing. Install bolts and washers. Tighten to
Position center pump drive gear. specified torque.
Figure 119
Install new sealing ring expander spring and oil sealing ring
on support. NOTE: Expander spring gap to be 180° from
sealing ring hook joint. Position support on turbine shaft to
Figure 116 clear pump drive gear. Align support holes with converter
Install left pump drive gear. housing.
Figure 123
Figure 120 Install a new oil baffle seal ring.
Install stator support bolts and tighten to specified torque.
Figure 121
NOTE: See page 33 for 13 inch special impeller hub bearing and
12 bolt assembly instructions. Figure 124
Install new “0” ring on impeller hub. Align holes in impeller Install oil baffle on impeller assembly. Use caution as not to
hub with holes in impeller. Install bolts and tighten to specified damage oil seal.
torque. Lockwire in pairs to prevent loosening.
Figure 122
Apply a light coat of Permatex No. 2 on the outer diameter
of the oil baffle seal. Press seal in oil baffle with lip of seal Figure 125
down. Install impeller Hub gear.
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22 Material
Secure impeller hub gear with retainer ring. Install reaction member spacer with tang of spacer out.
Install reaction member. NOTE: Casted knob on reaction
member must be positioned between the 3 & 6 o’clock loca-
tion on support, preferably between 4 & 5 o’clock.
Figure 127
Grease stator support piston ring, oil baffle oil seal and seal
ring to facilitate reassembly. Install impeller and oil baffle Figure 130
assembly in converter housing. Install reaction member retainer ring.
Figure 128
Position oil baffle in housing. Secure with oil baffle retainer Figure 131
ring, being sure ring is in full position in ring groove. Install turbine locating ring on turbine shaft.
23
Figure 135
Figure 132 Install a new impeller cover O-Ring and grease lightly to
Install turbine. facilitate reassembly.
Figure 136
Figure 133 Align holes in impeller cover with holes in impeller. Install
Install turbine to turbine shaft retainer ring. bolts and washers and tighten to specified torque.

If impeller cover bearing was removed, press bearing in Position detent balls and springs in control valve. Install
position and secure with retainer ring. new gasket.
Intended 24
for CLARK dealers only
Figure 138
Secure valve with bolts and washers. Tighten to specified Figure 141
torque. With new valve body to pump gasket in position insert
pump drive shaft through valve body. Use caution as not to
damage valve body oil seal. It may be necessary to turn
impeller one way or the other to align pump shaft with
drive sleeves.
Figure 139
Install pump drive sleeves.
Figure 142
Install new O-Ring in filter adaptor housing. Install filter element
and housing. Tighten filter housihg 20 to 25 ft. Ibs. torque.
(27,2-33,8 Nom.)
Figure 140
Position new gasket and O-Rings on pressure regulator
valve. Install valve on studs.
The transmission, torque converter, and its allied 5. On remote mounted torque converters remove
hydraulic system are important links in the drive line drain plug from torque converter and inspect
between the engine and the wheels. The proper oper- interior of converter housing, gears, etc. If
ation of either unit depends greatly on the condition presence of considerable foreign material is
and operation of the other; therefore, whenever repair noted, it will be necessary that converter be re-
or overhaul of one unit is performed, the balance of moved, disassembled and cleaned thoroughly.
the system must be considered before the job can be It is realized this entails extra labor; however,
considered completed. such labor is a minor cost compared to cost of
difficulties which can result from presence of
After the overhauled or repaired transmission has such foreign material in the system.
been installed in the machine, the oil cooler, and con-
necting hydraulic system must be thoroughly cleaned. Reassemble all components and use only type
6.
This can be accomplished in several manners and a de- oil recommended in lubrication section. Fill
gree-of judgment must be exercised as to the method transmission through filler opening until fluid
employed. comes up to LOW mark on transmission dipstick.
NOTE: If the dipstick is not accessible oil level
The following are considered the minimum steps to
check plugs are provided.
be taken:
Remove LOWER check plug, fill until oil runs
1. Drain entire system thoroughly. from LOWER oil hole. Replace filler and level
plug.
2. Disconnect and clean all hydraulic lines. Where
feasible, hydraulic lines should be removed from Run engine two minutes at 500-600 RPM to
machine for cleaning. prime torque converter and hydraulic lines. Re-
check level of fluid in transmission with engine
3. Replace oil filter elements, cleaning out filter running at idle (500-600 RPM).
cases thoroughly. Add quantity necessary to bring fluid level
to LOW mark on dipstick or runs freely from
4. The oil cooler must be thoroughly cleaned. The LOWER oil level check plug hole. Install oil
cooler should be “back flushed” with oil and
level plug or dipstick. Recheck with hot oil
compressed air until all foreign
material has been (180-200” F.) [82, 2-93, 3” Cl.
removed. Flushing in direction
of normal oil flow
will not adequately clean the
cooler. If neces- Bring oil level to FULL mark on dipstick or
sary, cooler assembly should be removed from runs freely from UPPER oil level plug.
machine for cleaning, using oil, compressed air
and steam cleaner for that purpose. DO NOT 7. Recheck all drain plugs, lines, connections, etc.,
use flushing compounds for cleaning purposes. for leaks and tighten where necessary.
TORQUE IN (LBS.-FT.)
BOLTS, CAPSCREWS, STUDS AND NUTS
Grade 5 Identification, 3 Radial Grade 8 Identification, 6 Radial

Dashes 120’ Apart on Head of Bolt Dashes 60’ Apart on Head of Bolt
0/\
Torque Specification for Lubricated
Grade 5 0 or Plated Screw Threads Grade 8 A/-
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26 Material
SPECIFICATIONS AND SERVICE DATA-POWER SHIFT TRANSMISSION
AND TORQUE CONVERTER
CONVERTER OUT Converter outlet oil temp. 180° - 200° F. OIL FILTRATION Full flow oil filter safety by-pass, also strainer screen
PRESSURE 182,3O - 93,3O Cl. in sump at bottom of transmission case.
Trans.&ion in NEUTRAL. CLUTCH PRESSURE 240 300 psi 11654.8 2068.4 kPal - With parking
Operating specifications: brake set lsee note), oil temperature 180° 200°F.
25 PSI. 1172.4 kPal minimum pressure at 2000 l82,2O 93,3°Cl, engine at idle (400 to 600 RPM),
R.P.M. engine speed AND a maximum of 70 P.S.I. shift thru direction and speed clutches. All clutch
1482.6 kPal outlet pressure with engine operating at pressure must be equal within 5 psi. c34.5 kPa1. If
no-load governed speed. clutch pressure varies In any one clutch more than 5
CONTROLS Forward and Reverse - Manual psi 134.5 kPal repair clutch.
Speed Selection - Manual NOTE: Never use service brakes while making
CLUTCH TYPE Multiple discs, hydraulically actuated, spring released, clutch pressure checks. Units having brake ac-
automatic wear compensation and no adjustment. All tuated declutching in forward and/or reverse will
clutches oil cooled and lubricated. not give a true reading.
CLUTCH INNER DISC Friction. ALWAYS USE PARKING BRAKE WHEN MAK-
CLUTCH OUTER DISC Steel. ING CLUTCH PRESSURE CHECKS.
LUBRICATION
RECOMMENDED LUBRICANTS FOR CLARK-HURTH COMPONENTS POWER SHIFTED

TRANSMlSSlONANOTORQUECONVERTERS
TYPE OF OIL See Lube Chart.

(al C-2 Grade 30
T*,“p*,at”,* ,b) C-3 Grade 30
CAPACITY Consult Operator’s Manual on applicable
Range “1” (c) Engine 0ll:Grade 30 API-CD/SE 0, CD/SF
machine model for system capacity. Torque A
(d) MI,.-L-21 OdC-Grade 30
Converter, Transmission and allied hydraulic (e) MIL-L-PIOdD-Grade 30
system must be considered as a whole to
(a, MIL.L-2104C-Grade 10
determine capacity. (bl MIL-L-PIOdD-Grade 10
Te”lpe,af”,e “2,’ (c, C-2 Grade 10
Ra”qe Ldl C-3 Grade 10
CHECK PERIOD Check oil level DAILY with engine running
(e, Engine 011 .G,ade 10 API-CD/SE 0, CD/SF
at 500.600 RPM and oil at 180” to 200” F. (I) out”tolub,~ 822.220 (No” Phosphate Ester F,,e
[82,2. 93, 3” C]. Maintain oil level to FULL Res,s,ant Flu(d)
mark.
Temperature “3” (a) D
‘ exron
Range (b) *Dex,on II D. See Caution Below
Temperature (ai MIL-L-46167
NORMAL * Every 500 hours, change oil filter element. Range “4” (b) MIL-L-46167 A
DRAIN PERIOD Every 1000 hours, drain and refill system as
Temperature ,,5,, (a) Conoco H,gh-Performance Synthebc Motor 011 -
follows: Drain with oil at 150” to 200’ F. spec. NO 6718
Flange
[65,6 - 93,3” C]. PREFERRED OIL VISCOSITY Select h~ghesf 011wcos,ty compati-
ble w,th p,eva,l,ng amb,enl temperatures and 011appl,cat~o” chart.
NOTE: It is recommended that filter elements Temperature ranges “2” and “3” may be used 10 lower ambient
be changed after 50 and 100 hours of op- temperatures when sump preheaten are used.
eration on new and rebuilt or repaired units. Temperafure range “‘4 sho”ld be wed only I” amble”, temperature
range shown
MODULATED SHIFT TRANSMISSIONS: T12WO. 18Mx). 24ooo.

(4 Drain transmission and remove rump
28000 &32OQO seres transmissions wth modulated shdl use only
screen. Clean screen thoroughly and C-3 O, femperature range 3 ,fems (a) & (b) D‘ exron 0, D‘ exron
replete, using new gaskets. I, D. SEE CAUTION BELOW. 3000, 4000, 5000. 6000, 8000.
15000 & 34000 seres ,,ansm,ss,~ns w,th modulated shlff “se Only
C-3 O, tempetature range 3 ,tem (a) only D
‘ exron Do NOT use
(b) Drain oil filters, remove and discard D
‘ exron II D. SEE CAUTION BELOW.
filter elements. Clean filter shells end CAUTION: D ‘ exron II D is not compatible with grsphiiic clutch
instell new elements. plate friction material UNLESS IT MEETS THE APPROVED Q
SPECIFICATIONS. D
‘ exron II D cannot be used in the 3000.
4000, 5oclo. 6000. aooo. 16000 or 34000 *ene* power d”nl
.
Refill transmission to LOW mark.
transmissions. or the HR28000 A HR32000 series having con-
vene, lock-up. O, the C270 series co”veRe, having loctup
Run engine at 500400 RPM to prime UNLESS IT MEETS THE APPROVED C-3 SPECIFICATIONS.
converter end lines. Any deviation from this than must have wine” apprwal from
the application depanment of the Clark-Hunh Components
Engineering and Marketing Department.
Cd Recheck level with engine running at
500.600 RPM and add oil to bring
level to LOW mark. When oil tempera-
ture is hot (180-200’ F.) [82,2-93,3” C]
make final oil level check. BRING OIL
LEVEL TO FULL MARK.
*Normal drain periods and filter change intervals are for average environmental and duty-cycle conditions.
Severe or sustained high operating temperatures or very dusty atmospheric conditions will cause acceler-
ated deterioration and contamination. For extreme conditions judgment must be used to determine the
required change intervals.
TROUBLE SHOOTING GUIDE
For The
R and HR Model, 28000 Transmission
The following data is presented as an aid to locating the others. By studying the principles of operation
the source of difficulty in a malfunctioning unit. It is together with data in this section, it may be possible
necessary to consider the torque converter charging to correct any malfunction which may occur in the
pump, transmission, oil cooler, and connecting lines system.
as a complete system when running down the source TROUBLE SHOOTING PROCEDURE BASICALLY CON-
of trouble since the proper operation of any unit there- SISTS OF TWO CLASSIFICATIONS: MECHANICAL AND
in depends greatly on the condition and operations of HYDRAULIC.
MECHANICAL CHECKS
Prior to checking any part of the system from a 2. Check shift levers and rods for binding or restric-
hydraulic standpoint, the following mechanical checks tions in travel that would prevent full engagement.
should be made: Shift levers by hand at control valve, if full engage-
1. A check should be made to be sure all control ment cannot be obtained, difficulty may be in control
lever linkage is properly connected and adiusted at all cover and valve assembly.
connecting points.
HYDRAULIC CHECKS
Before checking on the torque converter, transmis- the converter. Where the former means is impractical,
sion, and allied hydraulic system for pressures and the latter means should be employed as follows:
rate of oil flow, it is essential that the following pre- Engage shift levers in forward and high speed and
liminary checks be made: apply brakes. Accelerate engine half to three-quarter
Check oil level in transmission. This should be done throttle.
with oil temperatures of 180 to 200” F. [82,2-93,3’ Cl. Hold stall until desired converter outlet temperature
DO NOT ATTEMPT THESE CHECKS WITH COLD OIL. is reached. CAUTION: FULL THROTTLE STALL SPEEDS
To bring the oil temperature to this specification it FOR AN EXCESSIVE LENGTH OF TIME WILL OVERHEAT
is necessary to either work the machine or “stall” out THE CONVERTER.
LOW CLUTCH PRESSURE

Cause Remedy
1. Low oil level. 1. Fill to proper level.
2. Clutch pressure regulating valve spool stuck open. 2. Clean valve spool and housing.
3. Faulty charging pump. 3. Replace pump.
4. Broken or worn clutch shaft or piston sealing rings. 4. Replace sealing rings.
5. Clutch piston bleed valve stuck open. 5. Clean bleed valves thoroughly.
LOW CONVERTER CHARGING PUMP OUTPUT

2. Suction screen plugged. 2. Clean suction screen.
3. Air leaks at pump intake hose and connections or 3. Tighten all connections or replace hose if necessary.
collapsed hose. (R-28000 only)
4. Defective oil pump. 4. Replace pump.
OVERHEATING
1. Worn oil sealing rings. 1. Remove, disassemble, and rebuild converter assem-
bly.
2. Worn oil pump. 2. Replace.
4. Pump suction line taking air. (R-28000 only) 4. Check oil line connections and tighten securely.
NOISY CONVERTER
1. Worn coupling gears. 1. Replace.
2. Worn oil pump. 2. Replace.
3. Worn or damaged bearings. 3. A complete disassembly will be necessary to deter-
mine what bearing is faulty.
LACK OF POWER
1. Low engine RPM at converter stall. 1. Tune engine check governor.
2. See “Overheating” and make same checks. 2. Make corrections as explained in “Overheating.”
Copyrighted
28 Material
I /
COLOR KEY
m IST (LOW)
a *ND
_ 3RD (HI)
.
3 SPEED TRANSMISSION
28000 SERIES- 3 SPEED
CLUTCH & GEAR ARRANGEMENT
(SHORT DROP OUTPUT)
Copyrighted
30 Material
F1G.A
MODULATED FWD.
& REV. CLUTCHES
2nd & 3rd & NON-

F1G.B MODULATED FORWARD &
REVERSE CLUTCHES
FIG. C
LOW (1st)
CLUTCH
F1G.D
(4 SPEED ONLY)
4TH
- -+
31
BEARING SHIELD
MUST FACE IN
BEARING SHIELD
M
‘ UST FACE OUT
SHIELD
BEARING SHIELD
T FACE OUT
BEARING SHIELD
MUST FACE IN
SHIELDED BEARING INSTALLATION
Copyrighted
32 Material
TURBINE HUB
BACKING RING
8-TURBINE HUB
SCREWS
REFERENCE - 12 IMPELLER HUB

SCREWS ON 13” CONVERTERS
MUSi BE LOOSE INTERNAL

FIT BEARING. SEE PARTS LIST
IMPELLER HUB, TURBINE HUB AND BACKING RING WITH SPECIAL SCREWS
1. CLEAN HUB MOUNTING SURFACE AND TAPPED HOLES WITH SOLVENT. DRY THOROUGHLY BEING
CERTAIN TAPPED HOLES ARE DRY AND CLEAN.
2. INSTALL BACKING RING AND SPECIAL SELF-LOCKING SCREWS TO APP,ROXIMATELY .06 INCH [1,5] OF
SEATED POSITION. WITH A CALIBRATED TORQUE WRENCH, TIGHTEN SCREWS 40 TO 45 LBS. FT.
[54,3 - 61,0 N.m.1 TORQUE.
NOTE: ASSEMBLY OF HUB MUST BE COMPLETED WITHIN A FIFTEEN MINUTE PERIOD FROM START OF
SCREW INSTALLATION. THE SCREWS ARE PREPARED WITH AN EPOXY COATING WHICH BEGINS TO
HARDEN AFTER INSTALLATION. IF NOT TIGHTENED TO PROPER TORQUE WITHIN THE FIFTEEN
MINUTE PERIOD, INSUFFICIENT SCREW CLAMPING TENSION WILL RESULT.
THIS SPECIAL SCREW IS TO BE USED FOR ONE INSTALLATION ONLY. IF THE SCREW IS REMOVED FOR
ANY REASON IT MUST BE REPLACED.
THE EPOXY LEFT IN THE HUB HOLES MUST BE REMOVED WITH THE PROPER TAP AND CLEANED
WITH SOLVENT. DRY HOLE THOROUGHLY AND USE A NEW SCREW FOR REINSTALLATION.
ASSEMBLY INSTRUCTIONS FOR 28000 CONVERTER

WITH SPEClAL APPLICATION IMPELLER HUB BEARING.
16 SCREW RING GEAR INSTALLATION PROCEDURE
(Non-Asbestos Ring Gear)
1. Remove all burrs from flywheel mounting face and pilot bores. Clean the torque converter ring gear flywheel mounting surface
and the ring gear screw tapped holes with solvent. Dry thoroughly, being certain ring gear screw holes are dry and clean.
2. Check engine flywheel and housing or housing adaptor for conformance to standard S.A.E. No. 3 - SAE J927 and J1033
tolerance specifications for pilot bores size, pilot bores eccentricities and mounting face deviations. Measure and record engine
crankshaft end play.
3. Install torque converter ring gear as shown.
NOTE: Assembly of the ring gear must be completed within a fifteen minute
period from start of screw installation. The screws are prepared with an epoxy
coating which begins to harden after installation in the flywheel mounting holes. If not
tightened to proper torque within the fifteen minute period insufficient screw clamping
tension will result.
4. Install backing ring and sixteen (16) special screws to approximately .06 inch II ,5 mm1 of seated position. It is permissible to use
a power wrench for this installation phase. With a calibrated torque wrench tighten screws 30 to 33 pounds feet of torque 140,7 -
44,7 N.ml.
To obtain maximum effectiveness of the special screw’s locking feature, a minimum time period after screw installation of
twelve (I 2) hours is suggested before engine start-up.
The special screw is to be used for ONE installation only. If the screw is removed for any reason it MUST BE REPLACED. It is
recommended that the epoxy left in the flywheel hole be removed with the proper tap and cleaned with solvent. Dry hole
5. Assemble torque converter to engine flywheel by sliding converter into position by hand before fastening housing attachment
screws. This may require more than one trial to match the drive gear teeth. Pulling the converter into position with housing
attachment bolts is not recommended.
6. Measure engine crankshaft end play after assembly of torque converter. This value must be within one thousandth t.001) of an
inch [0,0254mml of end play recorded (in Paragraph #2) before assembly of torque converter.
802553 - 1.5 INCH [38,11 16 SCREW RING GEAR KIT 802554 - 1.5 INCH 138.1116 SCREW RING GEAR KIT
1 249341 Torque Converter Ring Gear 1 24934 1 Torque Converter Ring Gear
16 236288 Ring Gear Screw 1.5 inch 138,l I 16 236288 Ring Gear Screw 1.5 Inch 138.1 I
1 802555 installation Instructron Sheet 1 243767 Backing Ring
1 802555 lnstallatron Instruction Sheet
243767 Backing Ring not included in 802553 Rrng Gear Krt Must be Ordered Separately.
Dimensions are in inches - Dimensions in I I are mm
SEE PAGE 35 FOR INSTALLATION ILLUSTRATIONS
SEE PAGE 36 FOR 32 BOLT INSTALLATION
Copyrighted
34 Material
\ BACKING RING
*. /
ENGINE FLYWHEEL
TORQUE CONVERTER
RING GEAR
RING GEAR SCREW
RING GEAR SCREW ENGINE FLYWHEEL

(16) 236288 1.500 [38,1] /
1
I
r-- -.I SEE PAGE 34

FOR INSTALLATION
PROCEDURE AND
BOLT TORQUE
RING
243767
TORQUE CONVERTER
RING GEAR 249341
35
32 SCREW RING GEAR INSTALLATION PROCEDURE
(Non-Asbestos Ring Gear)
Remove all burrs from flywheel mounting face and pilot bores. Clean the torque converter ring gear flywheel mounting surface
and the ring gear screw tapped holes with solvent. Dry thoroughly, being certain ring gear screw holes are dry and clean.
Check engine flywheel and housing or housing adaptor for conformance to standard S.A.E. No. 3 - SAE J927 and J1033
tolerance specifications for pilot bores size, pilot bores eccentricities and mounting face deviations. Measure and record engine
Install torque converter ring gear as shown.
NOTE: Assembly of the ring gear must be completed within a fifteen minute
period from start of screw installation. The screws are prepared with an epoxy
coating which begins to harden after installation in the flywheel mounting holes. If not
tightened to proper torque within the fifteen minute period insufficient screw clamping
tension will result.
Install backing ring and thirty-two (32) special screws to approximately .06 inch [1,5 mm1 of seated position. It is permissible to
use a power wrench for this installation phase. With a calibrated torque wrench tighten screws 23 to 25 pounds feet of torque
131,2 - 33,8 N.ml.
To obtain maximum effectiveness of the special screw’s locking feature, a minimum time period after screw installation of
twelve (I 2) hours is suggested before engine start-up.
The special screw is to be used for ONE installation only. If the screw is removed for any reason it MUST BE REPLACED. It is
recommended that the epoxy left in the flywheel hole be removed with the proper tap and cleaned with solvent. Dry hole
5. Assemble torque converter to engine flywheel by sliding converter into position by hand before fastening housing attachment
screws. This may require more than one trial to match the drive gear teeth. Pulling the converter into position with housing
attachment bolts is not recommended.
6. Measure engine crankshaft end play after assembly of torque converter. This value must be within one thousandth (.OOl) of an
inch[0,0254mml of end play recorded (in Paragraph #212)before assembly of torque converter.
802644 - 1.5 INCH [38,11 32 SCREW RING GEAR KIT 802547 - 2.5 INCH L63.51 32 SCREW RING GEAR KIT
1 249265 Torque Converter Ring Gear 1 249265 Torque Converter Ring Gear
32 243970 Ring Gear Screw 1.5 Inch 138.1 I 32 237153 Ring Gear Screw 2.5 inch 163,51
1 802550 Installation Instruction Sheet 1 802550 Installation Instruction Sheet
802545 - 1.75 INCH L44.4132 SCREW RING GEAR KIT 802548 - 3.0 INCH U76.21 32 SCREW RING GEAR KIT
32 244903 Ring Gear Screw 1.75 Inch 144.41 32 236938 Ring Gear Screw 3.U Inch 176,21
802546 - 2.0 INCH L50.81 32 SCREW RING GEAR KIT 802549 - M8-32 SCREW RING GEAR KIT
32 240318 Ring Gear Screw 2.0 Inch 150,81 32 4200097 Ring Gear Screw IM8 x 1.251
236937 Backing Ring Not Included in Ring Gear Kit. Must be Ordered Separately.
NOTE: The initial installation drive gear mounting kit includes a converter air breather. This breather is used on C Et CL 270/C Et
CL 320 converters only and is not required for the HR Et LHR 28000iHR & LHR 32000 applications.
SEE PAGE 37 FOR INSTALLATION ILLUSTRATIONS
Copyrighted
36 Material
, BACKING RING
ENGINE FLYWHEEL
TORQUE CONVERTER
RING GEAR
RING GEAR SCREW
ENGINE FLYWHEEL
RING GEAR SCREW

(32) 243970 1.500 [38,11
(32) 244903 1.750 [44,41
(32) 240318 2.000 I50,81
(32) 237153 2.500 [63,51 SEE PAGE 36
(32) 236938 3.000 [76,21 FOR INSTALLATION
(32) 4200097 [M8 x 1.251 PROCEDURE AND
BOLT TORQUE
BACKING RING
TORQUE CONVERTER RING GEAR 249265
37
.I .060 + .007 126.9 f .17]
Stake 3 places approx.

equally spaced.
After curing of Loctite,

speed sensor bushinn
must be secure with 40
Ft. Lb. [54.2 N.m] torque.
Assemble Speed Sensor Bushing in housing to specified

REAR VIEW dimension with Loctite 262 and stake (3) three places.
SPEED SENSOR BUSHING INSTALLATION
-.-
:.,‘
Copyrighted
38
Material
PROPER INSTALLATION OF TEFLON PISTON RING AND PISTON RING EXPANDER SPRINGS
NOTE: NOT ALL TRANSMISSIONS WILL HAVE TEFLON PISTON RINGS AND EXPANDER SPRINGS
1. Fill the oil sealing ring grooves with a good grade of grease, this will help stabilize the teflon ring and expander spring in the ring
groove for installation.
2. Position the expander spring in the inner groove of the new piston ring, with the expander spring gap 180° from the hook joint gap
of the piston ring.
3. Carefully position the piston ring and expander spring on the clutch shaft in the inner most ring groove. Hook the piston piston ring
joint.
Repeat steps 1, 2 and 3 for the remaining ring or rings making certain all hook joints are fastened securely.
Apply a heavy coat of grease to the outer diameter of the rings and clutch shaft. Center the piston ring’s in the ring groove.
Before installing the clutch assembly in the front cover or converter housing it is recommended a piston ring sleeve PIN’s 241309,
237576 or 234265 be used to center all of the piston rings in their respective ring grooves. Use extreme caution to not damage
piston rings when installing the clutch shaft in the front trasnmission cover or converter housing.
USED FOR POSITIONING PISTON RING

SLEEVE 234265
OF PISTON RINGS
BEARING
LUTCH SHAFT CLUTCH SHAFT
BEARING
PISTON RING
Be sure that lead in chamfer and

intersection of lead in chamfer to piston
ring bore is free of burrs and nicks.
PISTON
RING GAP
248424
SPRING GAP AND RING GAP

ARE 180” APART
DRIVE PLATE INSTALLATION
SUBJECT: 28000/32000 Series Transmission and C-270/C-320 Series Converter Drive Plate Kits.
REASON FOR BULLETIN: Proper Identification by Bolt Circle Diameter.
Measure the “A” dimension (Bolt Circle diameter) and order Drive Plate Kit listed below.
ALIGNMENT HOLES
(1) DRIVE PLATE AND
WELD NUT ASSEMBLY
BOLT CIRCLE DIA 141 INTERMEDIATE

DRIVE PLATES
JACKING RING
“A” Dimension (Bolt Circle Diameter)
13.125” L333.375 mm1 Diameter

Kit No. 802335
13.50” [342,900 mm] Diameter
Kit No. 802333
17.00” [431,800 mm1 Diameter
Kit No. 802454
Each kit will include the following parts:
4 Intermediate Drive Plates
1 Drive Plate and Weld Nut Assembly.
1 Backing Ring.
10 Screw and Lockwasher Assembly.
1 instruction Sheet.
TO FACILITATE ASSEMBLY, ALIGN SMALL HOLES IN DRIVE PLATES - SEE ILLUSTRATION ABOVE.
Position drive plate and weld nut assembly on impeller cover with weld nuts toward cover. Align intermediate drive plate and
backing ring with holes in impeller cover. NOTE: Two dimples 180° apart in backing ring must be out (toward engine flywheel).
Install capscrews and washers. Tighten 23 to 25 ft. Ibs. torque [31,2 - 33,8 N.ml.
SEE PAGE 41 FOR TRANSMISSION TO ENGINE

INSTALLATION PROCEDURE
TRANSMISSION TO ENGINE INSTALLATION PROCEDURE
1. Remove all burrs from flywheel mounting face and

FLYWHEEL
nose pilot bore. Clean drive plate surface with solvent. HOUSING
2. Check engine flywheel and housing for conformance

to standard S.A.E. #3 - S.A.E. J-927 tolerance
specifications for pilot bore size, pilot bore runout and ENGINE
mounting face flatness. Measure and record engine

FLYWHEEL
PILOT SORE
3. Install two 3.50 [88,90 mm1 long transmission to
flywheel housing guide studs in the engine flywheel
housing as shown. Rotate the engine flywheel to align
a drive plate mounting screw hole with the flywheel
housing access hole. FlYWHEEl.
4. Install a 4.00 [101,60 mm1 long drive plate locating

stud .3750-24 fine thread in a drive plate nut. Align the
locating stud in the drive plate with the flywheel drive
plate mounting screw hole positioned in step No. 3.
5. Locate transmission on flywheel housing aligning

drive plate to flywheel and transmission to flywheel
housing.
Install transmission to flywheel housing screws.

Tighten screws to specified torque. Remove trans- h” ALlGNlNG
mission to engine guide studs. Install remaining

screws and tighten to specified torque.
6. Remove drive plate locating stud.
7. Install drive plate attaching screw and washer. Snug

screw but do not tighten. Some engine flywheel
housings have a hole located on the flywheel housing SPECIAL STUD, WASHER AND
FIG 2 SELF LOCK NUT FURNISHED
circumference in line with the drive plate screw access BY MACCHINE MANUFACTURER.
hole. A screwdriver or pry bar used to hold the drive
plate against the flywheel will facilitate installation of
the drive plate screws. Rotate the engine flywheel and
install the remaining seven (7) flywheel to drive plate
attaching screws. Snug screws but do not tighten.
After all eight (8) screws are installed torque each one
25 to 30 ft. Ibs. torque [33,9 - 40,6 N.m.1. This will re-
quire torquing each screw and rotating the engine
flywheel until the full amount of eight (8) screws have
been tightened.
(3) INTERMEDIATE
8. Measure engine crankshaft end play after trans- DRIVE PLATES
mission has been completely installed on engine

flywheel. This value must be within .OOl [0,025 mm1
of the end play recorded in step No. 2.
FIG 3 FIG 4 YLt
Copyrighted
41
Material
COMPONENTS
Statesville, North Carolina
Brugge, Belgium
Arco, Italy
Sao Paulo, Brazil Price on Request
59-905-0004 Intended for CLARK dealers only
PRINTED IN U.S.A.
CLARK-HURTH
INGERSOLLRAND
28000/32000 SERIES TRANSMISSION AND C-270/C-320 CONVERTER DRIVE PLATE
INSTALLATION INSTRUCTIONS
Proper Identification by Bolt Circle Diameter.
Measure the “A” dimension (Bolt Circle diameter) and order Drive Plate Kit listed below.
(I) Drive Plate and

Weld Nut Assembly
Drive Plates
“A”Dimension (Bolt Circle Diameter) NOTE: Assembly of flexplates must “A” Dimension (Bolt Circle
13.125” [333,375 mm] Diameter be completed within a 15 minute Diameter)
Kit No. 802335 period from start of screw installa- 13.125” [333.375 mm] Diameter
tion. If the screw is removed for any Kit No. 802521
13.50 [342,900 mm] Diameter reason it must be replaced. The
Kit No. 802517 adhesive left in the tapped hole must 13.50” 1342,900 mm] Diameter
be removed with the proper tap and Kit No. 802568
17.00” [431,800 mm] Diameter cleaned with solvent. Dry the hole
Kit No. 802454 thoroughly and use a new screw for 17.00” [431,800 mm] Diameter
reinstallation. Kit No. 802566
Each kit will include the following parts: Each kit will include the following parts:
4 Intermediate Drive Plates 5 Intermediate Drive Plates

1 Drive Plate and Weld Nut Assembly 1 Backing Ring
1 Backing Ring 10 Drive Plate Mounting Screws
10 Drive Plate Mounting Screws IO Drive Plate Washer
10 Drive Plate Washer 1 Instruction Sheet
1 Instruction Sheet
TO FACILITATE ASSEMBLY, ALIGN SMALL HOLES IN DRIVE PLATES-SEE ILLUSTRATION ABOVE.

Position drive plate and weld nut assembly on impeller cover with weld nuts toward cover. Align intermediate drive plate and
backing ring with holes in impeller cover. NOTE: Two dimples 180 degrees apart in backing ring must be out (toward engine fly-
wheel). Install capscrews and washers. Tighten 33 to 36 ft. Ibs. torque [45-49 N.m]
Over for TRANSMISSIONCopyrighted

TO ENGINEMaterial
INSTALLATION PROCEDURE
Intended for CLARK dealers only Instruction Sheet 802334 REV 9-96
TRANSMISSION TO ENGINE INSTALLATION PROCEDURE
1. Remove all burrs from flywheel mounting face and

FLYWHEEL
nose pilot bore. Clean drive plate surface with solvent. HOUSING
2. Check engine flywheel and housing for conformance

to standard S.A.E. #3 - S.A.E. J-927 tolerance
specifications for pilot bore size, pilot bore runout and ENGINE
mounting face flatness. Measure and record engine

FLYWHEEL
PILOT SORE
3. Install two 3.50 [88,90 mm1 long transmission to
flywheel housing guide studs in the engine flywheel
housing as shown. Rotate the engine flywheel to align
a drive plate mounting screw hole with the flywheel
housing access hole. FLYWHEEL
4. Install a 4.00 [101,60 mm] long drive plate locating

stud .3750-24 fine thread in a drive plate nut. Align the FIG 1
locating stud in the drive plate with the flywheel drive

plate mounting screw hole positioned in step No. 3. CONVERTE
HOUSING
5. Locate transmission on flywheel housing aligning

drive plate to flywheel and transmission to flywheel
housing.
Install transmission to flywheel housing screws.
Tighten screws to specified torque. Remove trans- 3’/1” ALlGNlNG
mission to engine guide studs. Install remaining

screws and tighten to specified torque.
6. Remove drive plate locating stud.
m
7. Install drive plate attaching screw and washer. Snug , FLYWHEEL
HOUSING
screw but do not tighten. Some engine flywheel
housings have a hole located on the flywheel housing SPECIAL STUD, WASHER AND
FIG 2 SELF LOCK NUT FURNISHED
circumference in line with the drive plate screw access BY MACHINE MANUFACTURER.
hole. A screwdriver or pry bar used to hold the drive
plate against the flywheel will facilitate installation of
the drive plate screws. Rotate the engine flywheel and
install the remaining seven (7) flywheel to drive plate
attaching screws. Snug screws but do not tighten.
After all eight (8) screws are installed torque each one
25 to 30 ft. Ibs. torque [33,9 - 40,6 N.m.1. This will re-
quire torquing each screw and rotating the engine
flywheel until the full amount of eight (8) screws have
been tightened.
INTERMEDIATE
8. Measure engine crankshaft end play after trans- DRIVE PLATES
mission has been completely installed on engine

flywheel. This value must be within .OOl 10,025 mm1
of the end play recorded in step No. 2.
FIG 3 FIG 4 v_Ll
TECHNICAL
SERVICE
BULLETIN
) ‘$, NO. U.S.A - 256 E 1 MO- Year l-96 )
SUBJECT: DRIVE GEAR REPLACEMENT PROCEDURE

IN THE EVENT OF DRIVE GEAR FAILURE OR REPLACEMENT THE FOLLOWING CHECKS AND/OR
CORRECTIONS ARE MANDATORY BEFORE INSTALLATION OF THE GEAR.
*Check impeller cover gear teeth visually
If they show signs of pitting or wear, the relative backlash between a new drive and the impeller
cover should be checked.
This can be done as follows:

1) With the impeller cover in a vertical position, locate the new converter drive gear in its designed
operating location by spacing from the front of the impeller cover using three spacer locations
as shown below.
2) Evaluate the gear tooth looseness by comparison of relative backlash between the drive gear and
impeller cover. The fit should be between zero and 0.0030 inch (0,08 mm) backlash. Excessive
backlash indicates a worn condition on the impeller teeth and replacement is necessary..
C+CL270 / 320 C+CL6000 / 8000 c+cL16000

HR+LHRLI / 32000 HR+LHR34000
Additional copies of this bulletin available upon request. Phone Clark-Hurth Components :
(704) 878-5858 (U.S.A) - (39) 464-532666 (Italy) - (32) 50-402442 (Belgium)
Copyright Clark-Equipment Company,l99S. All Rights Reserved

Check impeller cover nose and flywheel nose pilot for wear or scoring. If a drive gear has failed, in most
cases these parts need replacement. In case of doubt measure and determine if dimensions are within
specification.
FLYWHEEL HOUSING FLYWHEEL NOSE PILOT FLYWHEEL COVER NOSE

DIAMETER DIAMETER
SAE 3 2.04612.047 2.04412.045
SAE 1 2.04612.047 2.044l2.045
SAE 0 3.14913.150 3.14713.148

I I I
I I
I SAE 0
I
5.11815.119
I
5.11615.117
I
Review fit of the drive gear to the flywheel, assuring that the flywheel ring gear pilot length allows the con-
verter drive gear to seat on the mating flywheel surface. Be sure that the attachment screws or studs are
not located out of position, which would result in side loading of the drive gear.
Follow the specific installation procedure steps as outlined in the instructions which is included with the
converter drive gear and attachment kit.
Inspect engine torsional vibration damper for correct functions. Consult engine service manual for specifr-
cations.
In case of repetitive failures with all of the above specifications being correct, and expanded installation
check should be performed as described in CLARK-HURTH Bulletin 802563.
SUBJECT: SDC NON-ASBESTOS THIRTYTWO (32) BOLT
TORQUE CONVERTER DRIVE RING GEAR
REASON FOR BULLETIN: Proper Parts Ordering and Service Procedure
MODELS EFFECTED: C & CL 270, C & CL 320 Torque Converters

HR & LHR 28000 and HR & LHR 32000 Transmissions
A STABLEDRIVE CONNECTION CONVERTER DRIVE RING GEAR HAS

BEEN RELEASED FOR PRODUCTION AND SERVICE. THE DURABILITY OF
THIS GEAR HAS BEEN IMPROVED AND THE WEAR CONDITION WITH THE
MATING IMPELLER COVER GEAR TEETH HAS BEEN ADDRESSED.
Refer to installation instructions forms 802563, 802655 and Technical Service

Bulletin USA-256E for proper installation procedure.
WAS NEW
Bolt
SDC SDC
Length Drive Drive Gear Drive Drive Gear
Inches Thread Gear Kit Gear Kit
1.50 5/16-18 UNC 249265 802544 249473 802649
1.75 5/16-18 UNC 249265 802545 249473 802650
2.00 5/l 6-l 8 UNC 249265 802546 249473 802651
2.50 5/l 6-l 8 UNC 249265 802547 249473 802652
3.00 5/l 6-8 UNC 249265 802548 249473 802653
2.36 M8 X 1.25 249265 802549 249473 802654
The 236937 Backing Ring must be ordered separately, it is not included in the
Ring Gear Kit.
Copyright Clark-Equipment Company,1995 All Rights Reserved

No part ofthis work may be reproduced in any formw&r nary meanswithout the direct permission
Copyrighted Material of Clark Equipment Company
SUBJECT: SDC NON-ASBESTOS SIXTEEN (16) BOLTTORQUE
CONVERTER DRIVE RING GEAR
REASON FOR BULLETIN: Proper Parts Ordering and Service Procedure
MODELS EFFECTED: C & CL 270, C & CL 320 Torque Converters

HR & LHR 28000 and HR & LHR 32000 Transmissions
A STABLE DRIVE
CONVERTER DRIVE RING GEAR HAS BEEN RELEASED
FOR PRODUCTION AND SERVICE. THE DURABILITY OF THIS GEAR HAS
BEEN IMPROVED AND THE WEAR CONDITION WITH THE MATING
IMPELLER COVER GEAR TEETH HAS BEEN ADDRESSED.
Refer to installation instructions forms 802563, 802648 and Technical Service

Bulletin USA-256E for proper installation procedure.
WAS:
Drive Gear 249341
Drive Gear Kit 802553 Without Backing Ring
Drive Gear Kit 802554 With 243767 Backing Ring
NEW:
SDC Drive Gear 249474
SDC Drive Gear Kit 802646 Without Backing Ring
SDC Drive Gear Kit 802647 With 243767 Backing Ring
Copyright Clark-Equipment Compmy,1995. All Rights Reserved

No part ofthis work may be reproduced in anyformunderanymeanswithoutthe direct pondsion
Copyrighted Material ofCkzrkEquipment Company.
CLARICHURTID
l-77 at I-40
Route 18 Box 38
Statesville, NC 28677-7804
Telephone (704) 878-5855
TORQUE CONVERTER
DRIVE GEAR
INSTALLATION
15 JUNE 1993
802563
A Business Unit Copyrighted Material
of Clark Equipment Company Intended for CLARK dealers only
TORQUE CONVERTER INSTALLATION
When reinstalling a torque converter after rebuild it is essential that the proper in-
spection procedure be followed to insure correct alignment of the engine and torque
converter. (See Page 1, Engine Flywheel and Flywheel Housing Inspection Procedure.)
NOTE: Significant life reduction of the drive gear will result from excessive backlash and
radial or axail misalignment caused by mismachined or worn engine and/or converter
parts.
Visual inspection should include the condition of the impeller cover teeth (see page C)
and nose bushing. Look for any signs of wear or steps in the contacting surfaces.
Check the flywheel center pilot bushing bore for wear steps and confirm that the dimen-
sions are correct (see page B).
Review fit of the drive gear to the flywheel, assuring that the flywheel pilot length allows
the converter drive gear to seat on the mating flywheel surface. Be sure that the attachment
screws or studs are not located out of position, which would result in side loading of
the drive gear bolt holes.
Follow the specific installation procedure steps as outlined in the instructions included
with the drive gear and attachment kit.
Inspect engine torsional vibration damper for correct functions. Consult engine service
manual for specifications.
-A-
CLARKkHURTI=iB
COMPONENTS
The following is a summary of recommended SAE tolerance specifications which apply

to Clark-Hurth Torque Converter Drive Gear Installation.
DIMEMSIONAL VALUES
FLYWHEEL FLYWHEEL CONVERTER

HOUSING
RING NOSE HSG. NOSE HOUSING

GEAR PILOT PILOT PI LOT PILOT
PILOT DIA. DIA. DIA. DIA.
SAE #3
13.875 2.046 16.125 2.044 16.125
13.878 2.047 16.130 2.045 16.128
SAE #I
17.750 2.046 20.125 2.044 20.123
17.752 2.047 20.130 2.045 20.128
SAE #O
20.500 3.149 25.500 3.147 25.498
20.503 3.150 25.505 3.148 25.502
5.118 5.116
5.119 5.117
REF: SAE J 927

SAE J 617
SAE J 1033
-B-
CLARWHURTKB
COMPONENTS
INSPECTION OF IMPELLER COVER GEAR TEETH
1) With the impeller cover in a vertical position, locate the new converter drive gear
in its designed operating location by spacing from the front of the impeller cover
using three spacer locators as shown below.
2) Evaluate the gear tooth looseness by comparison of relative backlash between

the drive gear and impeller cover. The fit should be between zero and 0.0030
inch backlash. Excessive backlash indicates a worn condition on the impeller cover
teeth and replacement is necessary.
C+Cl_270 / 320 C+Cl_5000 / 8000 C+CL16000

HR+LHR28 / 32000 HR+ LHR34000
17’ GEAR 22’ GEAR
CLARIGHURTID
COMPONENTS
ENGINE FLYWHEEL AND FLYWHEEL HOUSING INSPECTION PROCEDURE
FLYWHEEL HOUSING RUNOUT
Face Runout (axial eccentricityj of the

Flywheel Housing:
1. Fasten a dial indicator to the crankshaft flange so the

anvil of the indicator will touch the face of the Flywheel
housing.
2. Put a force on the crankshaft toward the rear before

reading the indicator at each point.
Dial Indicator Installed
3. With dial indicator set at 0.000 in. (0,O mm) at location

(6:00), turn the crankshaft and read the indicator at
locations (3:00), (1200) and (9:OO). 12:oo
(TOP)
4. The difference between lower and higher measure-

ments taken at all four points must not be more than
0.008 in. (0.203 mm), which is the maximum permissible
face runout (axial eccentricity) of the Flywheel housing.
6:00
3:oo
6:00
(BOTTOM)
12:oo
9:oo
Face Runout:
(Maximum Value - Minumum Value)=
-l-
CLARIGHURTID
FLYWHEEL HOUSING BORE
NOTE: Write the dial indicator measurements with their

positive (+) and negative (-) notation (signs). This
notation is necessary for making the calculations in
the chart correctly.
12:oo
(TOW
1. With the dial indicator in position at (12:00), adjust
the indicator to “0” (zero). Push the crankshaft up
against the top of the bearing. Do not push against the
flywheel housing as this may cause the housing to
deflect, giving an inaccurate reading or housing
deformation. Write the measurement for bearing
clearance on line I in column (12:OO). Page 3
2. Divide the measurement from Step 1 by 2. Write

this number on line I in columns (3:00) & (9:OO).
3. Turn the crankshaft to put the dial indicator at (6:OO).

Adjust the dial indicator to “0” (zero).
6:00
(BOTTOM)
4. Turn the crankshaft counterclockwise to put the

dial indicator at (3:OO). Write the measurement in the
chart on line II. Page 3


7. Algebraically add lines I and II by columns and

record on line III.
8. Subtract the smaller number from the larger num-

ber in line III in columns (3:00) & (9:OO). The result is
the horizontal “eccentricity” (out of round). Line III,
column (12:OO) is the vertical eccentricity. Page 3
-2-
Copyrighted Material REV. 2-94
CLARIGHURTKB
EOMPONENTS
* Total vetiical eccentricity (out of round).

CHARTFORDlALlNDlCAlOR
** Subtract the smaller number from the larger number.
MEASUREMENCS The difference is the total horizontal eccentricity.
Position of
9. On the graph for total eccentricity find the point of
Dial Indicator intersection of the lines for vertical eccentricity and
horizontal eccentricity.
10. If the point of intersection is in the range marked

“Acceptable” the bore is in alignment. If the point of
intersection is in the range marked “Not Acceptable” do
step 11.
11. Loosen the bolts holding the Flywheel housing to

Dial the cylinder block. Hit the Flywheel housing lightly with a
Indicator 11 0 hammer to put in the correct position. Tighten the bolts
Reading holding the Flywheel housing to the cylinder block and
do steps 1 through 10 again.
Diierenceof 111 0 (A) * (C) *
(B) .A-+2
RESULTANT TOTAL INDICATOR READING, In
Vertical Eccentricity
1, = (A)
Horizontal Eccentricity
l,=(B)-(C)=
0.0 f0.002 f0.004 +0.006 +0.006 *0.010 iO.012

@0.05) (fO.10) (f0.15) (kO.20) (f0.25) (fO.30)
TOTAL HORIZONTAL INDICATOR READING, I,,

NOTE: Dimensions are: inches(mm)
-3-
COMPONENTS
FLYWHEELRUNOUT
Face runout (axial eccentricity) of the flywheel.
- Install the dial indicator as shown. Put a force on the

flywheel toward the rear
- Set the dial indicator to read 0.000 in. (0,O mm).
- Turn the flywheel and read the indicator every 90’. Put
a force on the flywheel to the rear before each reading.
-The difference between the lower and higher measure-
ments taken at all four points must not be more than
0.005 in. (0,127 mm), which is the maximum permissible
face runout (axial eccentricity) of the flywheel.
Converter Drive Gear Mounting Surface, Figure 1. Figure 1

A
Checking Converter Drive Gear Flywheel Face Runout
B Maximum Difference 0.005(0,127mm)
C
D
Converter Drive Gear Pilot Diameter, Figure 2.
A
C
D
Converter Nose Support Pilot Diameter, Figure 3.
A
C
D
Bore Runout (radial eccentricity) of the Flywheel

Drive Gear Bore:
1. Install thedial indicator and adjust so it makes contact
Figure 2
as shown in Figure 2.
Checking Flywheel Converter Drive Gear Pilot Bore
2. Set the dial indicator to read 0.000 in. (0,O mm).
3. Turn the Flywheel and read the indicator every 90’.
Record readings on Page 5 (Converter Drive Gear Pilot
Diameter).
4. The difference between the lower and higher mea-
surements taken at all four points must not be more than
0.005 in. (0,127 mm), which is the maximum bore runout
(radial eccentricity) of the Flywheel.
Flywheel and Sleeve Assembly Runout (Radial Ec-

centricity) of Converter Nose Support Bore:
1. Install the dial indicator and adjust so it makes contact
as shown in Figure 3.
2. Set the dial indicator to read 0.000 in. (0,O mm).
3. Turn the Flywheel and read the indicator every 90’.
Record readings on Page 5 (Converter Nose Support
Diameter).
4. The difference between the lower and higher mea- Figure 3
surements taken at all four points must not be more than Checking Flywheel Converter Nose Support Bore
0.005 in. (0,127 mm), which is the maximum bore runout
(radial eccentricity) of the Flywheel.
-4-
COMPONENTS
Eccentricity - Drive Gear to Nose Pilot
+
Converter Drive Gear Pilot Diameter Mark Flywheel As Shown
Indicator Set Up per Fig. 2 Sheet 4 &
0
Dial Indicator A B
Reading
CH DH D B
I A-C I B-D
Difference Of
(BOAOM)
Important- Record if lndictaor Value is (+) Larger or (-)
Converter Nose Supporf Diameter Smaller than “Set” Value.
Indicator Set Up per Fig. 3 Sheet 4
Dial Indicator A B
Reading
CH DH
II A-C
II 0-D
Difference Of
Eccentricity: Drive Gear Pilot Diameter To

Nose Support Pilot Diameter. f0.012
(m.30)
Eccentricity A-C: kO.010

(m.25)
I A-C
II A-W *O.W6
Y (rn.20)
a
A-C Plot On Chart >
5
z-5
m.006
(m.i 5)
Eccentricity B-D: s
I B-D B
W
II B-D(-)
m.002
(m.05)
B-D Plot On Chart
0.0 ma02 f0.004 rn.006 rn.006 m.010 f0.012

(m.05) (rn.10) (m.15) (m.20) (i0.25) (m.30)
ECCENTR+;ClTYB-D
_
NOTE: “Eccentricity” refers to total indicator readings. Actual eccentricity is equal to one-half this value.
--S-
C500 Y2235 Group 06
SECTION 6
LINKAGEAND CONTROLS
SM575 Copyrighted
Section Material
Title Page July 97
ClflRK Group 06, Transmission
TRANSMISSION LINKAGE AND CONTROLS

,,/ KNOBS
DIRECTION CONTROL LEV ER
1. To replace lever knobs, apply Loctite primer N.F.

and Loctite minute bond 312 to I. D. and 0. D. of the
tolerance ring. Apply primer to I. D. of knobs and 0. D.
of lever. Primer should be allowed to dry before minute
bond 312 is applied.
NOTE: Later design eliminated the tolerance ring and LEVER
provided screw on knobs.
DIRECTION CONTROL CABLE
SHIFT CONTROL CABLE

3rd
2nd F
2. Adjust cables and clevises to provide 1.OOinch 125.4 mm] clear-

ance at “x” between control levers and cowl with levers in FORWARD’
‘
AND THIRD’
‘ positions.
Copyrighted Material Linkage and Controls 06-6-l

SM 575, July 9
‘7 l

GROUP 14
C500 Y 180-2009225s~225L-250S-250L-300S-300L-350
GROUP 14-ELECTRICAL
General Troubleshooting ................................................ Section 1
Starter and Battery Troubleshooting ............................ Section 2
Alternator Troubleshooting ........................................... Section 3
Wiring Diagrams ............................................................ Section 4
Electrical Tools ................................................................ Section 5
SM 575, July 9
‘7 Copyrighted Material Electrical
C500 Y2235 Group 14
SECTION 1
GENERAL TROUBLESHOOTING
SM575 Section
Copyrighted Title Page
Material July 97
General Troubleshooting GROUP 14
Parking brake low pres- 1. Fuse defective. 1. Replace fuse.

sure warning buzzer not 2. Buzzer defective. 2. Replace buzzer.
functioning. 3. Air pressure switch defective. 3. Replace air pressure switch.
4. Wiring defective. 4. Replace defective section of
wirina.
1. Repair or replace alternator.

- 2. Replace defective voltage
regulator.
1. Loose connectors or corroded 1. Clean terminals and connec-

battery terminals. tors. Tighten connectors.
2. Defective battery(ies). Replace battery(ies).
3. Short circuit in electrical :: Locate short circuit using con-
system. tinuity checks and repair.
IBattery discharges
rapidly. 4. Drive belt slipping. -
4. Check operation of belt ten-
If worn or damaged, replace.
5. Alternator defective. 5. Repair or replace alternator.
6. Voltage regulator (within alter- 6. Replace defective voltage
nator) defective. regulator.
t :
No battery voltage. 1. Disconnected battery cable(s). 1. Connect cable(s).

2. Battery(ies) discharged. 2. Charge battery(ies). Perform
heavy load tests. If battery(ies)
not defective, recharge
battery(ies).
Improper system 1. Alternator defective. 1. Replace or repair alternator.

voltage. 2. Voltage regulator (within alter- - 2. Replace defective voltage
nator) defective. regulator.
1. Improper system voltage. 1. Refer to Improper System

1 Frequent lamp failures. I- Voltage in Group 14, Section
12.
2. Poor battery connections. 2. Clean battery terminals and
connections. Tighten connec-
I tions.
1. Fuse defective. 1. Replace fuse.

2. Wiring defective. 2. Replace defective section of
Instrument(s) do not wiring.
operate. 3. Instrument(s) defective. 3. Replace instrument(s).
4. Instrument sender(s) defective. 4. Replace sender(s).
SM575 14-1-1 July 97
ClfllW Group 14, Electrical System
Section 2
Starter and Battery

Troubleshooting
General Information ...................................................................................................................... 1
Minimum Tools Required ............................................................................................................. 1
Electrical Checks ............................................................................................................................ 3

Problem 1: Slow or Sluggish Cranking .................................................................................. .3
Problem 2: Nothing Happens When Start Attempt Is Made ................................................... .4
Volt Drop Tests .............................................................................................................................. 6
General Information A CAUTION

Remove all jewelry (watch, rings, brace-
l When troubleshooting an engine cranking or starting
lets, etc.) before working on electrical sys-
system, keep in mind that more than the starter is
tems. Severe burns can result from contact
involved. The cranking motor is only one of the ele-
with electrical circuits.
ments in the starting system. The motor, battery, wir-
ing and switches all make up the system and each
contributes to the proper functioning of that system. A WARNING
Battery service must be done by trained
l It will be helpful to have a good understanding of
personnel. Battery acid can cause severe
solenoid, motor and circuit operation.
burns and injury. Do not smoke or have
l The following is an important point. The starter de- open flames around batteries.
mands high current flow from the battery to perform
its job. It is essential that the switches, wiring, and
connections do not have high resistance which can Minimum Tools Required
cause arcing or heat damage to components and ex-
Digital voltmeter, Clark Part No. 1801989, or equiva-
cessive battery current use during starter operation.
lent.
l All electrical connections must be clean and tight for
Volt-ohm meter (V-O-M), such as Dynamic Engine
minimum resistance. This is especially important for
Analyzer, Clark Part No. 1802047; Simpson 260-w;
the battery cable connections at the battery terminals.
or equivalent.
l The starter is a special type electric motor that oper-
Carbon pile control or battery tester, such as SUN
ates on low dc voltage and must be able to withstand
VAT 40, or equivalent.
extremely high current. The high current carrying
requirement means that the motor can be operated for
only short periods of time. To prevent overheating, IMPORTANT
periods of operation of more than 30 seconds in dura-
Always follow the manufacturer’s instruc-
tion are not recommended.
tions for the test instrument being used
Before performing electrical system service procedures: when making connections and tests on elec-
l Park truck safely. trical circuits.
l Apply parking brake and block drive wheels.

= Return all controls to neutral and turn ignition key
OFF, except as otherwise noted.
SM 575, July 97
‘ Copyrighted MaterialStarter and Battery Troubleshooting l 14-2-l
Group 14, Electrical System CulRK
Starting System Inspection
1. Check the battery.
Be sore that the battery is in good condition and fully
charged before attempting to test the starter and wiring
circuit for problems. It is recommended that you per-
form a voltmeter test and a battery load test.
(BREAKERLESS TYPE)
DISTRIBUTOR
I
BAlTERY
a
L
I
CHARGE LAMP
II
PILOT LAMP
I ALTERNATOR
WATER TEMP
SENDER
SOLENOID VALVE FUEL OUT

(GASOLINE ONLY)
Ignition (Gas and LPG only) and Charging System
14-2-2 l Starter and Battery TroubleshootingCopyrighted Material SM 575, July 9

‘7
ElfIRK Group 14, Electrical System
2. Check the wiring.

Inspect the wiring for damage. Inspect all connections
to starter motor, solenoid, starterrelay, ignition switch,
neutral start switch or any other control switch, and
battery, including ground connections. See wiring
schenkicsin Section 2. Clean and tighten all connecl
tions as needed.
3. Check starter relay, neutral start relay and ignition key
switch.
Inspect all switches to determine their condition. With
switches closed, use avoltmeter to check thecircuit for
continuity. Replace defective switches and wiring as
required. Ground high tension (voltage) coil wire before performing
checks. (Gas and LPG only)
NOTE
When servicing the starting system, never
remove a component until tests have shown
it to be defective.
The following describes typical troubleshooting procedures

for two of the most common starting system problems.
Problem 1: Slow or Sluggish Cranking

Slow or sluggish cranking is one of the more complex
problems to solve. The battery, wiring, switches, starter
motor and engine are all factors that must be checked to
determine where the problem is.
Starting System Schematic
1. Perform a battery load test. Temperature should be
4. Check fuses. 70-80°F (21-27°C). Connect a voltmeter across the
battery terminals. Crank the engine for 15 seconds.
Measure the voltage on the voltmeter.
Electrical Checks
Before performing checks, ground the ignition system:
Disconnect the high tension (voltage) coil wire from the
distributor cap and connect it to a jumper wire that is
connected to ground on the engine. This will prevent the
engine from accidentally being started and also prevent
damage to electrical components while performing starting
system electrical checks and cranking tests.
If voltage is less than 9.6 volt go to step 2.

If voltage is above 9.6 volts got to step 3.
SM 575, July 9
‘7 Copyrighted MaterialStarter and Battery Troubleshooting l 14-2-3
Group 14, Electrical System CUIRK
2. Zf voltage measured in step 1 is less than 9.4 volts, c. Compare the measured system draw with the
check battery and connections. typical current requirements of the gasoline/LsG
engine lift truck system.
l Test the battery with a voltmeter. If the battery is
discharged or suspected of being defective, charge Typical starter current draw: HO-220 amps.
it and test it per recommended procedures.
If current draw is low go to step 4.
l Replace the battery, if necessary.
l Be sure that the correct battery (size and rating) is If current draw is high go to step 5.
installed in the truck. 4. Zf the current draw measured in step 3 is low, it means
l Check for bad connections at battery terminals. high circuit resistance. Measure the voltage drops in
l Clean and tighten all battery connections. the starter motor circuit (see “Additional Starting Sys-
tem Electrical Checks” below ) while cranking the
3. If the voltage measured in step 1 is above 9.6 volts, engine. Large drops of over 0.4-l volt indicate theneed
check motor current draw: to clean and tighten connections or replace wiring in
a. Besmeallbatteryconnectionsarecleanandtight. that portion of the circuit.
Connect an ammeter and carbon pile (e.g., a
Use volt-drop test to find source of high resistance.
battery load tester) in parallel with the battery
Refer to “Additional Starting System Electrical
terminal of the starter solenoidand ground (frame
Checks”, below.
or battery negative terminal). Be sure that the
carbon pile control, or tester, is turned OFF. (Clip- 5. Zfthe current draw measured in step 3 is high, it means
on inductance tester may be used.) high mechanical resistance. Either a poor engine con-
dition exists, such as tight rings, or tight bearings, or
lack of lubrication, or the starter motor needs to be
removed and repaired. The starter motor should be
checked for tight bearings, pole shoe rubbing, shorted
or grounded armature or field coils. Use torque wrench
to measure force required to turn engine over or check
by hand.
Problem 2: Nothing Happens When Start

Attempt Is Made
If the starter motor won’t crank the engine, it may be
simply a poor electrical contact that is the problem. Loose
or corroded battery connections can slow down or stop a
Battery Load Tester starter motor. A loose connection may allow enough cur-
rent to pass to operate some electrical accessories but not
b. Increase the load (current) until the same voltage the starter motor. Or, the problem may be either a defective
is reached as measured when cranking the engine. or discharged battery.
Note the ammeter reading. Turn OFF the load. But the problem may be an open circuit, loose connection
The ammeter reading indicates the cranking sys- or other defect in the starter motor, solenoid switch, starter
tem current draw. relay, neutral start relay, ignition switch, or the wiring.
The best procedure in diagnosing this type of starting prob-
lem is to systematically check the possible trouble points,
starting with the easiest. See following.
1. Check the neutral start relay.
Try moving (jiggling) the directional control lever in
the NEUTRAL position, or shifting into NEUTRAL
while turning the ignition key switch to the START
position. The key switch must be turned back to the
OFF position each time before turning to the START
position.
14-2-4 l Starter and Battery TroubleshootingCopyrighted Material SM 575, July 9

‘7
EUIRK Group 14, Electrical System
A CAUTION Reconnect the battery cables in reverse order of re-

To be safe when checking or removing bat- moval, by connecting positive (+) cable first, then
tery connections for cleaning, first discon- negative (-) cable, and attaching the negative cable to
nect the negative battery cable at the end the engine or frame grotmd last. This way, any spark
where it is attached to the engine or frame that’s produced will be far from the battery. Wipe the
ground connection. Then, try to move battery clean with a cloth or paper towel.
(twist) the cable connectors at the battery
Try starting the engine again.
back and forth to be sure that they are
tight. 4. If the starter still does not operate, check the charge
condition of the battery with a hydrometer or digital
2. Check the connections at the battery. They should be voltmeter.
free from corrosion and securely tightened. If heat is
felt at any of the connections, this is an indication that
a poor connection exists.
3. Perform a volt drop test on the battery post terminal

connections, as described in “Volt Drop Test” later in
this Section,
5. If battery is discharged and the case is not cracked or

damaged and otherwise appears to be in good condi-
tion, recharge the battery and see whether it holds the
charge. If the battery does not hold a charge, check the
charging system. Refer to “Charging System Trouble-
If the connections are tight but need cleaning, remove shooting,” Section.
the cables and clean the battery posts and the inside of Check the fan/alternator drive belt for damage and
the cable connectors, using a wire brush or a special correct tension. Replace or adjust the belt, as neces-
battery terminal cleaning tool to remove the oxidation sary. Refer to “Cooling System and Alternator Belt
film. Also, remove any contamination and sulfate Servicing” in Group 0 1.
deposits that may have formed on the battery. Clean
the battery with a solution of baking soda and water.
Rinse with clean water. Be careful not to get any NOTE
cleaner or dirt in the battery vent holes. Just as a discharged battery isn’t necessar-
ily bad, a charged battery isn’t necessarily
good. An old, or defective battery may show
a full charge but be unable to produce ad-
equate electrical energy to meet the heavy
load demand of the starter motor. The only
way to tell is with a load test.
Battery must be fully charged to perform
load test.
SM 575, July 9
‘7 Copyrighted MaterialStarter and Battery Troubleshooting l 14-2-5
Group 14, Electrical System ElIIRK
6. Perform a load test to determine whether the battery is
good or defective.
Disconnect the battery cables at the terminals. Either

remove the battery for testing, or connect the tester to If voltage measured in step 7 is 0 or less than 7 volts,
the battery in the truck. Refer to the manufacturer’s check for wiring continuity (broken, loose or discon-
instructions for recommended load test procedure us- nected wire) or defective switches such as the ignition
ing a battery tester. key switch, starter relay, or neutral start relay. Also,
check the starter motor-to-engine block ground con-
If the battery is defective, replace battery. Reconnect
nection and the battery negative (ground) cable con-
the battery cables in the correct order of installation
nections.
(ground cable last).
If the battery is good, continue in service and go to step If the voltage measured in step 7 is over 7 volts, the
7. starter solenoid is defective and must be repaired or
replaced.
7. If the battery and its connections are good as deter-
mined in step 3, but the starter still won’t crank the
engine, the problem is probably in the starter motor, the NOTE
solenoid switch, the starter relay, the ignition switch, The ignition switch has a circuit through
or the wiring. the starter relay (magnetic switch) and neu-
tral start switch, separate from the circuit
Check voltageat the starter solenoid S terminal, while
attempting to crank the engine. through the starter relay to the starter so-
lenoid.
Connect the voltmeter between the “switch” terminal
and the frame (body) of the starter motor or the battery
negative terminal, and try to crank the engine. Volt Drop Tests
If voltage is less than 7.0 volts, go to step 8. The objective of volt drop tests is to check circuit resis-
If voltage is over than 7.0 volts, go to step 9. tances of wiring and starter motor circuit in order to locate
trouble spots.
Check voltage drops with engine cranking. The procedure
is to look at resistance in terms of the voltage drop across a
portion of the circuit while the engine is being cranked.
NOTE
The following tests assume that the engine
is in good operating condition and the bat-
tery is at or close to full charge.
14-2-6 . Starter and Battery TroubleshootingCopyrighted Material SM 575, July 9

‘7
Rule of thumb formula for measuring volt- To check positive post battery terminal connection,
age drops: Maximum circuit voltage drop= connect voltmeter from the battery post to the terminal
0.20 volts per 100 amps. on cable. Crank the engine. A voltage reading above 0
volts indicates a poor connection. Clean the terminal
post and cable end. Tighten bolt.
A CAUTION
For safety when checking or removing bat-
tery connections, always first disconnect
the negative battery cable at the engine
ground connection. Do not smoke or allow
open flames around batteries.
To prevent engine from starting when
cranking, ground the ignition system. See
“Electrical Checks”, above.
IMPORTANT
Never operate the starter motor more than 2. Check battery negative (ground) cable and connec-
30 seconds at a time without pausing to tions. To check negative post battery terminal connec-
allow it to cool for at least 2 minutes. Over- tion, connect voltmeter from the battery post to the
heating caused by excessive cranking will terminal on cable. Crank the engine. A voltage reading
seriously damage the starter motor. above 0 volts indicates a poor connection. Clean the
terminal post and cable end. Tighten bolt.
Crank engine and read voltage.
1. Check battery positive cable and connections.

Connect a voltmeter from the positive (+) battery
terminal to the “Battery” terminal on the starter sole-
noid. With the voltmeter set on its lowest scale, crank
the engine for 15 seconds, and measure the voltage. A
reading higher than 0.4 volts indicates high resistance.
Check the cable for loose connections or the battery
terminal connection for corrosion.
BATTERY
STARTER
SM 575, July 9
‘7 Copyrighted Material Starter and Battery Troubleshooting l 14-2-7
Group 14, Electrical System elfIRK
To check negative post battery terminal connection, 5. Check starter ground circuit.
connect voltmeter from the battery post to the terminal
Connect a voltmeter from the frame (body) of the
on cable. Crank the engine. A voltage reading above 0
starter motor, to either a point on the engine flywheel
volts indicates a poor connection. Clean the terminal
housing or the bolt that mounts the battery negative
post and cable end. Tighten bolt.
cable to the ground connection on the engine or frame.
While cranking the engine, a reading higher than 0.2
volts indicates excessive resistance. Clean the starter
mounting bolts and flange.
r’I
mm m&
1
IGNITION
SWITCH NEUTRAL STARTER
START RELAY
3. Check key switch, starter relay and solenoid circuit.

Connect a voltmeter across the “Battery” terminal of
the solenoid and the “Switch” terminal of the solenoid.
A voltmeter reading of 1.0-2.0 volts is expected with
the engine cranking. A reading of more than 2 volts I I SAlTERY
I
indicates excessive resistance. Check the wiring, con- =

:
nections, and switches in this portion of the circuit.
Alternate Method. Connect the voltmeter from the

frame of the starter motor, to the battery negative
terminal post. While cranking, a reading higher than
0.4-0.6 volts indicates excessive resistance. Clean
starter mounting flange and bolts, check battery nega-
tive cable for damage, clean and tighten battery cable
connections.
4. Check the starter solenoid disc contact.
Connect a voltmeter across the solenoid “Battery”
terminal and the solenoid motor terminal. With the
engine cranking, avoltagereading of less than 0.2 volts
should be measured. A reading higher than 0.2 volts
indicates excessive resistance within the solenoid.
Check the solenoid contact disc and terminals.
BATTERY
14-2-8 9 Starter and Battery Troubleshooting Copyrighted Material SM 575, July 97

‘
Section 3
Alternator
Troubleshooting
Alternator Maintenance Precautions .. .. ... .. ................... ................. ..... .......................... ............... 1
Troubleshooting Procedures ......................................................................................................... 2

Abnormal Operation of Charging System ....................................................................................... 3
Symptoms, Causes, and Remedies .... ..... ..... ................... ................. .............................................. 3
Do not short across or ground any of the terminals on

Alternator Maintenance Precautions the alternator or in the charging circuit, except as
Disconnect the battery, before connecting or discon- specifically instructed in a troubleshooting procedure.
necting test instruments (except voltmeter) or before The alternator must not be operated on open circuit
removing or replacing any unit or wiring. Accidental with the rotor winding energized. Check all terminals
grounding or shorting at the regulator, alternator, am- for tight connections.
meter or accessories, will cause severe damage to the
Be sure the alternator and battery have the same ground
units and/or wiring.
polarity.
NOTE Reversed battery connections may damage the rectifi-
Disconnect the negative (-) battery cable ers, wiring or other components of the charging sys-
first. tem. Battery polarity should be checked with a
voltmeter before connecting the battery.
Always follow the manufacturer’s instructions for the
If a booster battery or a fast charger is used, its polar-
test instrument being used when making connections
ity must be connected correctly to prevent damage to
and tests on electrical circuits.
the electrical system components. Connect positive to
To avoid damage to the regulator, do not at any time, positive, negative to negative. Connect the negative
connect battery to the regulator field terminal. cable ground connection last (but not to the battery
The field circuit must never be grounded on this sys- because an explosion could result).
tem, between the alternator and the regulator. Ground-
ing of the field terminal either at the alternator or A
CAUTION
regulator will damage the regulator. SAFE PARKING. Before working on truck:
Grounding of the alternator output terminal may dam- 1. Park truck on a hard, level,-and solid
age the alternator and/or circuit and components. surface, such as a concrete floor with no
gaps or breaks.
If it is necessary to solder any lead to a rectifier lead,
2. Put upright in vertical position and fully
use a pair of pliers as a heat dam between the solder
lower the forks or attachment.
joint and the rectifier.
3. Put all controls in neutral. Turn key switch
Do not attempt to polarize the alternator. No polariza- OFF and remove key.
tion is required. Any attempt to do so may result in 4. Apply the parking brake and block the
damage to the alternator, regulator, or circuits. wheels.
SM 575, July 9
‘7 Copyrighted Material Alternator Troubleshooting l 14-3-1
Group 14, Electrical System ClRRK
A basic charging system wiring diagram showing charging

circuit connections for gas/LPG trucks and diesel trucks are
Troubleshooting Procedures shown below.
For complete details of truck wiring, refer to the schematics
NOTE appearing in Section 4.
Following these procedures in the order Trouble in the charging system will show up as either or
presented will lead to the location and cor- both of the following conditions:
rection of charging system defects in the
l Abnormal ammeter operation.
shortest possible time. Usually only a por-
tion of these procedures will need to be l Abnormal charging system operation.
performed. It will never be necessary to
perform all the procedures in order to lo-
cate the trouble.
BATTERY
Basic GasILPG Charging System Diagram Basic Diesel Charging System Diagram
14-3-2 l Alternator Troubleshooting Copyrighted Material SM 575, July 97

‘
ClflRK Group 14, Electrical System
Abnormal Operation (Negative Reading) of

the Ammeter
If the ammeter shows a negative condition with the engine Symptoms, Causes, and Remedies
running, an abnormal condition in the charging system is
indicated. Proceed to perform the following checks to de-
Battery Undercharged-Ammeter Reads Negative
termine the casue.
Defective cables, dirty posts, corroded terminals, etc.
Check, clean, repair or replace as needed.
Abnormal Operation of Charging System
Loose or broken belt. Check belt.
1. Be sure that an undercharged condition (discharged Worn or broken brushes. Replace brush assembly.
battery) has not been caused by ignition key switch or
Defective alternator system. Repair or replace alter-
other accessories having been left on for extended
nator.
periods.
Battery Undercharged-Ammeter Neutral With Key On
2. Check the alternator drive belt for damage and proper And Engine Stopped (Normal Condition Is Slight
tension. Negative Reading)
3. If a battery defect is suspected, check condition of the l Plug at rear of alternator. Check plug to ensure it is
battery. fully seated.
4. Inspect the wiring for defects. Check all connections l Broken brush. Replace brush assembly.
for tightness and cleanliness, including the connectors l Defective alternator system. Replace regulator.
at the alternator and connections at the battery.
5. With ignition switch ON and all wiring harness leads Battery Overcharges;
connected, connect a voltmeter from: Excessive Use Of Water;
l Alternator BAT terminal to ground. Voltmeter Indicates Greater Than 14.5 Volts
0 Alternator terminal L to ground. (Connected Across Battery With No Load) With
Engine Idling
l Alternator terminal S to ground.-
l Defective alternator system. Repair or replace regula-
A zero reading indicates a break between voltmeter tor.
connection and battery. Repair as required.
With all accessories turned off, connect a voltmeter Battery Charges At Idle, But Discharges Under Load
across the battery. Operate engine at moderate speed Conditions
(1500-1800rpm).Ifvoltageis 15.5voltsormore(12- l Slipping belts. Check belts and adjust tension or re-
volt system), remove alternator for repair.
place, as necessary.
If previous Steps 1 through 6 check satisfactorily, l Alternator defective. Repair or replace alternator.
check alternator as follows:
a. Disconnect battery ground cable. Ammeter Shows Slight Charge Under Moderate Load;
b. Connect an ammeter in the circuit at the BAT Battery Appears Charged
terminal of the alternator. Defective diode trio. Replace diode trio.
c. Reconnect battery ground cable.
d. Connect a carbon pile across the battery. Turn on
all accessories.
e. Disconnect ignition coil. Crank engine for 15
seconds with coil disconnected. Connect coil.
Start engine and operate engine at maximum no-
load governed speed. Adjust carbon pile as re-
quired to obtain maximum current output. Amme-
ter should read within 10 amps of rating.
f. If ampere output is within 10 amps of rated output
as stamped on alternator frame, alternator most
likely is not defective. Recheck Steps 1 through 6.
SM 575, July 9‘ 7 Copyrighted Material Alternator Troubleshooting l 14-3-3

ITEM I DESCRIPTION
20 Adjusting Ring - L.H.
21 Cotter* or Pin’
22 Caps - Differential Bearing
23 Washers
24 Capscrews - Diff. Bearing Cap
25 Lock Plate* - Adjusting Ring
26 Washers* - Lock Plate*
27 Capscrews* - Lock Plate*
28 Cover* - Air Cylinder Opening
29 Washers* - Cover*
30 Capscrews* - Cover*
31 Adjusting Ring - R.H.
32 Plug* - Oil Fill Hole (carrier)
33 Washer’ - Capscrew/Plug*
34 Capscrew/Plug* - Sensor Hole
35 Thrust Block*
36 Washers* - Differential Case
37 Nuts* - Differential Case
38 Bearing Cup - Differential L.H.
39 Bearing Cone - Differential L.H.
40 Nuts* - Ring Gear and Case
Half
41 Case Half - Flange
42 Ring Gear
43 Bolts* or Rivets* - Ring Gear
and Case Half
44 Side Gears - Differential
45 Thrust Washers - Differential
Pinion
46 Pinions - Differential
47 Spider - Differential
48 Thrust Washers - Differential
Side Gear
49 Capscrews - Differential Case
50 Bolts* - Differential Case
51 Bearing Cup - Differential R.H.
52 Bearing Cone - Differential
R.H.
53 Case Half - Plain
THE FOLLOWING PARTS ARE FOR DIFF.

LOCK CARRIERS ONLY
54 Lock Nut - Sensor Switch

55 Sensor Switch
56 Spring - Shift Shaft
57 Shift Shaft
58 Pin - Spring Retaining
59 Washer* or Silastic’ - Air
Cylinder
SINGLE REDUCTION Tube - Air Cylinder
60
DIFFERENTIAL CARRIER 61 Piston
1ITEM 1 DESCRIPTION ITEM 1 DESCRIPTIQN 62 O-Ring - Piston
63 Copper Gasket - Cylinder
1 Nut - Drive Pinion 11 Shims Cover
2 Washer - Drive Pinion* 12 Spacer - Pinion Bearing 64 Capscrew - Manual Actuation
NOTE DIFFERENTIAL CARRIERS WITHOUT DIFF. LOCK DO NOT HAVE PARTS 54
3 Input Yoke* or Flange* 13 Bearing Cup - Pinion Inner 65 Cylinder Cover
THROUGH 72. SOME OF THESE CARRIERS HAVE A COVER AND PLUG
4 Deflector 14 Bearing Cone - Pinion Inner 66 Capscrews - Cylinder Cover
INSTALLED OVER THE AIR CYLINDER OPENING AND SENSOR SWITCH HOLE IN
5 Oil Seal 15 Drive Pinion 67 Plug - Cylinder Cover
THE CARRIER.
6 Capscrew - Bearing Cage 16 Spigot Bearing 68 Gasket - Cover Plug
7 Washer 16A Snap Ring 69 Washers - Cylinder Cover
8 Bearing Cone - Pinion Outer 17 Carrier 70 Shift Collar
9 Bearing Cup - Pinion Outer 18 Thrust Screw* 71 Pins - Shift Fork
10 Bearing Cage - Drive Pinion 19 Jam Nut* - Thrust Screw* 72 Shift Fork
L
*Some Rockwell Carriers do not have the part5 described.

15” Q PLUS
16.5” Q SERIES AND Q PLUS BRAKE 15” Q .SERIES BRAKE P SERIES BRAKE
ITEM DESCRIPTION ITEM DESCRIPTION ITEM

! DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION
Shoe and lining assembly 13 Spider - brake Camshaft 15 Spring - shoe return 1 Spider - brake 14 Bracket - camshaft & chamber
2 Spring - shoe retaining 14 Seal - chamber bracket 2 Washer - camhead 16 Rollers - brake shoe 2 Shoe and lining assembly 15 Washer - bracket capscrew
3 Bushing -Anchorpin 15 Bracket - camshaft & chamber 3 Seal - camshaft (grease) 17 Anchor Pins - brake shoe 3 Spring - brake shoe return 16 Capscrew - camshaft bracket
4 Anchor pin - brake shoe 16 Capscrew - chamber bracket 4 Bu.shing - camshaft 18 Plate - support 4 Snap Ring - anchor pin 17 Fitting- grease
5 Camshaft - “s” head 17 Fitting - grease 5 Bracket - camshaft 19 Backing Plate 5 Anchor Pin - brake shoe 18 Slack Adj. - automatic
6 Washer - camhead 18 Washer - camshaft (thick) 6 Nut - camshaft bracket 20 Washer - anchor pin 6 Bushing - anchor pin 19 Washer - spacing
7 Seal - camshaft (grease) 19 Slack Adj. - automatic 7 Grease Fitting 21 Nut - anchor pin 7 Camshaft - “s” head 20 Snap ring - camshaft
8 Bushing - camshaft 20 Washer - spacing 8 Washer - spacing 22 Dust Shield 8 Washer - camhead 21 Dust Shield
9 Pin - return spring 21 Snap ring - camshaft 9 Slack Adjuster - automatic 23 Bolt - shoe clip 9 Seal - camshaft (grease) 22 Capscrew - dust shield
10 Roller- brake shoe 22 Dust Shield 10 Spacers - camshaft 24 Bolt - camshaft bracket 10 Bushing -camshaft 23 Plug
11 Retainer - shoe roller 23 Capscrew - dust shield 11 Snap Ring - camshaft 25 Nut - clip to backing plate 11 Pin - return spring
12 Spring - brake shoe return 24 Plug 12 Spring - shoe retaining 26 Capscrew - dust shield 12 Roller - brake shoe
13 Shoe & lining assembly 27 Nut - dust shield 13 Seal - camshaft bracket
14 Clips - anti-rattle
T SERIES BRAKE
-
TEM DESCRIPTION ITEM DESCRIPTION
-
1 Camshaft 13 Spring - anti-rattle
2 Washer - camhead 14 Rod - anti-rattle
3 Seal - camshaft (grease) 15 Shoe & lining assembly
4 Bushing 16 Spring - shoe return
5 Bracket - camshaft & chamber 17 Roller - brake shoe
6 Lockwasher - bracket 18 Snap Ring -Anchor pin
7 Nut - bracket 19 Anchor Pin - brake shoe
8 Washer - spacing 20 Washer - anchor pin
9 Slack Adj - automatic 21 Nut - anchor pin
10 Washer - spacer 22 Backing Plate
11 Snap ring - camshaft 23 Capscrew - dust shield
12 Retainer - anti-rattle spring
-
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C500 Y2235 Group 14
SECTION 5
ELECTRICAL TOOLS

CUIRK Group 14, Electrical System
ELECTRICAL TOOLS
Wherever possible, Packard Electric “Weather Pack”

connectors have been used in the Y2235 lift truck
wiring. These are considered by Clark to be a design
improvement over electrical connectors previously
used. They are described by the manufacturer as
follows:
Weather Pack connectors are made for signal level

circuits in harsh environmental conditions where even
a small degradation in the connection may be critical.
Special materials and seals are used to allow the
Weather Pack removal tool.
connector to withstand conditions of extreme tempera- Packard Electric part number 12014012
ture and moisture. The connector employs a pin and
sleeve-type terminal. The pin flexes outward to main-
tain contact with the sleeve and is therefore called a
flexpin. The sleeve has a laplock to reduce relaxation. Use removal tool to remove wire terminal from connec-
Weather Pack connectors have cylindrical cavities and tor body on either male or female end. First release
generally have positive locking and secondary locking plastic latch at back of connector body. Then insert
features. Since the female terminal has more stability removal tool into front of body to release terminal
in the extended cylinders, the connectors are de- locking nib. Terminal and wire can then be removed
scribed as being either tower (female terminal) or from connector.
shroud (male terminal).
Crimping and removal tools may be purchased from:
The Weather Pack connectors require the use of the
following special tools: PIONEER-STANDARD ELECTRONICS, INC.
PACKARD BRANCH
5400 NAIMAN PARKWAY
SOLON, OHIO 44139 / (216) 587-3600
IN OHIO: l-(800) 447-4567
OUTSIDE OHIO: l-(800) PACKARD
Weather Pack hand crimper for 14,16,18 & 20

gauge terminals.
Packard Electric part number 12014254
This unit crimps terminal and seal simultaneously and

will release automatically when the proper crimping
pressure has been applied. A less expensive hand
crimper that lacks the dual crimping and automatic
pressure release features is also available. It is Pack-
ard Electric part number 12085272.
SM 575, July 9
‘7 Copyrighted Material Electrical Tools l 14-5-l
GROUP 20
C500 Y 180-200-225S-225L-25OS-25OL-3OOS-3OOL-350
GROUP 20-DRIVE AXLE
Drive Axle Removal ........................................................ Section 2
Drive Axle Wheel Bearing Adjustment.. ....................... Section 3
Drive Axle Maintenance and Service ............................ Section 4
SM 575, July 9
‘7 Copyrighted Material Drive Axle
C500 Y2235 Group 20
SECTION I
TROUBLESHOOTING
SM575 Copyrighted
SectionMaterial
Tile Page July 97
1. Lubricant not to specified level. 1. Check lubricant level. Fill as

required. Check for leaks.
2. Incorrect lubricant. 2. Check specifications. Drain
and refill with correct lubricant.
3. Gear and pinion set not ad- 3. Remove for inspection. Adjust
justed for proper tooth contact. as necessary.
4. Teeth of gear and pinion set 4. Replace gear and pinion set.
chipped or worn.
5. Incorrect gear to pinion back- 5. Adjust backlash.
lash.
Constant noise from 6. Teeth of planet carrier assem- 6. Replace as necessary.
bly and/or gear hub worn or -
drive axle.
chipped.
7. Loose or worn pinion bearing. 7. Adjust or replace pinion
bearing.
8. Teeth of pinion and side gear 8. Replace as necessary.
and differential spider worn or
chipped.
9. Teeth of sun gear worn or 9. Replace sun gear.
chipped.
10. Loose or worn differential bear- 10. Adjust or replace as neces-
ing cone(s). sary. Replace bearing
cone(s) and bearing cups as a
set.
11. Loose or worn hub bearing 11. Adjust or replace hub bearing
cone(s). cone(s). Replace bearing
-I
set.
Intermittent noise from 1. Gear of gear and pinion set 1. Uneven pressure on capscrews
drive axle. does not run true. attaching gear to differential
case flanged half. If gear is
warped, replace gearand
I pinion as a set. I
1. Incorrect lubricant. 1. Check specifications. Drain ant

refill with correct lubricant.
2. Lubricant above specified 2. Drain excess lubricant.
level. 3. Replace hub seal.
3. Worn hub seal. 4. Disassemble and reseal.
ILubricant leaks at drive

axle wheel hub. I-
4. Defective sealant between
spindle end and housing
assembly. 5. Disassemble and reseal.
5. Defective sealant between sun
gear thrust cap assembly and
planet carrier assembly.
6. Drain or servicing plugs loose. 6. Tighten plugs.
1. Incorrect lubricant. 1. Check specifications. Drain

I t&&ant leaks at pinion t and refill with correct lubricant.
2. Lubricant above specified 2. Drain excess lubricant.
level.
Intended for CLARK
20-l-l dealers only
1. Loss of seal at breather or

Lubricant leaks at drive defective breather.
axle housing. 2. Drain or servicing plugs loose.
1. Side gear tight in differential 1. Inspect for cause and correct.

and carrier assembly.
2. Planet pinion and sun gears 2. Replace gears.
worn.
Noisy on turns only. 3. Defective pinion and/or side 3. Replace pinion and side gears
gear. in sets.
4. Thrust washer worn or 4. Replace thrust washers in
defective. sets.
5. Excessive backlash between 5. Adjust backlash.
pinion and side gear.
1. Improper tire inflation. 1. Inflate tire(s) to correct

pressure.
Excessive tire wear. 2. Loose wheel lugs and nuts. 2. Tighten wheel lugs and nuts.
3. Mismatched tires. 3. Correctly match tires.
4. Tires installed incorrectly. 4. Correctly install tires accord-
t
ind to directional arrow.
July 97 Intended for CLARK
20-l -2 dealers only SM575
C500 Y2235 Group 20
SECTION 2
DRIVE AXLE REMOVAL
SM575 Copyrighted
SectionMaterial
Tile Page July 97
ClflRK Group 20, Drive Axle
DRIVE AXLE REMOVAL
1. Park truck on level surface and chock front and

rear of steer axle wheels.
4. Remove floor plates as shown.
2. Fasten chain and hoist to upright as shown and

lift front of truck and place solid blocking or jack
stands under upright.
Note: A hoist of a minimum capacity of 10 tons [9074
kg] is required.
5. Remove bolts from transmission and axle flanges
3. Remove wheels, tires and spacers, if used. and then remove prop shaft from truck as shown.
A DANGER
Check tire inflation before removing. If
less than 80 p.s.i., either inflate to 100
p.s.i. using portable restraining device
or totally deflate tire. Keep face and
body to side of tire when inflating or
deflating. Make sure no other person-
nel are in area in front of tireand wheel.
Note: Refer to Group 22 for information on the safe 6. Disconnect air brake lines at brake chamber on
handling of split rim wheels and tires. drive axle. Cap or plug all exposed fittings or ports.
Lay hoses back where they will not interfere with
drive axle removal.
SM 575, July 9
‘7 Copyrighted Material Drive Axle Removal l 20-2-l
Group 20, Drive Axle ClllRK
A DANGER A CAUTION
If you are not absolutely sure of correct
Depressure air system by applying
brakes until gauge readszero pressure. bolt-to-piston engagement, repeat this
Severe injury or death can result if air step until you are sure.
system components are removed while
system is still pressurized. d.Turn release bolt l/4 turn clockwise and pull
bolt out to lock formed end into piston.
7. Disconnect brake chamber actuating levers.
A
Disengage the spring operated, “Automatic On”
parking brake in the following manner: CAUTION
If bolt does not lock into position in less
a. Remove end-cover cap from center of hole in than a 112 inch outward movement,
head of brake chamber. repeat steps 4 and 5 until you are sure
it does.
e.Holding bolt locked into piston, install flat

washer and release-nut on end of release bolt
and turn down nut against flatwasher until
finger tight.
f. Using a 3/4 inch hand wrench (DO NOT USE

AN IMPACT WRENCH), turn release nut clock-
wise until three inches of bolt extends above
the nut. (A three inch wide strip of paper can
be rolled up and taped to use to measure the
exposed nut).
b. Using a 3/4 inch wrench, unscrew release nut,

flat washer and release bolt from their storage
pocket on side of chamber.
c. Insert release bolt into centerhole of head and,

being sure formed end of bolt has entered hole
in piston inside the chamber, continue to insert
bolt until it bottoms out.
Unbolt brake chambers from mounting brackets and

remove from truck.
20-2-2 l Drive Axle Removal Copyrighted Material SM 575, July 9

‘7
CIRRK Group 20, Drive Axle
8. Rig chain or web belt sling around both sides of

differential to support drive axle in balanced manner.
Attach suitable hoist and lift so that all slack is out of
sling and axle will be supported when mounting bolts
are removed.
Note: Drive axle weight 1700 pounds [771 kg].
9. Remove mounting bolts as shown.
10. Position a fork truck at approximately right angles

to drive axle and position forks to support axle.
Avoid lifting on brake shafts.
11. Lower hoist and ensure that drive axle is resting

securely on forks. If necessary, chain axle to forks.
Pull axle out from under truck and set on floor or
suitable stand. Avoid setting on brake shafts.
12. Reverse procedure to reinstall drive axle. Torque

axle to frame bolts to 447-503 Ibf-ft [606-681 Nom].
Refer to Group 23 for wheel lug nut torque and
tightening sequence.
13.To reactivate the piggyback/spring parking brake

portion of the brake chambers from their manually
released position, reverse procedure a. thru f.
Reinstall the release bolt, flat washer and nut into
the storage pocket using 10 Ibs-ft torque on nut
against flat washer.
SM 575, July 9
‘7 Drive Axle Removal l 20-2-3
C500 Y2235 Group 20
SECTION 3
DRIVEAXLE
WHEEL BEARING ADJUSTMENT
and
PLANETARYAXLE
WHEEL ENDS
There are two pieces of vendor literature in this

section. “DRIVE AXLE WHEEL BEARING AD-
JUSTMENTS” AND “PLANETARY AXLE
WHEEL ENDS”. The “DRIVE AXLE WHEEL
BEARING ADJUSTMENTS” covers the Clark/
Hurth drive axle used on models prior to lot
8518.The”PLANETARYAXLEWHEELENDS”
covers the Rockwell drive axle used on lots
8518 and above.
SM575 Section
Material July 97
Field Maintenance Manual No. 9
Planetary Axle
Wheel Ends
Steering and Rigid Models
Rockwell
TABLE OF CONTENTS
SUBJECT
AXLE DESIGNATION CHART.. .................................. 3
AXLE DESCRIPTION .......................................... 4
DISASSEMBLE WHEEL END .................................... 5

Prepare for Disassembly ............................................ 5
Remove Spider Assembly .......................................... 5
Disassemble Spider Assembly ...................................... 6
Remove Ring Gear Assembly ........................................ 7
Remove Hub and Drum Assembly .................................... 8
Disassemble Hub Spindle Assembly ................................... 8
Disassemble “Cardan” Steering Joint ................................. 9
Disassemble “Rzeppa” Steering Joint ................................ 10
RemoveAxleShafts ................................................ 10
Universal Joint Disassembly ........................................ 10
Remove Steering Knuckle Assembly
(One Piece Construction) .......................................... 11
Remove Trunnion Socket Assembly
(Split Type Construction) .......................................... 12
Disassemble Split Type Knuckle
(Tapered Bearing Type) .......................................... 12
(Bronze Bushing Type) ............................................ 13
PREPARE FOR REASSEMBLY .................................. 13

Clean ............................................................ 13
Inspect .......................................................... 14
Repair ............................................................ 15
Dri-LocFasteners .................................................. 15
REASSEMBLE WHEEL END .................................. ;;

Install Oil Seal
Reassemble”Carban”j‘dini:::::::::::::::::::::::::::::::::::::: 16
Reassemble “Rzeppa” Joint 16
Replacementof”Rzeppa”JoiniCompbnents:::::::::::::::::::::::: 17
Install Trunnion Socket Pin Bearings or Bushings .................... 18
Mount Trunnion Socket to Housing ................................ 18
Assemble Steering Knuckle .... ........ ...... . . . . . . . . . . . . . . . . . . .. ii
Adjust Steering Knuckle
Assemble Split Type Knuckle&d T&t%& Socket : : : : : : : : : : : : : : : : : : : : 19
Adjust Steering Knuckle Bearings ................................ 19
AttachComponents ............................................ 19
Install Axle Shaft and Universal Joint Assembly ...................... 19
Install Hub Spindle Assembly .................................... 20
Assemble Ring Gear Hub Assembly ................................ 20
Assemble Axle Shaft in Rigid Axles ................................ 21
Assemble Hub, Bearings, Oil Seal and Drum ...................... 21
Wheel Bearing Adjustment ...................................... 21
Install Ring and Sun Gears ...................................... 23
Assemble Planetary Spider ...................................... 23
TABLE OF CONTENTS (Continued)
SUBJECT PAGE
Install Spider Assembly ........................................ 25
install Spider Cover ............................................ 25
LUBRICATION .............................................. 26
FillProcedure .................................................. 26
STEERING ALIGNMENT . _. . . . . . . . . . . . . . . . . . . . . . . . . _. . . . . _. . 26
TIRE MATCHING . _ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
FASTENER TORQUE VALUES . . . . . . . . . . . . _. . . . . . . . . . . . . . . . . . . 28
MODEL CROSS REFERENCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . 31
IMPORTANT
Follow all CAUTION and IMPORTANT Notes used throughout this manual
to prevent personal injury and ensure mechanical integrity of components
being serviced. The wearing of appropriate and safe eye protection is
suggested while servicing and repairing components to prevent personal
injury from chips or splinters.
ROCKWELL PLANETARY AXLE DESIGNATIONS
I
P - CAM AIR
TW - FLAT CAM
RSH - ROCKWELL SINGLE I
HYD STOPMASTER
RSA - ROCKWELL SINGLE
AIR STOPMASTER
RDH - ROCKWELL DUAL
HYD STOPMASTER
RDA - ROCKWELL DUAL
AIR STOPMASTER
FSH - FLOATING SHOE HYD
M - MECHANICAL
N - NONE
D
‘ ISC SIZE
Intended for CLARK dealers only 3
HYPOID GEAR CARMER PLANETARY WHEEL END
(FIRST REDUCTION) (SECOND REDUCTION)
DOUBLE-REDUCTION PLANETARY AXLES

Rockwell double-reduction planetary axles incorpo- The spur teeth of the sun gear (which floats) mesh
rate a single reduction carrier with hypoid or spiral with teeth of the planet spur gears. The planet spur
bevel gearing mounted in the axle center. The sec- gears rotate on planet pins which are mounted in a
ond reduction is of planetary design spur gearing spider. The planet spur gear teeth in turn mesh with
built into the wheel hubs. teeth of the floating ring gear.
There are three types of housings, cast, stamped and Power is transmitted by the first reduction bevel gear
modular. set in the carrier to the axle shafts and the sun gear
of the planetary second reduction, through the re-
Rockwell Planetary Axles permit the bevel gearing of volving planet gears, and into the planetary spider
the carrier, and the axle shafts to carry nominal tor- which drives the wheel hub.
sional load while providing the highest practical nu-
merical gear reduction at the wheels. This manual covers the disassembly, inspection,
reassembly and adjustment procedures of the plane-
The hypoid or spiral pinion and differential assembly tary wheel end, steering joint and knuckle assembly.
of the first reduction are supported by tapered roller
bearings. The pinion bearing preload is adjusted and
maintained by a hardened precision spacer between NOTE: The servicing of the standard first reduction
the inner and outer bearings. The differential tapered gear carrier assembly mounted in the axle center
bearing preload is adjusted and maintained by the is thoroughly covered in our Field Maintenance
positioning of the threaded adjusting rings in the car- Manual No. 5 (and 5C if drive unit is the through-
rier leg and cap bores. drive tandem axle type).
4 Intended for CLARK dealers only
DISASSEMBLY
HUB/DRUM OIL SEAL

ASSEMBLY ASSEMBLY
WHEEL BRG.
ADJ. NUT
PLANETARY
SPIDER/COVER
HUB
PLANE
SPINDLE
PINS
/
CAPSCREW
AND
\
PLANET
GEAR
WASHER
WASHER
THRUST
WASHER
DISASSEMBLY OF PLANETARY WHEEL ENDS

PREPARE FOR DISASSEMBLY REMOVE PLANETARY SPIDER
NOTE: Unless service is planned for brakes and/
ASSEMBLY
or steering knuckles, it will not be necessary to
remove the tire and rim from the planetary MATCH MARK
wheel end to service the planetary gearing.
Before starting the disassembly of the planetary

wheel end the following procedure and precau-
tions should be taken:
A. Jack up wheel end of vehicle just enough so the

tire clears the ground.
B. Block up the axle in this position under the spring

seat using a jack stand or other suitable fixture.
After blocking up the vehicle remove the jacks.
A CAUTION: Do not attempt to perform any

type of service on the wheel end with the
vehicle supported by jacks only.
C. Rotate the hub asembly so that the oil drain plug NOTE: Before disassembly match mark both the
in the spider/cover is at the bottom. Remove the spider and wheel hub for identification of cor-
drain plug and drain the lubricant. rect alignment when reassembling the unit.
DISASSEMBLY
A. If wheel ends have a separate planetary spider DISASSEMBLE PLANETARY

and cover remove the spider cover capscrews
SPIDER ASSEMBLY
and cover.
Planetary spur gears rotate on planet pins. Each
B. Remove the planetary spider to hub stud nuts or gear rotates between hardened thrust washers.
capscrews and washers.
ULLER
‘
SCREW
HOLES
pins in the spider. Set screws are located at the

BOLTED COVER DESIGN small diameter ends of the planet pins.
B. Support the spider assembly in a press, flange
side down. Block up as required. To avoid dam-
C. Separate and remove planetary spider assembly
aging the pins place a block of wood under the
from wheel hub assembly: use puller screws in
press to cushion the pins as they are pressed out.
threaded holes when provided in the spider
Press the planet pins out through the spider and
flange.
planet gears. (It is possible/acceptable to encoun-
A
CAUTION: Rockwell planetary axles em- ter a non-press fit condition on the bolted cover
ploy a floating ring gear. Care should be design).
taken to prevent this gear from accidentally fall- NOTE: If a press is not available use a brass drift
ing out when planetary spider is removed. and mallet to tap out the pins.
A
CAUTION: Do not strike planet pins directly
with a steel hammer. Personal injury from
chips or splinters may result.
J
NOTE: The adhesive effect of the liquid gasket C. Remove the planet gears and their respective
material may necessitate the use of the pry bar thrust washer.
slots provided in some models to assist in loos-
ening the spider. If there are no pry bar slots NOTE: Thrust washers are designed for oppo-
break the spider loose from the hub by striking site sides of planet gears and can only be in-
it with a rawhide, plastic or rubber mallet. stalled in their correct locations.
DISASSEMBLY
REMOVE THE FLOATING to the hub spindle in different methods, depend-

RING GEAR ASSEMBLY ing upon the model.)
G. Remove the wheel bearing adjusting nut. Where

double nuts are employed remove the jam nut,
locking washer and the adjusting nut.
A CAUTION: Before removal of ring gear hub

assembly, be sure to provide a sling sup-
port for the wheel hub.
ULLER
‘
SCREW
HOLE
Steering and Smaller Rigid Models

A. Remove floating ring gear (on models where gear
is not secured to ring gear hub).
B. Remove the snap ring from end of axle shaft.
C. Remove the axle shaft sun gear.
NOTE: On some of the larger rigid models the H. Remove the ring gear hub. Puller screw holes are
axle shaft and sun gear are integral. On these provided on the larger models in the ring gear hub
models remove the complete axle shaft, exer- flange to aid in the removal of the hub.
cising care not to damage the oil seal. The sun NOTE: Some models may secure the ring gear
gear thrust washer may then be removed from to the ring gear hub with capscrews and plates
the axle shaft. on the back side of the assembly.
RING OUTER
GEPR
HyB
WWEEL
D. Remove the sun gear thrust washer. The outer wheel bearing is mounted on the ring
gear hub.
E. Remove the axle shaft on rigid models that do not
employ the integral sun gear. J. Remove outer wheel bearing from ring gear hub.
F. Remove the wheel bearing adjusting nut lock. NOTE: In some models the ring gear hub as-
(Wheel bearing adjusting nuts can be of either sin- sembly is made up of the hub and a ring sleeve
gle or double nut construction and may be locked insert. These parts are not serviced separately.
7
Larger Rigid Models Dura-Disc Wet Disc
Brakes - FMM#4L
Larger rigid models are provided with threaded Dura-Master Air
puller screw holes in the ring gear hub flange. There Disc Brakes - FMM#4M
are also threaded holes of a smaller size in the wheel
hub behind the ring gear hub.
DISASSEMBLE HUB SPINDLE
ASSEMBLY
A. Turn the complete hub assembly so that the puller A. Remove brake shoe return spring and push brake
screw holes in the ring gear hub flange entirely shoes aside to permit access to the hub spindle
miss the smaller holes of the wheel hub in back. fasteners.
B. Install puller screws and turn in until they butt B. Remove the inner wheel bearing.
against the flat surface of the wheel hub.
C. Remove the spindle stud nuts, bolts, and
C. Tighten puller screws alternately to pull ring gear washers.
assembly out.
NOTE: You must remove the brake spider to al-
low removal of the spindle on certain models.
REMOVE THE WHEEL HUB All modular housing models have welded on
AND DRUM ASSEMBLY spindles. Also, some rigid models utilizing a
stamped axle housing have welded on spindles.
A. Lift the hub and drum slightly to relieve the hub
weight and drum to brake shoe drag and remove
the assembly from the hub spindle.
A
CAUTION: Removal of hub and drum
assemblies from larger model axles will
require use of a chain fall.
SOME PS MODELS
B. If wheel bearings are to be replaced, remove
wheel bearing cups with a suitable puller. D. Remove the spindle. Care must be taken on some
BRAKES steering models not to damage the inner oil seal,
NOTE: In most cases, complete disassembly of in bore of spindle, while sliding past axle shaft
the brake is not necessary for the removal of the splines.
hub spindle. Adequate working clearance is
NOTE: The wheel hub oil seal/retainer may ad-
provided by removing the brake shoe return
here to the spindle flange due to liquid gasket in
springs. If brakes are to be disassembled for
the joint on some PS models.
service or inspection, refer to one of the follow-
ing Rockwell Field Maintenance Manuals: E. Remove the oil seal assembly. Original design
Hydraulic Brakes - FMM#4
models use a retainer held in position against the
Cam Brakes - FMM#4
spindle flange by a dowel.
Stopmaster Brakes
(17”-36”) - FMM#4P F. On all rigid and some steering models the oil seal
Stopmaster Brakes and retainer assembly is located in the hub out-
(15”) - FMM#4R side the hub rear bearing and wipes the hub spin-
8
DISASSEMBLY
CURRENT DESIGN (PS MODELS)
CARDAN JmNT
A. Remove the axle shaft and universal joint as-

sembly from the housing assembly. Care must
ORIGINAL DESIGN be excercised not to damage the oil seal in the
housing.
dle. Remove the retainer and seal assembly from B. If universal joints are disassembled for the pur-
hub with a suitable puller. Remove bearing. pose of cleaning, inspecting or replacing of
individual components, use the following proce-
NOTE: Do not remove the oil seal from the re- dure.
tainer unless replacement is necessary. 1. Remove the snap rings from the two ears
in each yoke, with a suitable tool.
2. Position the joint assembly in an open vise
with one yoke “horizontal” and resting on top
of the vise jaws (do not tighten the vise).
3. With a suitable soft mallet, tap the upper ear

DISASSEMBLE “CARDAN” of the “vertical” yoke several times. This will
STEERING JOINT. drive the vertical yoke down and push out the
Shown here is the standard “Cardan” steering joint. upper needle bearing and cap (Bearing cap
For service instructions on the “Rzeppa” or “con- has a highly polished surface and care should
stant velocity” joint move ahead to the Rzeppa be exercised not to mar or scratch surface
Steering Joint section on page IO. during removal operation).
DISASSEMBLY
4. If the metal retainershave worked free from REMOVE AXLE SHAFTS

the bearing caps, remove from the arms of
the cross through the hole in the yokes.
5. Turn the “vertical” yoke upside down and

remove the needle bearing and retainer on
the opposite side following procedure out-
lined in items 3 and 4.
Remove the axle shaft and ball joint assembly from

the housing assembly. Care must be exercised not to
damage the oil seal in the housing.
A. Clamp the inner shaft into a bronze jawed vise

with outer race bell in downward position.
6. Remove “vertical” yoke by gently working

yoke off arms of the cross.
7. To complete the disassembly, hold the re-

maining yoke in a “vertical” position and rest
the cross arms on top of the open vise. Re-
peat steps 3,4 and 5.
8. Remove cross from yoke by gently working

cross free.
9. Clean and inspect all parts. When inspecting

bearings, keep needles, caps and retainers
together.
10. Replace parts that show excessive wear or

damage. If it is necessary to use a new cross,
the needle bearings should also be replaced.
Do not mix new and used bearings together.
Replacement should be made in sets of four.
DISASSEMBLE “RZEPPA”
STEERING JOINT B. Drive off the shaft, bell, bearing and cage as-
sembly by use of a bronze drift against end of in-
ner race.
A
CAUTION: Do not strike these hardened
steel pieces directly with a steel hammer.
Personal injury from chips or splinters may
result.
C. Remove the lock ring and discard. When shaft is
reinstalled, a new lock ring should always be
used.
UNIVERSAL JOINT DISASSEMBLY

If universal joints are disassembled for the purpose
of cleaning, inspecting or replacing of individual
components, use the following procedure:
DISASSEMBLY
REMOVE STEERING
KNUCKLE ASSEMBLY
One Piece Construction
A. Disconnect the steering arm linkage.
B. Disconnect the tie rod ends at clevis joint.
C. Remove dust shields where used.
D. Remove brake line from wheel cylinder inlet

fitting.
A. Tilt the inner race in the outer race bell until one
joint ball can be lifted out. Then tilt the inner race
until the next ball can be lifted out, continue until
all the balls are removed.
E. Remove the steering arm cap and or knuckle pin

capscrews.
B. Roll the cage and inner race at right angles to the

outer race bell with the two elongated openings in
cage aligned with opposite teeth of bell. Then lift
cage and inner race from the outer race bell.
F. Remove the lower knuckle pin cap, shims and

thrust washer. Then remove the upper knuckle
pin cap and shims. Keep the shims together for
reassembly. (Do not mix the upper and lower
shim packs).
G. Loosen the outer boot clamp wire and fold

C. To separate the inner race from the cage, turn back the boot (where used).
race at right angle to cage, align tooth on race
with elongated hole in cage and roll inner race H. Remove the steering knuckle from the socket.
from cage. The knuckle can be tipped to clear the socket.
DISASSEMBLY
REMOVE TRUNNION SOCKET

ASSEMBLY
Bolted Type Construction
A. Disconnect the steering arm linkage.
B. Disconnect the tie rod ends at clevis joint.
C. Remove dust shields where employed.
D. Remove the stud nuts and lock washers from the

socket to axle housing flange.
E. Separate the trunnion socket assembly from the

axle housing.
F. The trunnion socket assembly can be placed in a

bronze jawed vise for further disassembly.
Remove the bearing cups and separate the knuc-

DISASSEMBLE THE SPLIT TYPE
kle flange assembly. The inner half of knuckle
KNUCKLE ASSEMBLY
flange may be tipped at an angle to clear inner
connecting flange.
Tapered Bearing Type
A. Remove the steering arm stud nuts and lock

washers. G. If bearings are to be replaced, remove the bear-
ings with a suitable puller.
B. Remove the steering arm and shim pack. Shim
pack should be wired together to keep intact to H. Remove the oil seal from the oil seal recess in the
facilitate adjustment on reassembling. housing at connecting flange.
C. Remove the lower bearing cap stud nuts and lock I. Remove the knuckle flange socket felt or oil seal.
washers. New felts or seals should always be used in knuc-
kle rebuild.
D. Remove the lower bearing cap and shim pack.
Wire shim pack together to keep intact to facili- NOTE: Some models may also have a hardened
tate adjustment on reassembling. cover guide plate in front of the oil seal as a seal
.element protector during the installation and
E. Remove fasteners holding knuckle halves together. removal of the axle shafts. These guide plates
DISASSEMBLY
are machined with an interference fit to the

housing seal bore. To remove seals on axles
that employ these guide plates, it is necessary
to drive the plates out by means of a long bar
from the opposite end of housing.
DISASSEMBLE THE TRUNNION SOCKET

ASSEMBLY
Bronze Bushing Type
A. Remove the steering knuckle from the socket. The

knuckle can be tipped to clear the socket.
B. Remove the stud nuts at the connecting flange

and separate the trunnion socket from the axle
housing.
C. Loosen inner boot clamp wire and remove boot. 1 I
NOTE: FLUSH TOTAL AXLE BEFORE the carrier can spread to all other areas of the axle.
REASSEMBLY. Most current rigid axles (PRC, Therefore the entire axle (both wheel ends and
PRM and PRS) do not utilize axle shaft oil seals: center section) should be thoroughly drained and
the lube is common to the wheel ends and the ten: flushed.
ter section. Contamination from either wheel end or
PREPARE FQR REASSEMBLY- CLEAN, INSPECT AND REPAIR

CLEAN Premature failure of bearings, gears and other parts
can be caused by this practice. Assembled drive
Parts having ground and polished surfaces, such as
units cannot be properly cleaned by steam cleaning,
gears, bearings, shafts and collars, should be
dipping or slushing. Complete drive unit disassembly
cleaned in a suitable solvent, such as kerosene or
is a necessary requisite to thorough cleaning.
diesel fuel oil.
Rough Parts
Clean all mating surfaces where fiber or liquid gas-
ket material is used. It may be necessary to use a Rough parts, such as differential carrier castings,
scraper to completely remove gasket materials. Be cast brackets and some brake parts may be cleaned
careful not to damage mating surfaces. in hot solution tanks with mild alkali solutions provid-
ing these parts are not ground or polished. The parts
A
CAUTION: Exercise care to avoid skin rashes,
should remain in the tank long enough to be thor-
fire hazards and inhalation of vapors when
oughly cleaned and heated through. This will aid the
using solvent type cleaners.
evaporation of the rinse water. The parts should be
GASOLINE SHOULD NOT BE USED AS A SOLVENT thoroughly rinsed after cleaning to remove all traces
DO NOT clean these parts in a hot solution tank or of alkali.
A
with water and alkaline solutions, such as sodium CAUTION: Exercise care to avoid skin rashes
hydroxide, orthosilicates or phosphates. and inhalation of vapors when using alkali
cleaners.
DO NOT steam clean assembled drive units after
they have been removed from the housing. When Complete Assemblies
this method of cleaning is used, water is trapped in Completely assembled axles may be steam cleaned
the cored passage of the castings and in the close on the outside only to facilitate initial removal and
clearances between parts as well as on the parts. disassembly, providing all openings are closed.
This can lead to corrosion (rust) of critical parts of Breathers, vented shift units, and all other openings
the assembly and the possibility of circulating rust should be tightly covered or closed to prevent the
particles in the lubricant. possibility of water entering the assembly.
13
Drying
Parts should be thoroughly dried immediately after
cleaning. Use soft, clean, lintless absorbent paper
towels or wiping rags free of abrasive material, such
as lapping compound, metal filings or contaminated
oil. Bearings should never be dried by spinning with
compressed air.
Corrosion Prevention
Parts that have been cleaned, dried, inspected and 3. (a) Visible step wear, particularly at the smai
are to be immediately reassembled should be coated end of the roller track.
with light oil to prevent corrosion. If these parts are (b) Deep indentations, cracks or breaks in
to be stored for any length of time, they should be bearing cup and/or cone surfaces.
treated with a good rust preventive and wrapped in
special paper or other material designed to prevent
corrosion.
INSPECT
It is impossible to overstress the importance of care-
ful and thorough inspection of parts prior to reas-
sembly. Thorough visual inspection for indications of
wear or stress, and the replacement of such parts as 4. Etching or pitting on functioning surfaces.
are necessary will eliminate costly and avoidable
failure.
A. Inspect all bearings, cups and cones, and replace

if rollers or cups are worn, pitted or damaged in
any way. Remove parts needing replacement with
a suitable puller or in a press with sleeves. Avoid
the use of drifts and hammers. They may easily I I
mutilate or distort component parts. 5. Spalling or flaking on bearing cup and/or cone
If any of the following bearing conditions exist, bear- surfaces.
ings must be replaced:
B. Inspect the planetary reduction, planet gears, sun
gear and ring gear assembly for wear or damage.
Gears, shafts or thrust washers which are scored,
pitted, ridged, chipped or worn should be re-
placed.
C. Inspect axle shafts for signs of torsional fractures

or other indications of impending failure.
D. Inspect seals on tie rod ends for any indications of

1. Large ends of rollers worn flush to recess or damage. Also check to make sure seal is securely
radii at large ends of rollers worn flat. seated on socket. If tie rod end has a grease fit-
ting, replace damaged seals. Tie rod ends not
having a greasing provision should be replaced if
seals are damaged or loose.
IMPORTANT: Rockwell does not recommend at-

tempts to salvage damaged ends by repacking and
replacing the boot seal on nongreasable ends.
Check the turning torque value between the tie

rod end assembly stud and the ball cavity. If
torque value is less than five (5) inch pounds, the
tie rod end assembly should be replaced. This is
2. Bright rubbing marks on the dark phosphate not to say the end assembly will fail at this point,
surfaces of the bearing cage. but it can no longer provide the type of steering
control designed into it once lateral movement Reusing Dri-Lot Fasteners and Rockwell Liquid
develops between the stud and the ball cavity. Adhesive 2297-C-3747 (Loctite #277) Application
E. Inspect axle housing for cracks, loose studs and 1. Wipe excess oil residue from the fasteners and
nicks or burrs at machined surfaces. Make all threaded holes. The fasteners and holes should
necessary repair or parts replacement. be relatively oil free, however, no special cleaning
is required. When reusing Dri-Lot fasteners, it is
not necessary to remove the Dri-Lot residue from
threads.
REPAIR
2. Apply Rockwell Liquid Adhesive to the threaded
A. Replace all worn or damaged parts. Trunnion holes only, by letting four or five drops run down
sockets if scratched. Replace all hex nuts with the side of each hole. Before threading in the fas-
rounded corners, distorted washers and snap teners, visually check to make sure that the adhe-
rings, oil seals, gaskets and socket felts at time of sive has contacted the threads.
overhaul. IMPORTANT: Do not apply adhesive to the fas-
tener, since trapped air in the hole will create
IMPORTANT: Use only genuine Rockwell parts for
back pressure and “blow out” the adhesive as
satisfactory service. For example, using gaskets of
the fastener advances.
improper material generally leads to mechanical
trouble due to variations in thickness and the ina- 3. Tighten the fasteners to the specific torque value
bility of certain materials to withstand compres- recommended for that size fastener. Rockwell
sion, oil, and temperature extremes. Liquid Adhesive will not alter the torque require-
ment. Refer to the Fastener Torque Charts on
B. Remove nicks, mars and burrs from machined or page 28.
ground surfaces. Threads must be clean and free NOTE: No cure time is required for Rockwell
to obtain accurate adjustment and correct torque. Liquid Adhesive prior to rebuilding the axle and
A fine mill file or India stone is suitable for this returning it to service.
purpose. Studs must be tight prior to reassem- IMPORTANT: When servicing drive units assem-
bling the parts. bled with Dri-Lot fasteners or with Rockwell
Liquid Adhesive in Threaded holes where the
C. Tighten all the nuts and capscrews to the correct fasteners do not require removal:
torque. (See torque limits on page 27). -Check each fastener for tightness by applying
the minimum amount of torque specified for
USE OF DRI-LOC FASTENERS that size fastener. If the fastener does not rotate,
AND ROCKWELL LIQUID ADHESIVE 2297-C-3747 it is satisfactory. If the fastener rotates to any
(LOCTITE #277) degree, it must be removed from the component
Using New Dri-Lot Fasteners and adhesive must be applied to the threaded
hole. Use the procedures under c6Reuse of Dri-
1. Wipe excess oil and any residue from the Lot Fasteners and Rockwell Liquid Adhesive
threaded holes. The holes should be relatively oil 2297-C-3747 (Loctite #277) Application.”
free, however, no special cleaning is required.
Further, if fastener removal becomes difficult
due to worn heads or unusually high breakaway
2. Assemble the components using Dri-Lot fasten- torques, the locking strength of either Rockwell
ers. DO NOT APPLY ROCKWELL LIQUID ADHE- Liquid Adhesive or Dri-Lot can be reduced by
SIVE OR ANY OTHER TYPE OF FASTENER heating. Heat the fastener for only a few sec-
RETAINER MATERIAL, SEALANT OR ADHESIVE onds at a time while trying to loosen it.
ON DRI-LOC FASTENERS OR IN THE DO NOT EXCEED 177OC (350°Fj maximum.
THREADED HOLES. Heating should be done slowly to avoid thermal
stresses in other components. Application of
3. Tighten the Dri-Lot fasteners to the specified heat reduces the strength of the adhesive and
torque value. Refer to Fastener Torque Chart at Dri-Lot below recommended installation
end of manual. torque.
Rockwell does not recommend removing fas-
NOTE: No cure time is required for Dri-Lot fasteners with an impact wrench or by striking with
teners prior to rebuilding the axle and returning a hammer. Damage to fastener heads can
it to service. result.
Copyrighted Material 15
REASSEMBLY
REASSEMBLE PLANETARY (Cross must move freely in both caps; if cross

should bind, remove cap and check for upset nee-
WHEEL END dles).
INSTALL OIL SEAL IN
HOUSING
A. Install oil seal in axle housing at the outer end with
a suitable driver. Care must be exercised to locate
the seal squarely against the seal recessed shoul-
der or shaft guide.
B. On units incorporating the axle shaft guide plate,

start the plate into the end bore evenly with a mal-
let. Once plate is started square, drive the plate
into position with a suitable driver.
A
CAUTION: Do not strike hardened steel
parts directly with a hammer. Personal in-
jury from chips or splinters may result.
For steering axle models continue on for reassem-

bling steering joints and knuckle assemblies. For
rigid axle models proceed to “Install Hub Spindle
F. With the aid of a short plug, move bearing caps
Assembly” on page 20.
past snap ring groove. Insert snap rings in
REASSEMBLY OF CARDAN JOINT grooves, one with each bearing cap.
A. Insert needle bearing cap into ear of yoke. G. Repeat procedure as outlined in items A thru F for
installing remaining caps and yoke.
B. Place yoke in vise and press needle bearing cap
into the proper position. Bearing cap has a highly
polished surface and care should be exercised
not to mar or scratch surface during installation REASSEMBLE “RZEPPA”
operation. STEERING JOINT
ELONGATED
C. Remove yoke from vise and gently work one arm HOLE
of cross into the yoke and bearing cap.
D. Install opposite bearing cap by hand and line up

A. Install the inner bearing race into cage at right
cross arm.
angle and align race teeth with elongated cage
E. Place yoke in vise and press needle bearing cap hole. Turn race within cage to position parallel
into the yoke and onto the arm of the cross. with cage.
16
REPLACEMENT OF INDIVIDUAL
COMPONENTS IN RZEPPA BALL JOINTS
This will acquaint you with the fact that approxi-
mately 10% of original Rzeppa universal joints are
made with .012” oversize balls, raceways and cages.
All original joints that employ oversize components
are marked on the individual pieces aside from the
balls in the places noted on the following figures:
ETCH ON SHOULDER +.012
FOR IDENTIFICATION
B. Insert the race and cage into the universal bell at

right angle and tilt into position while at the same
time aligning bell teeth with elongated openings.
OUTER RACE BELL
ETCH ON FACE f.012

FOR IDENTIFICATION
ETCH ON FACE +.Ol
CAGE
INNER RACE
C. Tilt, in the bell, the inner race and cage until one
joint ball can be inserted. Then tilt race and cage When disassembling these universal joints for the
with aligning bell teeth until the next joint ball can purpose of cleaning, inspecting or replacing individ-
be inserted. Continue until all the joint balls are in ual components, it is advisable to rework them one
at a time and thus avoid a chance of mixing parts
place.
from standard and oversize assemblies.
D. Clamp the outer end of bell shaft in a bronze
jawed vise or holding fixture with inner race If a considerable number of joints are to be reworked
at one time, it will be necessary to segregate the
splines parallel with the bell face.
components from standard and oversize joints.
E. Install a new locking ring in the inner shaft lock
ring groove. It should be noted further that only standard size
components are furnished for service replacement.
F. Align the splines of inner shaft with splines of the The standard size parts are to be used for replace-
inner race, holding shaft in a vertical position so ment of either standard or oversize parts in the origi-
that lock ring rests in inner race entering chamfer. nal assemblies. It should be noted, however, that if
the outer race, the inner race or the cage in an origi-
G. Tap the end of shaft with a rawhide mallet to col- nal oversize joint is replaced, it will also be necessary
lapse the lock ring. to replace all the balls at the same time. If the origi-
nal oversize balls were to be re-used, the resulting
H. Drive the shaft through the inner race until lock
ring clears splines and opens, thus locking the assembly would be too tight and would lead to hard
steering and short life.
shaft in place.
A
CAUTION: Do not strike these hardened The use of standard size replacement balls in a joint
steel pieces directly with a steel hammer. having one or more of the other components over-
Personal injury from chips or splinters may size, will in no way affect performance or life though
result. there will be slightly more backlash.
REASSEMBLY
INSTALL TRUNNION SOCKET PIN C. Install the inner boot clamp wire in the trunnion
BEARINGS OR BUSHINGS socket groove.
A. If trunnion socket pin bearings have been re- ASSEMBLE STEERING

moved, place knuckle pin end of housing in a KNUCKLE ASSEMBLY
bronze jawed vise or other suitable fixture.
A. Lubricate king pin bushing bores with grease

(Rockwell O-61 7-A or O-61 7-B Spec.).
B. Install the bearing on the knuckle pin by usi of
B. Install knuckle over trunnion socket.
a sleeve driver that bears against the bearing
inner race, or . . . C. Install upper king pin cap with original shim pack.
It may be necessary to drive the cap into the
C. Install bronze bushings with a suitable driver.
knuckle by tightening the king pin capscrews al-
Check fit of the knuckle pin caps in new bush-
ternately in small increments, keeping the king pin
ings and ream if necessary.
cap straight with respect to the knuckle bore.
MOUNT TRUNNION SOCKET D. Install lower king pin cap with original shim pack.
ASSEMBLY TO HOUSING The thrust washer must have tangs facing the
Bronze Bushing Type trunnion socket.
A. Slip the boot over the connecting flange of the NOTE: Apply grease to the grooved face of the
trunnion socket. thrust washer prior to installation on the king pin
cap.
E. Make sure that the thrust washer tangs engage

the slots in the trunnion socket boss before final
tightening of the lower king pin cap fasteners.
ADJUST STEERING KNUCKLE

Steering knuckle adjustment is accomplished by use
of shims located under the upper and lower king pin
caps. The knuckle vertical end play specification is
.005 to .013 inch.
A. Measure the vertical end play of the steering

knuckle and record. This may be determined by
B. Mount the trunnion socket on the axle housing using a feeler gauge to measure the gap between
studs and install the stud nuts. Tighten the nuts to the upper king pin cap shoulder and the top sur-
specified torque. face of the trunnion socket king pin boss while
18
the wheels are on the ground - or - if wheels E. Join the two flanges together by installing the
are removed (axle supported on blocks) measure knuckle flange bolts, lock washers and nuts.
the gap with the knuckle assembly forced maxi-
mum upward (with hydraulic jack or pry bar), or F. Tighten the knuckle flange nuts to correct torque.
check maximum vertical movement of knuckle G. Install the upper and lower bearing cups.
with a dial indicator.
B. (1) If end play is .013 inch or less; no readjust- ADJUST STEERING KNUCKLE
ment is necessary. BEARINGS
(2) If current end play exceeds .013 inch; con- Split Type Knuckle
tinue the following steps. A. Install the original shim packs between steering
arm cap and lower bearing cap.
C. Remove lower and upper king pin caps and mea-
sure the total current shim pack thickness (upper B. Install the caps, lock washers and nuts.
pack plus lower pack).
C. Tighten the nuts to correct torque and check for
D. Subtract actual end play (value from step A) end play and oscillating freeness.
from the total shim pack thickness (value from
step C) and divide this result by two. D. The knuckle should be adjusted by adding or re-
moving shims as required.
E. Make the “new” lower shim pack thickness the
same as the value from the step D calculation. If E. After zero end play with oscillation has been es-
this thickness cannot be met exactly, choose the tablished, remove a .OOS’ shim from each shim
nearest thicker pack. pack.
F. Make the “new” upper shim pack thickness the F. Replace the caps, lock washers and nuts. Tighten
same as the value from the step D calculation nuts to correct torque. After this is done a small
plus .005 inch. If this result cannot be met ex- amount of drag in rotating the steering knuckle
actly, choose the nearest thicker pack. should be felt, but it should not bind.
G. The size of the shim pack at the top and the bot-
EXAMPLE: tom should be nearly the same so as to center the
joint assembly for proper shaft alignment.
Step A. Current end play = .020 inch
H. Install the dust shields where used.
Step B. Conclude readjustment necessary
Step C. Current total pack thickness = .066 inch

ATTACH COMPONENTS
Step D. .066-.020 divided by 2 = .023
(.046 divided by 2 = .023) All Knuckle Styles
A. Install brake line to wheel cylinder inlet fitting.
Step E. New lower pack = .023 inch
B. Attach power steer cylinder to knuckle arm.
Step F. New upper pack = .023 + .005 = .028 inch.
C. Attach tie rod to knuckle, use correct specifica-
ASSEMBLE SPLIT TYPE tions as listed in torque chart following service
KNUCKLE AND instructions.
TRUNNION SOCKET
D. Install brake dust shields.
A. Install the inner ha:f of the knuckle flange by tilting
and sliding it over the trunnion socket flange end.
B. Mount the trunnion socket onto housing studs INSTALL AXLE SHAFT AND UNIVERSAL
and install washers and nuts. JOINT ASSEMBLY
C. Tighten nuts to correct specifications as listed on A. Hand pack universal joint assembly by forcing
torque chart following service instructions. grease into bell and race cavities. (Rzeppa only)
D. Align mating outer knuckle flange with inner knuc- B. Hand pack inner walls of flange socket. (Rzeppa
kle flange. only)
19
REASSEMBLY.
CURRENT DESIGN (PS MODELS)
C. Insert axle shaft through housing and into side Older models use oil seal and retainer assembly
gear of carrier using care not to damage oil seal which is held in place against the spindle by
in housing end. means of a dowel.
IMPORTANT: First apply a film of waterproof G. On models with bolted brake spiders install brake
grease to housing oil seal lips, bronze bushing spider to the spindle while supporting the spindle.
bore and oil seal journal on axle shaft long end. Then install and tighten mounting fasteners.
INSTALL HUB SPINDLE ASSEMBLY Rigid Axle Models

PS Models H. On cast or stamped housing models mount
spindle, “0”-ring and brake spider or backing
A. If replacement of the spindle inner oil seal is
plate to housing flange with bolts, washers, and
necessary, install new seal from inner end with
nuts, if used (or with capscrews and washers
a suitable driver.
where employed). Tighten nuts or capscrews to
NOTE: Oil seal replacement should be made at
specified torque.
regular maintenance intervals.
B. For models that do not have oil seal installed in NOTE: On recent models liquid gasket is used in
wheel hub inner bearing bore, install the inner place of “0”-ring. Apply a continuous bead (ap-
wheel bearing cone on the hub spindle and apply prox. .09 in dia.) of liquid gasket around spindle
lube to bearing rollers. flange between the mounting pilot and the bolt
holes.
C. Apply a film of waterproof grease to lips of oil
seal in the spindle bore, the bore of the bronze On modular models when the spindle is welded
bushing in the spindle and to the oil seal journal to the housing, mount brake spider to the
on the axle shaft short end. Then install the spin- flange on spindle or housing.
dle by carefully sliding it over the end of the axle
shaft. INSTALL BRAKE ASSEMBLIES
For brake installation details refer to the pertaining
NOTE: Care must be exercised to avoid damage
Rockwell Field Maintenance Manual. (See page 8).
to seals.
(Steps D Through F For PS-166, 334, 824, 826 And ASSEMBLE RING GEAR HUB ASSEMBLY
1044 Models Only)
A. On those models incorporating a planetary ring
D. Assemble O-ring, if used, in spindle face groove.
gear with tapped holes, lock plates and cap-
E. Where O-ring is not incorporated, apply a bead of screws, the ring gear must be assembled to the
liquid gasket (approximately .09 inch diameter) to ring gear hub at this time.
the mounting face of the wheel hub oil seal retain- NOTE: Most models incorporate an axially float-
ers. The bead must go around the inner side of ing ring gear (does not have tapped holes)
the bolt holes. which can be assembled later, just prior to as-
sembly of the planetary spider.
F. Place the oil seal and retainer assembly over the
studs and install flat washers and nuts (where B. Install the outer wheel bearing cone on ring gear
bolted type oil seal is used). hub journal squarely against hub shoulder and
20
apply lubricant. The inner race of bearing is a slip B. Install the ring gear hub assembly, while at the
fit over the spindle journal. same time lifting the weight of the hub and drum
NOTE: Do not assemble onto spindle at this assembly to allow the outer bearing to mate with
time. outer hub bearing cup.
C. Install the wheel bearing adjusting nut.

ASSEMBLE AXLE SHAFT IN RIGID
AXLES
Larger Models
On rigid planetary axles it is more convenient to as-
semble the axle shaft before the wheel hub as- On larger models the ring gear hub assembly and
sembly is installed. Insert axle shaft through spindle bearing may be temporarily mounted to the wheel
and housing and into side gear of carrier. hub assembly by capscrews through the puller holes
of ring gear hub flange, into the smaller threaded
ASSEMBLE HUB, BEARINGS, OIL SEAL holes of the wheel hub.
AND DRUM
A. Place hub and drum assembly on floor or bench
A. If hub bearing cups have been removed for re- vertically with brake drum up.
placement, install new cups with a suitable driving
sleeve. B. Install rear bearing in cup (with lube on rollers).
B. Most models then require installation of the inner C. Install seal and retainer with suitable driver.
bearing cone prior to installation of wheel hub oil
D. Invert the hub and drum assembly.
seal in bore of wheel hub. Apply lubricant to bear-
ing rollers before installation. E. Install the ring gear hub assembly and outer bear-
ing (with lube on rollers).
C. Install new wheel hub oil seal with proper driver.
Drive seal to same location as the original, this F. Align ring gear hub puller holes with hub threaded
may be to bottom of bore in hub or flush with the holes.
bottom end face of hub. New wear sleeves are to
be installed on the spindle where employed. Use G. Install capscrews to temporarily hold the as-
extreme care to avoid any nicks on the sleeve end semblies together.
which can damage the seal lip during wheel hub
H. Supporting the weight by use of chain falls, locate
installation.
the combined assembly on the spindle splines.
D. Apply lubricant to lips of oil seal, or to inside di-
J. Install the wheel bearing nut and draw assembly
ameter of unitized type of oil seal, or to interface
into position.
area of metal rings of face seals. Do not lubricate
any other part of face seals. Also apply a film of K. Remove the temporary capscrews from the ring
lubricant to the oil seal journal surface of the spin- gear hub.
dle (or wheel hub journal surface on certain PS
models). WHEEL BEARING ADJUSTMENT
E. Install brake drum and oil slinger where applica- New Bearings - Single Nut Design
I
ble. If slinger fit is not tight between hub and
drum, a bead of liquid gasket can be applied to
prevent rattle. Install drum mounting capscrews
and washers and tighten to proper torque.
NOTE: On dual tire models make sure the air

valve clearance notch in drum O.D. aligns with
notch in wheel hub.
Smaller Models
A. Lift the hub and drum assembly onto the hub
spindle and position so that the inner cup rests
on the inner bearing rollers.
Seat the bearings and related components by
NOTE: Alignment must be maintained during in- tightening the adjusting nut to 400 lb. ft. while
stallation to prevent damage to hub oil seal. hub is rotated in both directions. Rap the hub
REASSEMBLY
several times with a brass or plastic mallet,

then re-torque to 400 lb. ft. Repeat procedure until
nut will not advance with application of 400 lb. ft.
EXCEPTION: Seating torque on adjusting to be

100 lb. ft. for following models:
PRA/PRS/PRLC-130 through 265 (PI?-35 through

68) and PSC/PSS-185 through 200 (PS-50
through 60).
Back off adjusting nut to relieve preload on bear-

ings. Torque on nut should be 0 lb. ft.
An alternate method for determining wheel hub

rolling torque is to wrap a cord around hub barrel,
attach a spring scale and pull straight out at a
steady rate. Torque in units of lb. ft. = (lb. pull x
inches of hub barrel radius) + 12.
D. Tighten adjusting nut and re-check the hub rolling

torque. The increase in rolling torque from that
determined in step “C” (no preload position)
should be as indicated in the chart below.
C. Determine the wheel hub rolling torque. Torque

value must be obtained while hub is rotated at a
steady rate (not starting torque). Rockwell recom-
mends the use of a flat bar, with a welded nut in
the center, attached to the planetary mounting
face of the wheel hub; and a torque wrench to ob-
tain rotation and the torque reading (see illustra-
tion above).
ORIGINAL AXLE CURRENT AXLE HUB ROLLING

MODEL MODEL TORQUE INCREASE
PR-35 thru 68, PS-50 8 60 PR-130 thru 265, PS-165 thru 200 3 to 5 lb. ft.
PR-100, PS-100 PR-344 thru 614, PS-334 4 to 8 lb. ft.
PR-150 thru 200, PS-150
thru 200 PR-672 thru 677, PS-614 thru 825 5 to 9 lb. ft.
PR-250, PS-250 thru 270 PR-863 thru 1757, PS-826 thru 1614 6tolOIb.ft.
PR-300 thru 440, PS-350 PR-1923 thru 4025, PS-1874 & 1875 8to12Ib.ft.
PR-500, PS-500 PR-4264 thru 4807, PS-4564 lOto14Ib.ft.
PR-700 PR-7314 14to18Ib.ft.
IMPORTANT: The final nut setting must result in a hub rolling torque which is the sum of the “initial” value from
step “C” plus the “increase” from above chart.
REASSEMBLY
E. Install nut lockplate and capscrews. Tighten to D. Tighten adjusting nut slightly (approximately 25
grade 8 value (see page 27). There are several lb. ft.). Install the nut lock ring washer with the
types of nut locks/lockplates used among the washer tang into the slot on the spindle and
various axle series. The V-notch lockplates will with a washer hole engaging the protrusion of
allow use of the plate flat toward flat of nut if the adjusting nut.
the V-notch does not properly engage a nut
corner. E. Install the jam nut and tighten to 800 lb. ft.
F. Recheck the wheel hub rolling torque. The “in-

IMPORTANT: The lockplate assembly method
crease” from step “C” (no preload position)
chosen must prevent nut rotation.
should be 5 to 9 lb. ft. If “increase” is out of
If new screws (with pre-applied locking agent) are this range, remove the jam nut and lock ring
not used, then several drops of Loctite #277 must washer and readjust the inner adjusting nut in
be applied to the internal threads in the planetary the appropriate direction. Repeat above proce-
ring gear hub. dure.
Flat head screws must be used in lockplates incor- NOTE: The rolling torque check for “increase”
porating counter sunk holes. must be performed after the jam nut is tight-
ened since the bearing preload is increased by
NOTE: For models PR-130 through 265 and PS- the jam nut tightening.
165 through 200 (“original” models PR-35,
through 68 and PS-50 through 60). Locking Reused Wheel Bearings
method is engagement of nut dowel pin into a
hole in the planetary ring gear/hub which is in- For both single nut and double nut designs the pro-
stalled affer the final nut/bearing adjustment is cedure is the same as for new bearings (pages 21
made. The final nut position must orient the thru 23) except the “INCREASE” in hub rolling
dowel pin with respect to a spindle spline same torque should be l/2 the value specified for new bear-
as “hole to spline” in the ring gear hub. ings.
EXAMPLE: EXAMPLE:
Axle is PR-672 series. Axle is PS-1614 series.
Initial hub rolling torque from step C with zero ad- Initial hub rolling torque (step C pg. 22) = 2 lb. ft.
justing nut torque = 8 lb. ft. Final hub rotating torque after nut adjustment:
Final hub rotating torque after nut adjustment: Min. = 2 + (6 + 2) = 5 lb. ft.
Min = 8 + 5 = 13 lb. ft. Max.=2+(10+2)=7Ib.ft.
Max = 8 + 9 = 17 lb. ft.
New Bearings - Double Nut Design Wheel Bearing Adjustment For

Axles With Wet Disc Brakes
A. Seat the bearings and related components by
Refer to Rockwell Field Maintenance Manual No. 4L.
installing the wheel bearing adjusting nut with
the locking protrusion facing outward. Tighten
the nut to 400 lb. ft. while hub is rotated in
both directions. Rap the hub several times with
a brass or plastic mallet, then re-torque to 400 INSTALL PLANETARY RING
lb. ft. AND SUN GEARS
B. Back off adjusting nut to relieve preload on A. Install sun gear thrust washer, sun gear and
bearings. Torque on nut should be 0 lb. ft. axle shaft snap ring. Thrust washer tangs must
engage slots in spindle or nut. Apply grease to
C. Determine the wheel hub rolling torque. Torque washer for temporary retention, then push sun
value must be obtained while the hub is rotated gear against the washer.
at a steady rate (not starting torque). See rec-
ommended procedure in step “C” under “Sin- B. Install planetary ring gear onto ring gear hub
gle Nut Design.” (floating ring gear design).
E. Place the spider in a press with the flange side
ASSEMBLE PLANETARY SPIDER
up. Block up as required.
NOTE: Later axle models incorporate nylon
coated steel planet pins. These pins are also F. Install inner thrust washer with the washer tab
used for service replacement of early model engaged in the spider indent and the washer bore
bronze planet pins. Utilize the following recom- aligned with the spider bore.
mendations to obtain satisfactory component
G. Coat the bore of the planet gear with a film of the
life and performance:
same GL-5 gear lube used in the wheel end. Slide
A. Carefully inspect bores of planet gears. Do not planet gear and outer thrust washer into the spi-
re-use planet gears with bore surface rough- der. Align the bores of the parts and engage the
ness from previous use. A smooth bore sur- outer thrust washer tab in the spider indent.
face is essential for proper function.
H. Install the planet pin into the spider and through
B. When servicing an early axle model (bronze
the planet gear and thrust washers by hand. The
pin design) with new nylon coated planet pins,
large end of the planet pin will bind in the spider
all three pins in the planetary spider should be
bore
‘ due to an interference fit.
changed. Do not mix bronze and nylon coated
pins in the same spider. For optimum planet I. On axle models with one-piece integral spider
pin life, it is strongly recommended that both and cover align the match mark on the large di-
wheel ends are changed to the nylon coated ameter of the pin with the match mark on the spi-
pins simultaneously. der. These match marks provide proper
alignment of the set screw hole in the small end of
IMPORTANT: Debris from wear or failure must the pin and the tapped set screw hole in the spi-
be thoroughly flushed from the wheel end (or der boss.
from entire axle if common lube system is em-
ployed) as stated in previous section on “axle
flush.”
MATCH
C. Use of nylon coated planet pins in early axle mod- MARKS
els (which utilized bronze pins) requires new

outer thrust washers which are included in kits
along with detailed instructions. The planetary
spider requires minor re-work to provide a recess
for the tangs of the new thrust washers.
If planet pins do not have “0”-ring grooves disre-
gard step D. J. Apply a film of non-hardening sealant (Permatex
51 or equivalent) to “O”-ring and large end of
D. Install the proper “0” -ring in the planet ring planet pin.
groove making sure that the “0”-ring is not
twisted.
IMPORTANT: Chamfers on large bores must be

smooth. Use an emery cloth to avoid damaging
O-ring and/or nylon coating on planet pin during
installation.
o-
- “0”~RING
(IF USED)
PLANET PIN K. If “0”-rings are not used, brush Loctite 271
(Rockwell Part No. 1199-B-3720) sealant/ adhe-
SPIDER
f
sive on the planet pin O.D. protruding from the
spider.
OUTER THRUST - c
L. Being careful to keep planet pin aligned, press pin
into spider until the shoulder of the pin bottoms
against the inner thrust washer.
NOTE: If a press is not available use a brass

drift and mallet to tap the pin through the spider
and planet gear.
REASSEMBLY
A CAUTION: Do not strike planet pins directly SILICONE (RTV) GASKET APPLICATION
with a steel hammer. Personal injury from NOTE: Where silicone RTV gasket material is
chips or splinters may result. used, Dow Silastic No. RTV-732 Black and Gen-
eral Electric No. RTV-1473 Black meet our re-
quirements. However, silicone RTV is also
available in bulk under Rockwell part number
1199-Q-2981; in 10 oz. tubes, part number 1250-
X-388, or in 3 oz. tubes, part number 1199-T-
TAPPED HOLE 3842.
IN SPIDER BOSS
Service
SETSCREW HOLE1 Removal of all gaskets including silicone RTV is
accomplished by peeling or scraping the used
M. Install set screws (if used) into spider and planet
gasket off both mating surfaces.
pin. New set screws have a pre-applied locking
agent on the threads. If original set screws are Application of silicone RTV gasket material is as
used, apply one or two drops of Loctite 277 follows:
(Rockwell Part No. 2297-C-3747) to threads of 1. Remove dirt, grease or moisture from both
spider before installing. Tighten set screw to 15 mating surfaces.
25 lb. ft. torque. 2. Dry both surfaces.
APPLY BEAD OF
RTV GASKET
MATERIAL
3. Apply a continuous thin bead, approximately

l/8’ diameter COfrIpletdy around one mating
surface and around the inner edge of all fas-
tener holes to assure complete sealing and
prevent leakage.
BtXTED COVER DESIGN
A
CAUTION: Minor concentrations of acetic
acid vapor may be produced during appli-
On axle models equipped with planet pins with
cation of silicone RTV. Adequate ventilation
machined flats, the pin must be installed so the
should be provided when silicone RTV is ap-
“flat” is facing the outside of the hub circle. This
plied in confined areas.
allows cover clearance and properly locates the
pin oiling holes.
Further, eye contact with these silicone RTV
NOTE: Nylon coated replacement pins do not gasket materials may cause irritation; if eye
have flats nor oiling holes in the area of planet contact takes place, flush eyes with water for 15
gear contact. minutes and have eyes examined by a doctor.
N. Repeat the reassembly procedures to install the 4. Assemble the components immediately to per-
second and third sets of planetary pins, gears mit silicone RTV gasket material to spread
and washers. evenly.
When rebuilding any assembly, always use
INSTALL SPIDER ASSEMBLY torque values on fasteners as specified by
either Rockwell or the vehicle manufacturer.
A. Apply silicone RTV gasket material to spider
flange at hub mounting face. Use silicone RTV NOTE: Failure to use appropriate gasket mate-
gasket application procedures as follows: rial will cause axle to leak.
25
REASSEMBLY
6. Start the spider and pinion assembly, aligning FILL PROCEDURE

teeth of planet gears with sun gear and ring gear
teeth. A. Rotate the wheel end to position the lube level
hole at the horizontal centerline of the axle.
Align the match marks on the spider flange and Lower the vehicle to the ground.
the wheel hub as previously marked at disassem-
bly. B. For bolted cover design:
Remove “fill/drain” plug from barrel of wheel
C. Align hub studs or holes with spider holes and hub (should be at top position) and the “oil lev-
push spider assembly against hub. el” plug from the planetary cover.
D. Install spider washers and nuts or washers and For one piece spider/cover design:
capscrews. Remove the “drain/level/fill” plug from the pla-
netary spider (one plug serves all purposes).
E. Tighten nuts or capscrews to specified torque. The level mark should be in horizontal position.
For a// axle models:
INSTALL PLANETARY Also remove the “fill/level” plug in the axle
SPIDER COVER (Where applicable) housing bowl or bowl area.
A. Apply silicone RTV gasket material to cover C. Make sure all magnetic plugs have been
flange at spider mounting face. Use Silicone RN cleaned of metal particles and are securely re-
gasket application procedure (see above). installed.
NOTE: Only certain special applications ap-
proved by Rockwell International employ the
carrier fill/level plug.
D. Fill wheel ends and housing bowl with the recom-

mended GL-5 gear lubricant to the bottom of the
level/fill hole. Wait for lube to evenly distribute
throughout the wheel end. Check lube levels and
add more lube if necessary. Replace all plugs and
tighten securely.
Most rigid axles have common wheel end/hous-
ing bowl oil and oil level (no axle shaft oil seals
are employed). To assure proper oil level, oil
should be added at each wheel end and to the
bowl. Do not fill through bowl only.
BOLTED COVER DESIGN
E. For axles with separate housing bowl and wheel
end lubricant (with axle shaft oil seals), fill each
B. Install the spider cover and capscrews. Fill arrow
until lubricant appears at the level hole. Replace
must be in line with hub fill plug.
all plugs and tighten securely. For lubricant ca-
C. Tighten cover capscrews to correct torque. (See pacities refer to Rockwell Field Maintenance
page 28.) Manual #1 on Lubrication.
LUBRICATION STEERING ALIGNMENT

NOTE: Correct types of lubrication and proper ARD
lubrication practices are specified in the Rock-
well Field Maintenance Manual No. 1 on lubrica-
tion.
New planetary axles should be drained of initial lu-
bricant after 75 to 100 hours of operation. Drain
while the axle is still warm.
The regular change interval should be whenever
seals are replaced, brakes are relined, every 1,000
to 1,500 hours of operation or twice a‘ year (spring
and fall). Y MINUS X EQUALS TOE-IN
26 Copyrighted Material
TIRE MATCHING
Toe-in should be checked and adjusted on all front Therefore, we recommend matching, as nearly as
steering axles after being installed in a vehicle. Toe- possible, the total tire circumference of each of the
in adjustment made by Rockwell on the assembly three driving axles.
line is.a single average setting. This will not be cor-
HOW TO MATCH TIRES
rect for all tire sizes and axle loadings. It is the
OEM’s responsibility to make the final setting.
Tandem Units:
Rockwell’s practice for off-highway steer axles is The vehicle should be on a level floor, carrying a cor-
1/16” + l/l 6” toe-in based on a 24” radius (theoreti- rectly distributed rated capacity load. Be sure all
cal tire of 48” outside diameter). tires are the same size.’
Toe-in setting of new axles is performed with the 1. Inflate all tires to the same pressure.
axle in the unloaded condition.
2. Carefully measure the rolling circumference of
each tire with a steel tape.
TANDEM/TRIDEM AXLE TIRE MATCHING
Unmatched tires on either Tandem Drive Units or 3. Mark the size on each tire with chalk and arrange
Tridem Drive Units will cause tire wear and scuffing them in order of size, largest to smallest.
and possible damage to the drive units. Conse-
4. Mount the two largest tires on one side of one
quently we recommend the tires be matched to
axle and mount the two smallest on the opposite
within l/g” of the same rolling radius, %I” of the same
side of the same axle.
rolling circumference.
5. Mount the four other tires on the other axle in the
Tandem Units:
same manner.
IMPORTANT: The four largest tires should never
be installed on one driving axle or the four 6. Test run the vehicle to get accurate rear axle lu-
smallest tires on the other driving axle. Such tire bricant temperature readings on the two axle lu-
mounting will cause an inter-axle “fight,” un- bricant temperature guages.
usually high axle lubricant temperatures that re-
sult in premature lubricant breakdown and 7. Vary tire air pressure, within the tire manufactur-
possible costly axle service. er’s recommended range, so the lubricant tem-
In addition to matching individual tire rolling radii or perature of both axles is within 30°F of each other
rolling circumference, we recommend matching, as and not in excess of 2OOOF.This will usually result
in uniform tire loading and good tire life.
nearly as possible, the total tire circumference of
one driving axle to the tire circumference of the Tridem Units:
other driving axle. This will usually result in satisfac-
Follow the same procedure (Items #l through #7)
tory tandem axle lubricant temperatures that
for matching tires on a Tridem Unit. Arrange the tires
lengthen drive unit service with higher tire mileage.
in order of size. The two largest and two smallest go
on one axle, the next two largest and smallest on the
Tridem Units: second axle, and the remaining four on the third
When three driving axles are “hooked” together in a axle.
Tridem Series, unmatched tires will compound the *Measure new tires to be sure they will be correctly
problems described in the preceding paragraphs. matched.
TORQUE VALUES
TORQUE VALUES FOR CURRENT DESIGN PLANETARY AXLES

(Axles Built Since 1978)
A. For select fasteners:
TORQUE (LB. FT.)
FASTENER THREAD SIZE MIN./MAX.
Tie Rod Yoke Lock Nut l”- 16 165 to 200
Tie Rod Yoke Lock Nut 13/b" - 16 165 to 200
Tie Rod Yoke Lock Nut 2”- 16 165 to 200
Tie Rod Clamp Bolt (Ball Joint End) 5/g” - 18 50 to 65
Tie Rod Yoke Clamp Bolt Nut '/2n - 20 100to130
Tie Rod Yoke Clamp Bolt Nut 3/q" - 16 125to175
*Tie Rod Yoke Bolt Nut %‘I - 14 0 to 5
*Tie Rod Ball Stud Nut 5/8n - 18 60 to 85
*Tie Rod Ball Stud Nut 78" - 14 150 to 200
Tie
‘ Rod Ball Stud Nut 1%” - 12 400 to 550
*Steer Arm Ball Stud Nut 5/8c - 1 1 60 to 85
“Steer Arm Ball Stud Nut 3h" - 16 got0125
*Steer Arm Ball Stud Nut 1” - 12 250 to 350
*Steer Arm Ball Stud Nut 1’/8” - 12 350 to 490
*Steer Arm Ball Stud Nut 1 l/4"- 12 400 to 550
Wheel Bearing Nut Lock Screw J/h" - 16 35 to 50
Wheel Bearing Nut Lock Screw /&”
‘ - 14 60 to 75
Steer Stop Bolt Jam Nut 78" - 14 150to190
Steer Stop Bolt Jam Nut 5/8" - 1 1 60 to 75
Steer Stop Bolt Jam Nut '/2n - 13 50 to 65
*Use wrench torque shown and as much more
as necessary to line up the next cotter pin
hole. Do not back off.
B. For all other fasteners (except carrier components - see appropriate Field Maintenance Manual on
carriers): Use appropriate GRADE 8 torque.
l Since 1978 all fasteners have been GRADE 8. See following torque chart for proper torque value based on
thread size and type of fastener.
l Nuts used on double end studs shou!d be tightened. to the appropriate coarse thread torque. If nut is a
locknut type, use coarse thread torque value under “locknut” heading.
I ROCKWELL TORQUE SPECIFICATIONS-STANDARD FASTENERS I
Grade 5 Grade 6 and 7 Grade 6

Plain Nuts Plain Nuts Plain Nuts
Size Series Locknuts And Screws Locknuts And Screws Locknuts And Screws
A
‘ -20 UNC 75-100 Lbs.-In. 85-115 Lbs.-In. 85-115 Lbs.-tn. 105-135 Lbs.-tn. 105-135 Lbs.-In. 120-l 60 Lbs.-In.
A
‘ -28 UNF 85-115 Lbs.-In. 105-135 Lbs.-In. 105-135 Lbs.-In. 120-l 60 Lbs.-in. 120-l 60 Lbs.-tn. 12-16 Lbs.-In.
5&-l 8 UNC 12-l 6 Lbs.-Ft. 15-20 Lbs.-Ft. 15-20 Lbs.-Ft. 18-24 Lbs.-Ft. 18-24 Lbs.-Ft. 20-30 Lbs.-Ft.
=&-24 UNF 15-20 Lbs-Ft. 18-24 Lbs.-Ft. 18-24 Lbs.-Ft. 20-30 Lbs.-Ft. 20-30 Lbs.-Ft. 20-30 Lbs.-Ft.
34-l 6 UNC 20-30 Lbs.-Ft. 25-35 Lbs.-Ft. 25-35 Lbs.-Ft. 30-40 Lbs.-Ft. 30-40 Lbs.-Ft. 35-50 Lbs.-Ft.
Sk-24 UNF 25-35 Lbs.-Ft. 30-40 Lbs.-Ft. 30-40 Lbs.-Ft. 35-50 Lbs.-Ft. 35-50 Lbs.-Ft. 40-55 Lbs.-Ft.
7&-l 4 UNC 35-50 Lbs.-Ft. 40-55 Lbs.-Ft. 40-55 Lbs.-Ft. 50-65 Lbs.-Ft. 50-65 Lbs.-Ft. 60-75 Lbs.-Ft.
7&20 UNF 40-55 Lbs.-Ft. 50-65 Lbs.-Ft. 50-65 Lbs.-Ft. 60-75 Lbs.-Ft. 60-75 Lbs.-Ft. 65-85 Lbs.-Ft.
h
‘ -13 UNC 60-75 Lbs.-Ft. 65-85 Lbs.-Ft. 65-85 Lbs.-Ft. 75-100 Lbs.-Ft. 75-100 Lbs.-Ft. 85-115 Lbs.-Ft.
d
‘ -20 UNF 65-85 Lbs.-Ft. 75-100 Lbs.-Ft. 75-l 00 Lbs.-Ft. 85-115 Lbs.-Ft. 85-115 Lbs.-Ft. 100-l 30 Lbs.-Ft.
94712 UNC 75-l 00 Lbs.-Ft. 85-115 Lbs.-Ft. 100-l 30 Lbs.-Ft. 11 O-l 45 Lbs.-Ft. 11 O-l 45 Lbs.-Ft. 130-l 65 Lbs.-Ft.
9&-l 8 UNF 85-l 15 Lbs.-Ft. 100-l 30 Lbs-Ft. 11 O-l 45 Lbs.-Ft. 130-l 65 Lbs.-Ft. 130-l 65 Lbs.-Ft. 150-l 90 Lbs.-Ft.
5/8-l1 UNC 11 O-l 45 Lbs.-Ft. 130-l 65 Lbs.-Ft. 130-l 65 Lbs.-Ft. 150-l 90 Lbs.-Ft. 150-l 90 Lbs.-Ft. 180-230 Lbs.-Ft.
5/8-l8 UNF 130-l 65 Lbs.-Ft. 150-l 90 Lbs.-Ft. 150-l 90 Lbs.-Ft. 180-230 Lbs.-Ft. 180-230 Lbs.-Ft. 210-270 Lbs.-Ft.
34-l 0 UNC 180-230 Lbs.-Ft. 230-300 Lbs.-Ft. 230-300 Lbs.-Ft. 270-350 Lbs.-Ft. 270-350 Lbs.-Ft. 31 O-400 Lbs.-Ft.
34-l 6 UNF 21 O-270 Lbs.-Ft. 270-350 Lbs.-Ft. 270-350 Lbs.-Ft. 31 O-400 Lbs.-Ft. 31 O-400 Lbs.-Ft. 360-470 Lbs.-Ft.
74-9 UNC 31 O-400 Lbs.-Ft. 360-470 Lbs.-Ft. 360-470 Lbs-Ft. 440-580 Lbs.-Ft. 440-580 Lbs.-Ft. 500-650 Lbs.-Ft.
d
‘ -14 UNF 360-470 Lbs.-Ft. 440-580 Lbs.-Ft. 440-580 Lbs.-Ft. 500-650 Lbs.-Ft. 500-650 Lbs.-Ft. 575-750 Lbs.-Ft.
1 .O-8 UNC 440-580 Lbs.-Ft. 500-650 Lbs.-Ft. 575-750 Lbs.-Ft. 650-875 Lbs.-Ft. 650-875 Lbs.-Ft. 775-l 000 Lbs.-Ft
1.0-l 2 UNF 500-650 Lbs.-Ft. 575-750 Lbs.-Ft. 650-875 Lbs.-Ft. 725-950 Lbs.-Ft. 725-950 Lbs.-Ft. 850-l 100 Lbs.-Ft
1.0-14 UN 500-650 Lbs.-Ft. 575-750 Lbs-Ft. 650-875 Lbs.-Ft. 725-950 Lbs.-Ft. 725-950 Lbs.-Ft. 850-l 100 Lbs.-Ft
Torques given apply to parts lightly covered with rust preventing oil, unplated and uncoated. For dry parts,
increase torques 10%. For parts coated with multi-purpose gear oil, decrease torques 10%. Nuts used on dou-
ble end studs require the appropriate coarse thread torque. Locknuts are normally coated with a lubricant (dry
to the touch) which reduces friction, therefore less torque is required to produce the clamping load.
TORQUE VALUES
TORQUE VALUES FOR ORIGINAL DESIGN PLANETARY AXLES

(Axles Built Prior to 1978)
A. For Tie Rod Yoke and/or Ball Joint Fasteners
Steer Arm Ball Stud Nuts
Steer Stop Bolt Jam Nuts
Wheel Bearing Nut Lock Screws
Use same torque as shown in part “A” of “Current Design Torque Values.”
B. For all other fasteners (except carrier components - see appropriate Field Maintenance Manual on
carriers) use appropriate torques for size, grade and type as shown on preceeding chart (page 28).
l Fastener Grade - the majority of threaded fasteners are grade 8, however, some grade 5 capscrews/bolts
and grade 6 studs (double ended) were used.
GRADE IDENTIFICATION
FASTENER GRADE 5 GRADE 6 GRADE 0

I I I
CAPSCREW
NOT
OR
USED
BOLT HEAD
NOT
STUDS USED
PLAIN END FIGURE 8
STAMPED
l Locations of GRADE 5 capscrews/bolts:

Brake dust shield mounting
Brake cylinder and actuator mounting
Brake camshaft collar
Housing flange half joint (PR-35 series)
l Locations of GRADE 6 studs (some axles):

Carrier to axle housing mounting studs
Brake camshaft support bracket mounting studs
Hydraulic motor mounting studs
Steer arm mounting studs
Planetary spider to wheel hub mounting studs (PR-75 through PR-120).
l Proper nut torque is based on:

Grade of stud or bolt
Thread size (where used on double ended studs tighten to the appropriat coarse thread torque value).
Type of nut (plain or self-locking type)
l Proper capscrew torque is based on:

Grade of capscrew
Thread size
PLANETARY AXLE MODEL CROSS-REFERENCE CHART
Old New Old New Old New
PR-30 PRA-104 PR-190 PRM-855 PS-50 PSS-165

PR-35 PRA-134’ PR-204 PRM-676, 7 PS-60 PSS-165
PR-35 PRA-1642 PR-205 PRM-676, 7 PS-61 PSS-165
PR-37 PRA-174 PR-207 PRM-676, 7 PS-101 PSS-334
PR-54 PRLC-176 PR-208 PRM-676, 7 PS-114 PSS-334
PR-60 PRS-165 PR-209 PRLC-675 PS-151 PSC-614
PR-62 PRC-184 PR-223 PRLC-1355 PS-157 PSM-824, 5
PR-65 PRS-204, 5 PR-235 PRC-1755 PS-201 PSC-616
PR-66 PRS-204, 5 PR-250 PRM-1756, 7 PS-205 PSC-616
PR-68 PRS-204, 5 PR-251 PRM-1756, 7 PS-210 PSC-826
PR-75 PRS-624, 5 PR-253 PRLC-1756, 7 PS-250 PSM-826
PR-76 PRS-624, 5 PR-256 PRM-1314, 5 PS-251 PSM-826
PR-78 PRC-574, 5 PR-256 PRM-16154 PS-254 PSC-1045
PR-80 PRS-594 PR-258 PRM-1724, 5 PS-256 PSM:826
PR-106 PRS-344 PR-270 PRLC-823 PS-260 PSM-1044, 5
PR-107 PRS-344 PR-273 PR LC-1374 PS-261 PSM-1044, 5
PR-108 PRLC-614 PR-275 PRLC-824 PS-270 PSM-1614
PR-108 PR LC-794 PR-305 PRC-1935 PS-350 PSC-1874, 5
PR-112 PRLC-344 PR-311 PRLC-1935 PS-500 PSC-4564
PR-112 PRLC-5963 PR-313 PRLC-1935
PR-114 PRC-345 PR-350 PRC-3795, 6
PR-115 PRS-626 PR-351 PRC-3796 SPR-150 SPRC-671
PR-118 PRC-672 PR-352 PRC-4025 SPR-200 SPRC-1357
PR-120 PRS-596 PR-400 PRC-1925 SPR-250 SPRC-1734
PR-130 PRC-694 PR-408 PRC-1925 SPR-270 SPRC-1736
PR-150 PRM-672, 3 PR-502 PRC-4805 SPR-400 SPRC-1923
PR-151 PRM-672, 3 PR-503 PRC-4805 SPR-570 SPRC-4806
PR-153 PRM-672, 3 PR-504 PRC-4807
PR-154 PRC-654, 5 PR-705 PRC-7314
PR-158 PRC-863, 4
l With welded spindle 3PR-80 wheel end

*With bolted spindle 4Wide planetary gearing
C5OOY2235 Group20
SECTION 4
DRIVEAXLE
MAINTENANCEAND SERVICE
There are two pieces of vendor literature in this

section. “PLANETARY DRIVE AXLE” covers
the ClaWHutth drive axle used on models prior
to lot 8518. The “SINGLE REDUCTION DIF-
FERENTIAL CARRIERS” covers the Rockwell
drive axle used on lots 8518 and above.
SM575 Copyrighted
SectionMaterial
Tile Page July 97
Planetary I
Drive Axle I
(Formerly D-l 7210)
CLARKkHURTIK,
COMPONENTS
Do not sell or distribute SM 14D1035 12-90
I
l-77 at I-40, Rt. 18, Box 38
@Copyright Clark Equipment Company, 1991

Unpublished material - All rights reserved
No part of this work may be reproduced in any form under
any means without direct written permission of Clark
Equipment Company.
FOREWORD
This manual has been prepared to provide the customer and the
maintenance personnel with information and instructions on the mainten-
ance and repair of the CLARK-HURTH COMPONENTS product.
Extreme care has been exercised in the design, selection of materials and
manufacturing of these units. The slight outlay in personal attention and
cost required to provide regular and proper lubrication, inspection at
stated intervals, and such adjustments as may be indicated will be
reimbursed many times in low cost operation and trouble free service.
In order to become familiar with the various parts of the product, its
principle of operation, trouble shooting and adjustments, it is urged that
the mechanic study the instructions in this manual carefully and use it as a
reference when performing maintenance and repair operations.
Whenever repair or replacement of component parts is required, only Clark-

Hurth Components-approved parts as listed in the applicable parts
manual should be used. Use of “will-fit” or non-approved parts may
endanger proper operation and performance of the equipment. Clark-
Hurth Components does not warrant repair or replacement parts, nor
failures resulting from the use of parts which are not supplied by or
approved by Clark-Hurth Components. IMPORTANT: Always furnish the
Distributor with the serial and model number when ordering parts.
TABLE OF CONTENTS
DESCRIPTION ................................................. 4
LUBRICATION .............................................. 4 Et 5
SECTIONAL VIEWS AND PARTS IDENTIFICATION
Axle Assembly ........................................... 6
Differential & Carrier Assembly. ............................. 8
AXLE ASSEMBLY INSTRUCTIONS. ............................... 10
DIFFERENTIAL ASSEMBLY INSTRUCTIONS. ....................... 11
DISASSEMBLY OF AXLE. ....................................... 13
DISASSEMBLY OF DIFFERENTIAL. ............................... 17
CLEANING AND INSPECTION. ................................... 20
REASSEMBLY OF DIFFERENTIAL ................................. 21
PLANET CARRIER DISASSEMBLY AND REASSEMBLY ............... 26
REASSEMBLY OF AXLE ......................................... 27
SERVICE BRAKES. ............................................. 31
AIR BRAKE ADJUSTMENT ...................................... 34
PINION STAKING .............................................. 35
WHEEL BEARING ADJUSTMENT. ............................ 36 8 37
SPIRAL BEVEL TOOTH CONTACT CHART (RIGHT HAND). ............ 38
SPIRAL BEVEL TOOTH CONTACT CHART (LEFT HAND). .............. 39
WHEEL tiOUNTING TORQUE. ................................... 40
TABLE OF TORQUE LIMITS. ..................................... 41
NOTE: Metric Dimensions Shown in Brackets I 1.
DESCRIPTION DESIGN
The axle assembly has a spiral bevel type ring gear and With full knowledge of the stresses encountered in off-
pinion with further reduction provided by planetary gear highway usage, planetary-drive axles are designed struc-
set within the wheel hub. turally to give long life. Clark planetary axles offer a selec-
tion of more than fifty standard models for on-off highway
PRIMARY REDUCTION equipment, with track and ratio availability to match most
vehicle configurations. Planetary gearing provides high
The spiral bevel pinion and ring gear transmit power numerical gear ratios for maximum performance.
through the center differential pinions, side gears and to
the axle shaft. The spiral bevel differential assembly is With final reduction made at the wheel ends, the three
mounted on tapered roller bearings which are adjusted by planetary gears take over and distribute torque smoothly
positioning of the two threaded adjusting nuts mounted and evenly. This secondary reduction at the wheel, as
in the differential carrier and cap assembly. The tapered compared with conventional axles, reduces torque loading
roller pinion bearing pre-load is adjusted and maintained on the axle shafts as much as 80%. As a result, there is
by a hardened and precision ground spacer positioned be- little axle shaft wind-up, less chance for chattering and
tween inner and outer bearings. Spacer is selected at digging in. In short, less maintenance-more equipment
assembly. availability.
SECONDARY REDUCTION
In the wheel hub, a self-centering sun gear is spline fitted
to the axle shaft and drives three planetary pinion gears.
These gears in turn mesh with and react against a rigidly
mounted internal ring gear. The planet gears rotate on
needle roller bearings mounted on hardened and ground
pins located in the planet carrier which in turn drives the
wheel hub. Positive lubrication keeps all moving parts bath-
ed in lubricant to reduce friction, heat and wear.
Recommended Lubricants for Clark Drive Axles

INITIAL FILL
Grade 85W140 qualified MIL-L-2105C gear lubricant as specified in Clark MS-8 engineering standard is preferred for initial
fill for most ambient temperatures. For other ambient temperature ranges use proper viscosities of MIL-L-210%.
Other lubricants approved to MIL-L-210% specifications are acceptable for initial fill or top off.
SERVICE FILL
Multipurpose gear lubricants approved to the MIL-L-2105C specifications are recommended. MIL-L-2105C classifies multigrade
gear lubricants on the basis of their viscosities at various temperatures.
.MS-8 Extreme Pressure Gear Lubricant

MS-8 specifications cover a gear lubricant for use in heavy-duty axles. It is a highly refined base stock properly compound-
ed with selected extreme pressure additives. MS-8 meets MIL-L-2105C, but is fortified with an additive package that pro-
vides added protection during the break-in period, and reduced wear and improved efficiency during subsequent operation.
Approximate Lubricant Capacities

NOTE: All quantities are shown in pints; 1 pint - 1 pound - 1 [liter]
Below listed capacities are approximate. There may be some axle variations that are not included in this list. If your model
axle does not appear on the list, fill to proper level as instructed in this manual. Always fill wheel ends and axle centers
to the bottom of the oil level plug hole.
Axle Series Each Wheel End Differential Total

14D1035 8 [3,81 14 [6,61 30 [14,2]
Pints Pints Pints
Copyrighted
-4- Material
Prevailing Ambient
Temperature For proper viscosity lube, refer to fahrenheit or celsius chart below.
ii 150 -
Gear Lubricant Chart
140 ---- 60
130 ----
120 ---- 50
Multigrade Viscosities
110 ---- MILG2105C
--- 40
100 -- Ambient Temperature Ranges See (a) note below.
90 -- -40°F to -10°F (-40°C to -23°C) 75W See (b) note below.
--- 30
80 -- -40°F to 0°F (-40°C to -18°C) 75W80
-40°F to +lOO”F (-40°C to -38°C) 75w90
-40°F + Above (-40°C + Above) 75w140
-15°F to 100°F (-26°C to 38°C) 8OW90
-15°F + Above (-26°C + Above) 8OW140
+lO”F + Above (-12’C + Above) 85W140
I Notes:
(a) The MIGL2105C Specification replaced the MIL-G2105B
Specification.
(b) The MIL-L-2105C 75W Classification replaced the

MIGG10324A Subartic Specification.
Fahrenheit Celsius Note: Specifications are subject to change.
Checking Oil Level in Drive Axles

For off-highway operation, check lubricant level after each 250 hours of operation. Always maintain lubricant level to
bottom of filler plug hole. Drain oil every 2500 hours, or one year whichever comes first.
For highway operation, lubricant should be checked each 5000 miles [8000 km]. Maintain lubricant level to bottom of filler
plug hole. Drain oil every 25,000 miles [40,000 km] or one year whichever comes first.
To check oil level in axles with differential drive and planetary wheel ends, the axle should be run first, then allowed to stand
for a minimum of five minutes on level ground. This procedure will allow oil to drain back to its normal level. After the five
minute interval, remove oil filler plug in axle center and in the planetary wheel ends for oil level inspection. If oil level is not to
the bottom of the filler hole, add necessary lubricant.
Checking and Filling Planetary Wheel Ends

Always check lubricant level in planetary wheel ends with wheel hub oil level plug and/or arrow in a down position. Remove
oil level plug. If lubricant is below oil level hole, remove filler plug and fill to oil level hole. Reinstall plugs.
Filling Drive Axles

Axles with single or double reduction at center: Fill axle housing through filler hole until lubricant is at bottom of filler hole.
Axles with planetary wheel ends. Follow procedure in “checking and filling planetary wheel ends.”
Draining
Draining is best accomplished immediately after vehicle has operated a short time or completed a trip. The lubricant is then
warm and will flow freely, allowing full drainage in minimum time. This is particularly desirable in cold weather.
Remove plug at bottom of axle housing and allow sufficient time for lubricant to drain. With planetary wheel ends, rotate
wheel until filler hole is down. Remove plug and allow sufficient time for draining. Be sure planet cover oil level hole is in proper
position when refilling wheel ends.
Flushing
After draining, axles should be flushed. Replace drain plugs and fill axles to proper level with a light flushing oil. Operate the
axles for a short period of time, then drain. Be sure to drain all of the flushing oil before refilling with new oil. Inspect the
magnetic drain plug for metal particles or other foreign matter indicative of wear or possible failure. When refilling, cleanliness
is extremely important.
Intended for -5-
CLARK dealers only
“\
\‘
\‘
\‘
\‘
\‘
1.
\‘ 1.
-\
64
53
\
54
B
55
-6-
ITEM DESCRIPTION QTY. ITEM DESCRIPTION QTY.
1. Internal Gear Hub ................... 2 36. Name Plate ......................... 1
2. Spindle Nut ........................ 2 37. Name Plate Screw ................... 2
3. Spindle Nut Lock .................... 2 38. Housing Filler Plug .................. 1
4. Spindle Nut ........................ 2 39. Brake Spider Grease Fitting ........... 2
5. Planet Carrier Assembly .............. 2 40. Return Spring Retainer ............... 4
6. Sun Gear Thrust Washer ............. 2 41. Brake Return Spring ................. 2
7. Sun Gear .......................... 2 42. Camshaft .......................... 2
8. Sun Gear Snap Ring ................. 2 43. Camshaft Thrust Washer ............. 2
9. Planet Cover Washer ................. 2 44. Camshaft “0” Ring .................. 2
10. PlanetCover ........................ 2 45. Brake Attaching Bolt ................. 32
11. Oil Level Plug ....................... 2 46. Brake Assembly ..................... 2
12. Planet Cover Capscrew ............... 12 47. Camshaft Bushing ................... 2
13. Planet Cover Capscrew 48. Camshaft Grease Retainer ............ 2
Lockwasher ........................ 12
49. Camshaft Retainer Washer ............ 2
14. Planet Carrier Capscrew .............. 10 50. Camshaft Snap Ring ................. 2
15. Planet Carrier Capscrew Washer ....... 10 51. Spindle End ........................ 2
16. Planet Carrier Stud Nut ............... 10 52. Air Chamber Bracket ................. 2
17. Planet Carrier Stud Washer ........... 10 53. Air Chamber Mounting
18. Planet Carrier Dowel ................. 10 Bracket Bushing ..................... 2
19. Planet Carrier Stud .................. 10 54. Air Chamber Bracket
20. Hub to Drum Bolt ................... 48 Grease Fitting ....................... 2
21. Hub to Drum Bolt Washer ............. 48 55. Chamber Bracket Capscrew ........... 4
22. BrakeDrum ........................ 2 56. Slack Adjuster ...................... 2
23. OilCatcher.. ....................... 2 57. Slack Adjuster Retainer Washer ........ 2
24. Hub Oil Seal ........................ 2 58. Slack Adjuster Retainer Ring .......... 2
25. Hub Bearing Inner Cone .............. 2 59. Chamber Bracket Nut ................ 4
26. Hub Bearing Inner Cup ............... 2 60. Housing Drain Plug .................. 1
27. Planet Filler Plug .................... 2 61. Differential Carrier Stud .............. 14
28. Wheel Hub .......................... 2 62. Differential Carrier Stud

Taper Dowel ........................ 3
29. WheelStud ........................ 24
63. Differential Carrier Stud Washer ....... 14
30. Wheel Attaching Lug ................. 24
64. Differential Carrier Stud Nut ........... 14
31. Wheel Attaching Nut ................. 24
65. Differential and Carrier Assembly ...... 1
32. Axle Shaft .......................... 2
66. Axle Housing ....................... 1
33. Hub Bearing Outer Cone .............. 2
34. Hub Bearing Outer Cup ............... 2
35. Breather ........................... 1
Copyrighted
-7-
Material
8
38
36 37
-8-
DIFFERENTIAL & CARRIER ASSEMBLY
ITEM DESCRIPTION QTY ITEM DESCRIPT ION

‘ QTY
1 Adjusting Nut Lock .................... 2 22 Carrier Cap Bolt Washer ................ 4
2 Adjusting Nut Lock Bolt Lockwasher ...... 2 23 Carrier Cap. .......................... 2
3 Adjusting Nut Lock Bolt ................ 2 24 Differential Carrier ..................... 1
4 Differential Adjusting Nut ............... 2 25 Center Pinion Bearing Cone ............. 1
5 Differential Bearing Cup ................ 2 26 Center Pinion Bearing Cup .............. 1
6 Differential Bearing Cone ............... 2 27 Pinion Bearing Spacer. ................. 1
7 Ring Gear Bolt Nut ................... .I2 28 Pinion Bearing Cage Shim .............. .AR
8 Flange Half Case ...................... 1 29 Pinion Bearing Cage ................... 1
9 Ring Gear ............................ 1 30 Outer Pinion Bearing Cup ............... 1
10 Ring Gear Bolt ....................... .I2 31 Outer Pinion Bearing Cone .............. 1
11 Side Gear Thrust Washer ............... 2 32 Pinion Oil Seal ........................ 1
12 Pinion Thrust Washer .................. 4 33 Oil Seal Retainer Lockwasher ............ 5
13 Pinion Gear .......................... 4 34 Oil Seal Retainer Bolt .................. 5
14 Pinion Gear Spider .................... 1 35 Pinion Shaft Nut ...................... 1
15 Side Gear ............................ 2 36 Companion Flange .................... 1
16 Plain Half Case ....................... 1 37 Oil Seal Retainer Locating Bolt ........... 1
17 Differential Case Bolt ................. .12 38 Oil Seal Retainer Locating Lockwasher .... 1
18 Differential Case Bolt Washer ........... .I2 39 Pinion Oil Seal Retainer. ................ 1
19 Inner Pinion Bearing ................... 1 40 Thrust Screw. ........................ 1
20 Pinion.. ............................. 1 41 Thrust Screw Nut ..................... 1
21 Carrier Cap Bolt ....................... 4
AR - As Required
-9-
14D1035
AXLE ASSEMBLY INSTRUCTION ILLUSTRATION
END VIEW OF AXLE

n 1 These surfaces must be dry and free from
sealing compounds, rust, nicks and burrs.
HOUSING
+
I
~ + -AXLE
2 Apply Loctite #262 Thread Locking
A
Compound.
n 3 Apply Dow Corning RTV-Q3-7069 Sealant.
4 Apply Loctite #515 Sealant. SERIAL

n NUMBER HERE
REAR VIEW OF HOUSING
n 5 Apply Loctite Pipe Sealant with Teflon, item
No. 59241.
ABOVE HORIZONTAL g OF AXLE.
A6 Axle assembly to be air checked at 12 PSI
(83 KPA) for 15 seconds with no drop in air VERTICAL $
pressure at Air Breather Hole.
n 7 Apply coating of E.i? Multi-Purpose Grease

.__.
TIGHTEN TO_2?0-230 LBS. FT.
Grade #2 to inside diameter of oil seals and

to spindle seal journal diameter prior to
assembly.
SLACK ADJUSTE
LBS. FT.
[240,8] r ADJUST BRAKES WITH AIR CHAMBER

TIGHTEN TO 90-100 LBS. ASSEMBLED OR WITH SLACK ADJUSTER
SECTION A-A TO DIMENSIONS SHOWN. ROTATE SLACK
(ROTATED 90°) ADJUSTER ADJUSTING SCREW TO 20 LBS. FT.
[27 N,m] AS LININGS CONTACT DRUM. BACK
OFF 112 TURN TO OBTAIN LINING
CLEARANCE.
SECTION THRU PLANET SPIDER 8 HUB

SHOWING STUD &TAPERED DOWEL
n
2
TIGHTEN TO 90-100 LBS. FT.
1125-135 N.m]
[410_450 N.m]
TIGHTEN TO 25-28 LBS. FT
n 6
EN TO 80-85 LBS. Ff.

[651-705 N.m]
-lO-
0
No-spin
Differential Standard
\ Differential P
Differential Bearing Nuts to

be adjusted to take up
all slack in
differential bearings.
Select a spacer and shims

to obtain a rollin
of lo-30 Lbs. In
pinion assembled -Assemble pinion bearing
This check to be spacer with chamfer
diff. is assembled toward input flange
include pinion oil
Q 3 Shim as req’d
Std. Seal Unitized Seal
1390 Series Differential (Ring Gear Diameter)

Assembly Instructions 81 Bolt Tightening Chart
- Lbs. Ft. Torque [N-m]
n 1
2
Apply Loctite #262 Thread Locking Compound
Apply Dow Corning RTV-Q3-7069 Sealant

A - 220 to 245 Lbs. Ft. 1300 - 330 N.m] n
B - Ring Gear Backlash Adjustment ,009 - ,013 3 Apply Loctite #515 Sealant
[0,22 - 0,33 N.m] n
C - 25 to 28 Lbs. Ft. [34 _38 N.m] Apply Loctite Pipe Sealant
D - 90 to 100 Lbs. Ft. [125 - 135 N.m] n 4 with Teflon, item No. 59241.
E - 275 Lbs. Ft. [373 N.m] Apply coating of E.P. Multipurpose Grease Grade #2
F - 90 to 100 Lbs. Ft. [125 - 135 N,m] between lips of oil seal
G - 480 to 520 Lbs. Ft. [651 - 705 N.m]
H - 125 to 140 Lbs. Ft. [170 - 190 N.m] Grease seal seat journal of drive flange with E.P.
J - 80 to 88 Lbs. Ft. [108 - 119 N.m] Multipurpose Grease Grade #2 prior to assembly
Boss provided on carrier has serial No., carrier

ratio, & N.S. when no-spin is used
Copyrighted
-ll- Material
14D1035
DRIVE AXLE MAINTENANCE AND SERVICE
The instructions contained herein cover the dis- CAUTION: Cleanliness is of extreme importance in the
assembly and reassembly of the axle assembly in a se- repair and overhaul of this unit. Before attempting any
quence that would normally be followed after the unit repairs, the exterior of the unit must be thoroughly
has been removed from the machine and is to be com- cleaned to prevent the possibility of dirt and foreign
pletely overhauled. Mount axle on steel horses or on matter entering the mechanism.
V-blocks. Allow axle housinn mountino pads to rest on
crossbars of horses to provide necessab’rigidity.
CAUTION: Before removina wheel hub and drum as-
sembly, install a “C” clamp on each end of axle housing
NOTE: Drain axle wheel ends and center section to prevent axle assembly from flipping off repair stand.
thoroughly before disassembly.
DISASSEMBLY:
Fig. 1. Fig. 3.
Overall view of axle assembly. Remove planet cover and sun gear thrust washer as-
sembly. NOTE: If the differential only is to be repaired,
pull the axle shaft and sun gear out of the planet carrier
assembly far enough to clear differential side gear.
Repeat Figures 2 and 3 on opposite end.
Fig. 4.
Fig. 2. Remove planet carrier stud nuts, washers, and
Remove planet cover capscrews. capscrews.
Copyrighted
-13-
Material
Fig. 5. Fig. 8.
On each stud is a taper dowel. Remove dowels by tap- Remove axle shaft sun gear retainer ring.
ping the blade of screwdriver in the slot of the taper
dowel. Twist screwdriver and dowel will come out of
planet housing.
Fig. 6. Fig. 9.
Pry planet carrier from wheel hub. Remove sun gear.
Fig. 7. Fig. 10.

Remove planet carrier assembly. Remove sun gear thrust washer.
Intended for-14-
CLARK dealers only
Fig. 11. Fig. 14.
Remove axle shaft. Remove internal gear and outer hub bearing.
Fig. 12. Fig. 15.

Straighten wheel nut lock tang from flats of outer jam Remove wheel hub and brake drum.
nut.
Fig. 13.
Remove jam nut (outer), nut lock, and inner adjusting
nut. CAUTION: It is recommended a chain hoist be Fig. 16.
attached to wheel hub before removing inner nut. Remove brake shoe return spring.
Copyrighted
-15-
Material
Fig. 20.
Remove slack adjuster to camshaft retainer ring. Remove camshaft and various sealing rings, retainer
rings and washers. Use caution as not to lose these
parts unless they are being replaced.
Fig. 18. Fig. 21.

Remove camshaft to brake spider retainer ring. Check camshaft bushing in air chamber bracket for re-
placement.
Fig. 22.
Fig. 19. Check cam shaft bushing in brake spider for replace-
Remove slack adjuster. ment.
Copyrighted
-16- Material
Fig. 23. Fig. 26.
Remove brake spider and spindle to axle housing bolts Install companion flange retainer tool, remove cotter
and washers. Remove brake spider and spindle. pin, and loosen nut securing flange to pinion shaft. This
See page 31 for brake service. will facilitate later flange removal.
Fig. 24.
Fig. 27.
Remove differential to axle housing stud nuts, washers,
Use center punch to matchmark bearing caps to carrier
and taper dowels. Remove differential straight off of
assembly. This is to insure correct match in reassembly.
studs.
DISASSEMBLY OF DIFFERENTIAL
Fig. 25.
Mount differential on differential overhaul stand. Check
and record ring gear backlash with a dial indicator. This Fig. 28.
information is necessary for reassembly unless a new Remove adjusting nut lock. REMOVE RING GEAR
gear set is installed. THRUST SCREW JAM NUT AND THRUST SCREW.
-17-
Fig. 32.
Remove bolts securing bearing caps to carrier assembly. Matchmark case halves to insure correct reassembly.
Remove caps and adjusting nuts. Insert metal bar
through differential to facilitate hoisting.
Fig. 30. Fig. 33.

Raise ends individually and remove bearing cups. If replacement is required, remove either or both dif-
ferential bearings. NOTE: Two recesses are provided
under the bearing mounts in each casting to facilitate
use of two-arm type puller.
Fig. 31.
While hoisting carefully, tilt differential to angle and
position shown. This will permit ring gear to clear pinion
shaft inner bearing boss in carrier assembly. Remove Fig. 34.
differential. Remove nuts and bolts. Remove ring gear.
-18-
If No-Spin differential is NOT used proceed with Fig-
ure 35. If No-Spin is used, use the following for remov-
ing and proceed to Figure 38.
Fig. 36.
Remove spider, pinions, and thrust washers.
Mark the mating halves of the differential case with

a center punch so they can be reassembled in the
original position when repairs or inspection is com-
pleted.
Insert a retaining bolt and washer assembly, (as
shown), threading the nut finger-tight against the
washer.
Separate the case halves and lift out the No-Spin Fig. 37.
assembly. Remove side gears and thrust washers from case
halves.
Fig. 38.
Remove differential bolts securing case halves, lift off Remove nut, washer and companion flange. Use puller
case half. Use soft mallet if necessary to aid removal. if necessary to remove flange.
Copyrighted
-19-Material
Fig. 39. Fig. 42.
Remove bolts securing seal retainer to carrier, remove Press center bearing cone from pinion assembly.
retainer. If necessary, tap with soft mallet to break seal
between parts.
Fig. 40. Fig. 43.

Using pry slots provided, remove bearing cone, bearing Press inner bearing from pinion assembly.
cage, bearing spacer and bearing cage shims. Retain
bearing cage shim pack intact for reuse in reassembly.
CLEANING AND INSPECTlON
CLEANING
Clean all parts thoroughly using solvent type cleaning
fluid. It is recommended that parts be immersed in
cleaning fluid and moved up and down slowly until all
old lubricant and foreign material is dissolved and parts
are thoroughly cleaned.
CAUTION: Care should be exercised to avoid skin

rashes, fire hazards and inhalation of vapors when using
solvent type cleaners.
BEARINGS
Remove bearings from cleaning fluid and strike larger
side of cone flat against a block of wood to dislodge
solidified particles of lubricant. Immerse again in clean-
ing fluid to flush out particles. Repeat above operation
Press pinion assembly from carrier. until bearings are thoroughly clean. Dry bearings using
Copyrighted
-2o- Material
moisture-free compressed air. Be careful to direct air through, replace with new gear. Small nicks may be
stream across bearing to avoid spinning. Do not spin removed with suitable hone. Inspect shafts to make cer-
bearings when drying. Bearings may be rotated slowly tain they are not sprung, bent, or splines twisted, and
by hand to facilitate drying process. that shafts are true. Differential pinions and s/de gears
must be replaced as sets. Differential ring gear and
bevel pinion must also be replaced as a set if either is
HOUSINGS
damaged.
Clean interior and exterior of housings, bearing caps,
etc., thoroughly. Cast parts may be cleaned in hot solu-
HOUSING AND COVERS
tion tanks with mild alkali solutions providing these
parts do not have ground or polished surfaces. Parts Inspect housing, covers, planet spider, and differential
should remain in solution long enough to be thoroughly case to be certain they are thoroughly cleaned and that
cleaned and heated. This will aid the evaporation of the mating surfaces, bearing bores, etc., are free from nicks
cleaning solution and rinse water. Parts cleaned in solu- or burrs. Check all parts carefully for evidence of cracks
tion tanks must be thoroughly rinsed with clean water to or conditions which cause subsequent oil leaks or
remove all traces of alkali. Cast parts may also be failures.
cleaned with steam cleaner.
At Reassembly Apply Thread Locking Compound
Where Noted.
CAUTION: Care should be exercised to avoid skin rashes
Guidelines For Application Where To Apply.
and inhalation of vapors when using alkali cleaners.
A. On bolts, cap screw and studs (anchor end) apply
compound on female threaded component part.
Thoroughly dry all parts cleaned immediately by using B. On nuts, apply compound to the male thread of the
moisture-free compressed air or soft, lintless absorbent mating fastener.
wiping rags free of abrasive materials such as metal
filings, contaminated oil or laping compound. C. Apply compound to coat the full length and circum-
ference of thread engagement.
INSPECTION D. Remove excess compound from mating parts after

fastener installation.
The importance of careful and thorough inspection of
all parts cannot be overstressed. Replacement of all
parts showing indication of wear or stress will eliminate REASSEMBLY OF DlFFERENTlAL AND CARRIER
costly and avoidable failures at a later date. (See Cleaning and Inspection Page)
BEARINGS REASSEMBLY OF DIFFERENTIAL RING GEAR AND

Carefully inspect all rollers, cages and cups for wear, DIFFERENTIAL CASE
chipping or nicks to determine fitness of bearings for NOTE: Lubricate all differential bearings, gears, and
further use. Do not replace a bearing cone or cup in- thrust washers.
dividually without replacing the mating cup or cone at
the same time. After inspection, dip bearings in clean
light oil and wrap in clean lintless cloth or paper to
protect them until installed.
OIL SEALS, GASKETS AND RETAINING RINGS

Replacement of spring loaded oil seals, gaskets and
snap rings is more economical when unit is disas-
sembled than to risk premature overhaul to replace
these parts at a future time. Loss of lubricant through a
worn seal may result in failure of other more expensive
parts of the assembly. Sealing members should be
handled carefully, particularly when being installed. Cut-
ting, scratching, or curling under lip of seal seriously
impairs its efficiency. At reassembly, lubricate lips of oil
seals with Lubriplate.
GEARS AND SHAFTS

If magna-flux process is available, use process to
check parts. Examine teeth and ground and polished
surfaces on all gears and shafts carefully for wear, pit-
ting, chipping, nicks, cracks or scores. If gear teeth are Check ring gear mounting surface of flanged half of dif-
cracked or show spots where case hardening is worn ferential case for burrs. Remove burrs with file.
Intended for CLARK
-2l- dealers only
Fig. 46.
Position ring gear on flanged half case. install bolts. In- Align matchmarks and install plain half case on flanged
stall bolt nuts, tighten to specified torque (See page 41). half assembly, making sure of full gear engagement. In-
If No-Spin is used install in case half as an assembly and stall bolts and tighten to specified torque. See torque
proceed to Figure 46. chart.
Fig. 46. Fig. 49.

Lubricate and install thrust washer and side gear in dif- Press differential bearing cones on case halves.
ferential case.
REASSEMBLY OF PINION SHAFT
Pig. 47.
Place pinions and thrust washers on differential spider,
lubricate and set in position on installed side gear. Lubri-
cate and install side gear and thrust washer on pinions.
Fig. 50.
Apply Loctite #I262 to internal threads in flanged half
Press inner bearing on pinion shaft.
case.
Intended-22-
for CLARK dealers only
Fig. 54.
If pinion and bearing cage parts were disassembled for
cleaning and inspection only and none of the parts were
replaced, use original pinion bearing spacer. If parts
Fig. 51. were changed a pinion bearing spacer and shim kit is
Stake bearing in four places equally spaced around provided for service repair of differential and carrier as-
diameter. Use square end staking tool as shown. See semblies. This kit, consisting of a spacer and quantity of
page 35 for proper pinion shaft staking. shims, is used to obtain proper pinion bearing preload
as described in Figure 58. Position bearing spacer (with
chamfer toward threaded end of shaft) and one .OlO
[0,25mmI shim on pinion shaft and install outer pinion
bearing cone.
Fig. 52.
Press center bearing onto pinion shaft.
Fig. 55.
Press outer pinion bearing cone on pinion shaft.
Fig, 56.
Install bearing cage shims (use original shim packs or
their equivalent thickness) and pinon shaft assembly in
differential carrier housing. Use five identical oil seal
retainer bolts with flat washers to pull pinion shaft as-
Fig. 53. sembly fully into carrier assembly. Make sure oil pas-
Position center bearjng cup and bearing cage on pinion sages are aligned. Tighten five bolts to specified torque.
shaft. See torque chart.
-23- dealers only
Intended for CLARK
Fig.60.
Temporarily install companion flange on end of pinion Position differential bearing cup and adjusting nut on
shaft without installing pinion oil seal retainer. Install lifting bar on one side of differential and lift bar slightly
flange washer and nut. Install companion flange retain- with hoist. Position bearing cup and adjusting nut on
ing tool on companion flange and torque companion carrier. Repeat procedure and install opposite bearing
flange nut to specified torque. See page 11. cup and adjusting nut. Turn adjusting nuts by hand to be
sure of proper thread alignment.
Fig.56. Fig.61.
Use “inch-pound” torque wrench to check bearing Position bearing caps on bearings and adjusting nuts,
preload. Bearing preload value is IO-30 [1,2-3,4 N’ml making sure matchmarks made during disassembly are
inch Ibs. rolling torque. Add shims to decrease preload properly aligned. Install cap bolts, and tighten lightly. Do
or remove shims to increase preload. NOTE: Pinion, not torque at this time.
bearing cage and flange will be removed after ring gear
to pinion tooth contact and backlash has been set.
Fig. 59.
Insert bar through differential to facilitate hoisting. Posi-
tion differential into carrier, tilting it so that ring gear will Tighten bearing adjusting nutsto adjust bearings to zero
clear inner bearing boss in carrier. end play.
Intended for
-24-CLARK dealers only
should be rotated, under slight load, until ring gear has
turned at least one revolution in both directions.
Check tooth contact pattern on drive side (convex side)
of ring gear teeth. Coast side will automatically correct
when drive side pattern is correct. Refer to gear tooth
contact chart. If proper tooth contact pattern is not as
shown, readjust backlash or, add to or subtract from
shim pack between bearing cage flange and differential
housing.
Addition of or subtraction of shims should be made in
small increments until proper contact is established.
Fig. 63.
Use a dial indicator as shown. Move ring gear by
loosening one adjusting nut and tightening opposite ad-
justing nut. Adjust position until gear backlash is to
backlash specifications (See page 11 for new gear set),
or adjust to backlash noted at disassembly for used
gears. When proper backlash is achieved, tighten op-
posite adjusting nut to set pre-load on taper bearings. Fig. 65.
Using only thumb and forefinger move ring gear. When Tighten differential cap bolts to specified torque. See
ring gear becomes difficult to move, pre-load on bearing torque chart. With dial indicator, recheck ring gear and
is set. pinion backlash. Recheck differential bearings for
preload as described in Figure 63.
Fig. 66.
Fig. 64. Use dial indicator to check back face of ring gear. Rotate
Check ring and pinion gear for proper tooth contact. at least one full turn. Runout must not exceed .005 [0,12
Paint ring gear with a gear tooth marking compound. mm1 total indicator reading. If runout is excessive
When ring and pinion gears are rotated, the compound remove assembly and check for burrs or dirt under
is squeezed away by the contact of the teeth, leaving mounting surface of ring gear. Reassemble and recheck.
bare areas the exact size, shape and location of the con-
Remove companion flange nut, washer, and flange.
tacts. As a rule, painting about 10 or 12 teeth is sufficient
Remove bolts and flat washers securing pinion cage to
for checking purposes.
differential carrier. Remove pinion cage assembly, coat
Sharper impressions may be obtained by applying a shim surface of carrier housing and shim surface of
smaH amount of resistance to the ring gear with a flat bearing cage with Loctite Sealer #515. Reinstall shims
steel bar and using a wrench to rotate the pinion. Gears and pinion and cage assembly on carrier housing.
Copyrighted
-25- Material
DISASSEMBLY OF PLANET CARRIER ASSEMBLY
Fig. 67. Fig. 69.

Apply Loctite Sealer #515 to oil seal retainer bore. Install Press pinion shaft from planet carrier assembly as
seal in retainer with lip of seal toward oil side. Coat shown. Use caution as not to lose pinion shaft lock ball.
retainer to cage surface with same sealer. Coat lip of
seal with Lubriplate. Coat internal threads with Loctite
Sealer #262.
Install oil seal retainer bolts and tighten to specified
torque. See torque chart.
Coat flange splines with Dow Corning RTV-Q3-7069
Sealant. Position companion flange on pinion shaft. In-
stall washer and nut. Tighten nut to specified torque.
See torque chart.
Fig. 70.
Remove pinion gear, pinion rollers, roller spacer and
thrust washers from carrier housing.
REASSEMBLY OF PLANET CARRIER ASSEMBLY

(See Cleaning and Inspection Page)
Fig. 68.
Apply a coat of Loctite #262 to internal threads and in-
stall adjusting nut lock with bolt and lockwasher. Tighten
to specified torque. See torque chart.
THRUST SCREW ADJUSTMENT

1. Apply Dow Corning RTV-Q3-7069 to thrust screw
threads.
2. Turn thrust screw IN to contact ring gear.
3. Install a dial indicator on end of thrust screw.
4. Turn thrust screw AWAY from ring gear until a .012
10,301 reading is taken on the dial indicator. The
specification is .OlO to .015 [0,25 - 0,381 distance
from end of thrust screw to side of ring gear. .012
[0,301 was used as an in-between reading.
5. See assembly instruction page 11. Hold thrust screw Fig. 71.
and tighten lock nut to 275 Ibf. ft. torque [373 N-ml. Coat inside of planet pinion with chassis grease to retain
NOTE: Dial indicator reading must not move during pinion needle rollers. Each pinion gear contains a
this operation. double row of needle rollers with spacer between rows.
Copyrighted
-26- Material
Fig. 72. Fig. 74.
Position assembled pinion and two pinion thrust Check differential mounting flange of axle housing to be
washers in planet spider assembly, making sure tangs sure it is free of dirt and burrs. Coat differential to axle
on thrust washers engage the grooves in the spider. housing surface with Dow Corning RTV-Q3-7069. Align
differential assembly with axle housing studs. Lower
into position. Use caution as not to damage studs. Apply
Loctite #262 to threads of stud.
Install taper dowels on studs. Install lockwashers and
stud nuts. Tighten taper dowel stud nut first. Tighten to
specified torque. See torque chart.
Fig. 73.
Align pinion shaft lock ball with notch in planet carrier.
Press shaft into position using caution as not to disturb
rollers in pinion gear. Press end of shaft flush or slightly Fig. 75.
below face of carrier. Install brake spider and spindle as shown.
REASSEMBLY OF AXLE
(See Cleaning and Inspection Page)
The following instructions describe the procedure to be
followed when reassembling and installing components
of axle. Instructions cover reassembly of only one side
of axle. Reassembly of opposite side is identical unless
otherwise noted.
IMPORTANT: Both grade 5 and Grade 8 fastening
hardware have been used in the production of the axle
assemblies covered by this manual. A table of proper
torque values for both Grade 5 and Grade 8 hardware is Fig. 76.
provided at the rear of this manual. Grade of hardware Tighten brake spider and spindle bolts to specified
may be determined by the “hash” marks contained on torque. See torque chart.
the head of each bolt; Grade 5 having three hash marks NOTE: When installing the camshaft, the “S” cam is
and Grade 8 having six hash marks as indicated on page made for clockwise and counterclockwise rotation. It is
41. imperative these camshafts be installed in the correct
Torque values specified in text of this manual are for wheel end for proper brake operation. The slack adjuster
end must move away from the air chamber and the “S”
Grade 8 hardware where presently used in production.
cam must spread the brake shoes out and away from
Grade 5 torque values are also specified when that
the brake spider. Installed backward there would be no
grade hardware is presently used. On all axles being
braking at all.
overhauled, bolts should be identified as described and
torque value chart consulted for correct torque.
.27-
Fig. 77. Fig. 80.
Install camshaft thrust washer and “0” ring on cam- Position slack adjuster on camshaft. Install retainer
shaft. Insert camshaft in brake spider bushing. Install washer and retaining ring.
grease retainer (felt washer), retainer washer, and
NOTE: After air chamber is installed slack adjuster may
retainer ring.
have to be removed and relocated to align with air
chamber actuating clevis.
Fig. 78.
Insert camshaft into air chamber bracket bushing. Note
part sequence on camshaft.
Fig. 81.
Position brake shoe and lining against “S” cam on cam-
shaft. NOTE: Check camshaft rotation away from air
chamber bracket to spread brake shoes. Install brake
shoe return spring. Move slack adjuster away from air
chamber bracket, brake shoes must spread, if they don’t,
the wrong camshaft was installed. Remove camshaft
and install correct one.
If hub and drum were disassembled, install inner and
outer taper bearing cups in wheel hub. Place inner taper
bearing in inner cup. Coat wheel hub oil seal outer
diameter with Loctite #262 Sealant. Press oil seal over
bearing with lip of seal toward bearing. Position oil
slinger on wheel hub. Align holes in brake drum with
holes in wheel hub. Do not disrupt oil slinger. Install
Fig. 79. washers and bolts. Tighten to specified torque. See
Install camshaft to brake spider retainer ring. torque chart.
-28-
Fig. 82. Fig. 85.
Position hub and drum over brake and spindle. Use cau- See Steps 4 & 5 on adjustment procedure.
tion as not to damage hub oil seal.
Fig. 83. Fig. 86.

Install internal gear and wheel hub outer bearing in See Steps 6,7, & 8 on adjustment procedure.
wheel hub and on spindle splines.
Fig. 84.
See Steps 1, 2, & 3 on wheel bearing adjustment proce- Fig. 87.
dure page 36. See Step 9 on adjustment procedure.
-29-
Fig. 88. Fig. 91.
Position axle shaft in axle housing. Install sun gear retainer ring.
Fig. 92.
Fig. 89. Apply a light coat of Dow Corning RTV-Q3-7069 Sealant
Install sun gear thrust washer on axle shaft. to face of wheel hub and install planet carrier assembly
on studs. NOTE: Align holes with a chamfer with the
studs. (taper dowels installed on studs only)
Fig. 93.
Install taper dowels at studs. (See guidelines for thread
locking compound). Install stud nut washers and stud
nuts. Install capscrews and washers. Tighten stud nuts
Fig. 90. first to specified torque. Tighten capscrews to specified
Install sun gear on axle shaft. torque. See torque chart.
-3o-
SERVICE BRAKES
Inspect anchor pins for wear or damage. If they are
worn or pitted, scored or deeply nicked, replace.
Check brake shoe bushings for wear.
Check cam rollers for wear and distortion. If inner
diameter is worn, or if outer diameter has flat spots
across roller, replace.
Check cam roller pins for wear and corrosion.
Inspect cam shafts for wear or corrosion of bearing
surfaces. If bearing surfaces are pitted, scored, or deeply
nicked, replace.
Check cam shaft spindle support bushings for wear.
Inspect brake drums for cracks, heat checks, scoring,
or other damage.
Fig. 94. REPLACE BRAKE SHOE RETURN SPRINGS EACH
Apply a light coat of Dow Corning RTV-Q3-7069 Sealant TIME AXLE IS OVERHAULED.
to planet carrier face. With wheel hub oil filler plug
If brake drum is to be rebored, do not exceed maxi-
above the axle center line, position planet cover on
mum rebore dimension casted on brake drum.
planet carrier with arrow casted on cover down. Install
capscrews.
DISASSEMBLY OF BRAKE SHOES
Fig. 95. Fig. 1.

Tighten planet cover capscrews to specified torque. See If worn or damaged, press brake shoe bushing from
torque chart. brake shoe.
Fig. 96.
See brake section for proper slack adjuster adjustment Fig. 2.
procedure. Remove cam roller pin lock pin.
-31-
Fig. 3. Fig. 6.
Remove cam roller pin and roller.
Fig. 4. Fig. 7.
If brake lining is to be replaced, remove brake lining to Tap brake lining plugs in lining bolt holes.
shoe bolt nuts and washers. Tap lining bolts and plugs
from brake shoes. When relining brakes both axle end
brakes must be relined. NOTE: Brake shoe shown has 16
lining attaching screws, some shoes have 12 attaching
screws. Procedure is the same.
REASSEMBLY OF BRAKE SHOES
Fig. 5. Fig. 8.
Install brake linings on brake shoes with washers and Position brake cam roller on brake shoe. Install brake
nuts. Torque nuts 200 to 220 Ibf. in. torque [22,6 - 24,8 cam roller pin in brake shoe and through cam roller.
N=ml. Tighten nuts in sequence shown in Figure 6. Install cam roller pin lockpins.
Copyrighted
-32-
Material
Fig. 9.
install brake shoe bushings into brake shoe.
-33-
BRAKE ASSEMBLY
QUANTITY FOR 2 WHEEL ENDS
ITEM DESCRIPTION QTY
1 Brake Lining Plug ........... I.. ....... 48
L Brake Lining to Shoe Bolt ..... ......... 48
3 Brake Lining ............... I.. ....... 8
4 Cam Roller Pin Lock Pin ...... .......... 4
5 Cam Roller Pin. ............. .......... 4
6 Cam Roller “0” Ring ......... .......... 4
7 Cam Roller. ................ .......... 4
8 Lining to Shoe Bolt Nut. ...... .......... 48
9 Lining to Shoe Bolt Lockwasher .......... 48
10 Cam Roller “0” Ring ......... .......... 4
11 Brake Spider ............... .......... 2
12 Anchor Pin. ................ .......... 4
13 Brake Shoe & Lining Assembly .......... 4
14 Anchor Pin Lock ............ .......... 2
15 Anchor Pin Lock Screw Lockwasher ...... 2
16 Anchor Pin Lock Screw. ................ 2
17 BrakeShoe .......................... 4
18 Brake Shoe Bushing ................... 4
AIR BRAKE ADJUSTMENT LUBRICATION
1. Use a torque wrench and socket to adjust slack adjusters to Air Brake Camshaft and Brake Shoe Bushings - Grease every
attain correct brake lining-to-brake drum clearance. time vehicle chassis is greased with a high quality E.P. (extreme
pressure) grease. DO NOT OVER-GREASE.
2. Position socket on adjusting screw and press far enough to
cause locking collar to disengage locking mechanism.
It is recommended brake dust cover be removed before greas-
3. While depressing collar, rotate adjusting screw clockwise ing to be certain no grease enters the brake drum and lining
until snug, approximately 20 Ibf.ft. (27 N.ml torque. area.
4. Back off adjusting screw approximately one-half turn. Lock-

ing collar will automatically return to locking position to lock
adjustmemt when socket is removed. This provides proper
brake lining-to-drum clearance.
Copyrighted
-34-
Material
When the inner pinion bearing or the pinion shaft and ring gear are being re-
placed staking of the pinion end to the inner pinion bearing is required.
If a staking groove is in the pinion shaft use procedure shown in Figure “A”
and a square end staking tool.
If pinion has no staking groove use procedure in Figure “B” and a standard
prick punch to up-set the metal over the bearing inner race.
l/8”
FIGURE A
OPTIONAL CONSTRUCTION
(NO STAKING GROOVE)
STAKE IN 6 PLACES1
FIGURE B
-35-
(DOUBLE NUT AND NUT LOCK)
WHEEL BEARING ADJUSTMENT PROCEDURE
FOR THE 12D, 12S, 14D, 14s AND 14T AXLES
(With drum, dry disc or no brakes).
1. Before wheel bearing adjustment is made, it is imperative all tapered bearings and bearing cups be
pressed to a fully seated position. DO NOT depend on the wheel bearing adjusting nut to “shoulder”
tapered bearings and cups.
2. Install inner wheel bearing adjusting nut and tighten to 500 Ibs. ft. torque 1677 N.ml. Shock internal
gear hub with a heavy bar or mallet. Rotate wheel hub two or three times.
3. Recheck inner nut torque. If nut moves, retorque to 500 Ibs. ft. torque [677 N.ml and repeat shocking
and checking nut torque until 500 Ibs. ft. 1677 N.ml does not advance nut.
4. Loosen inner nut l/4 to l/2 turn and shock wheel hub until a slight bearing end play is achieved and
the wheel hub can rotate freely. Measure the no-load rolling torque (normally 0 to 50 Ibs. ft. torque)
LO-68 N.ml. Retorque inner nut 100 - 150 Ibs. ft. [135-203 N.ml. Shock wheel hub and recheck rolling
torque. See chart for new and used wheel bearing rolling torque.
5. When proper pre-load is achieved, install adjusting nut lock. Coat inner face of jam nut and spindle
threads with Anti-Seize or Never-Seez lubricant and install jam nut. NOTE: The nut socket used to
torque the jam nut should be depth controlled to prevent contact between the socket face and outer
tangs of the nut lock (see page 37). This controlled depth will prevent torque from being transmitted
from the socket face to the nut lock outer tangs and the possiblity of shearing the nut lock inner tang.
6. Tighten jam nut to 500 Ibs. ft. torque [677 N.ml. Recheck rolling torque. Rolling torque must be in the
range of values shown in chart for new and used bearings.
7. If over the rolling torque value listed for new and used bearings, reduce the inner nut torque as
required to obtain the proper rolling torque value listed.
8. If under the rolling torque value listed for new and used bearings, increase inner nut torque as
required to obtain the proper rolling torque value listed.
9. When proper rolling torque is obtained, bend two tangs of the nut lock over the inner nut and two
tangs over the jam nut. (See page 37.)
Rolling Torque Range Jam Nut Torque
Adjusting NEW Tapered 7 to 12 Ibs. ft. torque. [l O-l 6 N.ml 500 Ibs. ft.
Bearings: Greater than “no-load rolling [677 N.ml
torque” value.
Readjusting USED 3 to 5 Ibs. ft. torque [4-6 N.ml. 500 Ibs. ft.
Tapered Bearings: Greater than “no-load rolling 1677 N.ml
torque” value.
-36-
3
5
DRILL TO SPEClFlC WHEEL HUB BOLT CIRCLE AND STUDOR =T DlAr 4
LIDRIVE
~FILLRT WELD 2 SOCKET
I WRENCH
I
I
DEPTH CONTROLLED
TO PREVENT FACE
OF SOCKET FROM
CONTACTING NUT LO
When proper pre-load is achieved install adjusting nut lock. NUT SOCKE
Coat inner face of jam nut with Anti-Seize or Never-See2
lubricant and install. NOTE: The nut socket used to torque the
jam nut should be depth controlled to prevent contact between
the socket face and outer tangs of the nut lock (see Figure 2).
This controlled depth will prevent torque from being trans-
mitted from the socket face to the nut lock outer tangs and the FIGURE 2
possiblity of shearing the nut lock inner tang. Tighten jam nut to
full recommended torque. Recheck final rolling torque, which
should not be greater than the sum of the “No-load” rolling
torque plus the highest valtie of rolling torque specified for
respective axle series.
WHEN PROPER PRE-LOAD IS ACHIEVED BEND TWO

TANGS OF NUT LOCK ON FLATS OF INNER NUT
(ADJUSTING) AND TWO TANGS ON FLAT OF JAM NUT.
ADJUSTING
NUT
FIGURE 3
SPIRAL BEVEL AND HYPOID TOOTH BEARING CONTACT CHART
MOVE PINION TOWARD

GEAR IN THIS DIRECTION
MOVE PINION AWAY FROM

GEAR
MOVE GEAR AWAY FROM MOVE GEAR TOWARD
V PINION IN THIS DIRECTION PINION IN THIS DIRECTION A
LARGE END - ALL CONTACT BEARINGS SHOWN BELOW ARE ON RIGHT HAND SPIRAL
RING GEAR - THE DRIVE IS ON THE CONVEX SIDE OF THE TOOTH.
FIG. 1
TYPICAL PREFERRED BEARING ON BOTH SIDES OF TOOTH
WHILE UNDER A LIGHT LOAD
FIG. 2
TOE BEARING ON BOTH SIDES OF TOOTH - GEAR SET NOISY. TO MOVE
BEARING TOWARD HEEL INCREASE BACKLASH WITHIN LIMITS BY MOV-
ING GEAR AWAY FROM PINION.
FIG. 3
HEEL BEARING ON BOTH SIDES OF TOOTH - GEARSET NOISY AND
COULD RESULT IN EARLY GEAR FAILURE. TO MOVE BEARING TOWARD
TOE PECREASE BACKLASH WITHIN LIMITS BY MOVING GEAR TOWARD
PINION.
FIG. 4
LOW BEARING ON GEAR AND HIGH BEARING ON PINION. CORRECT

BY PULLING PINION AWAY FROM GEAR (INCREASE MOUNTING DIS-
TANCE.
FIG. 5
HIGH BEARING ON GEAR AND LOW BEARING ON PINION. CORRECT
BY MOVING PINION IN TOWARD GEAR (DECREASE MOUNTING DIS-
TANCE.
BACKLASH
BACKLASH SHOULD BE MEASURED WITH A DIAL INDICATOR RIGIDLY MOUNTED WITH THE STEM PERPENDICU-
LAR TO THE TOOTH SURFACE AT THE EXTREME HEEL.
-38-
SPIRAL BEVEL AND HYPOID TOOTH BEARING CONTACT CHART
MOVE PINION TOWARD

MOVE GEAR AWAY FROM MOVE GEAR TOWARD

PINION IN THIS DIRECTION PINION IN THIS DIRECTION A
LARGE END - ALL CONTACT BEARINGS SHOWN BELOW ARE ON LEFT HAND SPIRAL
RING GEAR-THE DRIVE IS ON THE CONVEX SIDE OF THE TOOTH.
FIG. 1
TYPICAL PREFERRED BEARING ON BOTH SIDES OF TOOTH
WHILE UNDER A LIGHT LOAD
FIG. 2
TOE BEARING ON BOTH SIDES OF TOOTH - GEAR SET NOISY. TO MOVE
BEARING TOWARD HEEL INCREASE BACKLASH WITHIN LIMITS BY MOV-
ING GEAR AWAY FROM PINION.
FIG. 3
HEEL BEARING ON BOTH SIDES OF TOOTH -GEARSET NOISY AND
COULD RESULT IN EARLY GEAR FAILURE. TO MOVE BEARING TOWARD
TOE DECREASE BACKLASH WITHIN LIMITS BY MOVING GEAR TOWARD
PINION.
FIG. 4
LOW BEARING ON GEAR AND HIGH BEARING ON PINION. CORRECT
BY PULLING PINION AWAY FROM GEAR (INCREASE MOUNTING DIS-
TANCE.
FIG. 5
HIGH BEARING ON GEAR AND LOW BEARING ON PINION. CORRECT
BY MOVING PINION IN TOWARD GEAR (DECREASE MOUNTING DIS-
TANCE.
BACKLASH
SACKLASH SHOULD BE MEASURED WITH A DIAL INDICATOR RIGIDLY MOUNTED WITH THE STEM PERPENDICU-
.AR TO THE TOOTH SURFACE AT THE EXTREME HEEL.
-39-
PROPER TIGHTENING PROCEDURE
(Use Tightening Sequence Shown)
Thread Flat Nuts and Flat Nuts with Spherical

Size Hardened Washer Rim Clamps Nuts
5/8 (.625) 175 - 190 Lbs. Ft. --- 240 - 275 Lbs. Ft.
[240 - 260 N.m] [325 - 375 N.m]
3/4 (.750) 300 - 330 Lbs. Ft. 250 Max. Lbs. Ft. 450 - 500 Lbs. Ft.
[410 - 450 N.m] [340 N.m] [610 - 680 N.m]
7/8 (.875) 475 - 525 Lbs. Ft. 350 Max. Lbs. Ft. 600 - 700 Lbs. Ft.
[645 - 710 N.m] [475 N.m] [815 - 950 N.m]
1 (1.000) 725 - 800 Lbs. Ft. --- 750 - 900 Lbs. Ft.
[985 - 1085 N.m] [lo15 - 1220 N.m]
Copyrighted Material APPROVED BY AXLE ENGINEERING

Intended for-4o-
CLARK dealers only 7 MARCH 1980
TORQUE FOR BOLTS, CAPSCREWS, STUDS AND NUTS
AS SUPPLIED BY CLARK EQUIPMENT
Grade 5 Identification, 3 Radial Grade 8 Identification, 6 Radial

Dashes 1 20° Apart on Head of Bolt Dashes 60° Apart on Head of Bolt
Grade 5 Grade 8
:astener
Size lubricated and Plated lubricated and Plated
l/4-20
80 - 90 Lbs. In. 19- IO N.m] llO- 120 Lbs. In. [13 - 14 N.m]
l/4-28
5/l&18
180 - 200 Lbs. In. 121 - 23 N.m] 215 - 240 Lbs. In. [24 - 27 N.m]
5116-24
318-16
318-24 25 - 28 Lbs. Ft. [34 - 38 N.m] 35 - 40 Lbs. Ft. [48 - 54 N.m]
7/16-14
7116-20 40 - 45 Lbs. Ft. [54 - 61 N.m] 60 - 65 Lbs. Ft. [82 - 88 N.m]
112-13
l/2-20 65 - 70 Lbs. Ft. [88 - 95 N.m] 90 - 100 Lbs. Ft. [125 - 135 N.m]
9/16-12
9/16-18 90 - 100 Lbs. Ft. [125 - 135 N.m] 125 - 140 Lbs. Ft. [170 - 190 N.m]
5/8-11
518-18 125 - 140 Lbs. Ft. [ITO- 190 N.m] 175 - 190 Lbs. Ft. [240 - 260 N.m]
3/4-10
314-16 220 - 245 Lbs. Ft. [LOO- 330 N.m] 300 - 330 Lbs. Ft. [410 - 450 N.m]
718-9
718-14 330 - 360 Lbs. Ft. [450-490 N.m] 475 - 525 Lbs. Ft. [645 - 710 N.m]
l-8
l-12 475 - 525 Lbs. Ft. [645 - 710 N.m] 725 - 800 Lbs. Ft. [985 - 1085 N.m]
l-1/8 - 7
l-1/8 - 12 650 - 720 Lbs. Ft. [880 - 975 N.m] 1050 - 1175 Lbs. Ft. [1’425- 1600 N.m]
l-1/4-7
l-1/4 - 12 900 - 1000 Lbs. Ft. [1220 - 1360 N.m] 1475 - 1625 Lbs. Ft. 12000 - 2200 N.m]
APPROVED BY AXLE ENGINEERING

Copyrighted
-4l-
Material
REVISED 24 MARCH 1980
$2.00 MAINTENANCE MANUAL NO. 5
REVISED I-92
Standard and Diff. Lock Carriers For:
l Single Axles
l Rear of Tandem Axles
l Front Drive Steering
Axles
(See inside front cover for
specific axle models)
Use; only
genuine Rockwell Parts
Axle Models Covered in This Manual
Single drive axles:
A-150 E-l 00 F-140 H-l 72 Q-l 00 R-163 RS-16-140 RS-23-180
B-100 E-l 05 G-l 61 L-l 00 Q-145 R-l 70 RS-17-140 RS-26-180
B-140 E-l 50 H-l 00 L-140 RL-170 S-l 70 RS-16-141 RS36-180
B-150 F-l 00 H-140 L-l 55 R-l 00 U-l 40 RS-17-141
C-l 00 F-l 06 H-l 50 L-l 72 R-l 40 w-170 RS-19-145
D-l 00 F-l 20 H-l 62 M-172 R-155 RS-13-120 RS-21-145
D-140 F-l 21 H-l 70 QT-140 R-l 60 RS-15-120 RS-23-160
Rear axle of tandem axles:
SDHD SL-100 SQHD SSHD su-170 RT-34-140 RT-40-145 RT-48.180
SFHD SLHD SR-170 ST-l 70 SUHD RT-40-140 RT-44-145 RT-52-180
SHHD SO-1 00 SRHD STHD SW-1 70 RT-34-145 RT-46-160 RT-58-180
Front drive steering axles:
FDS-75 FDS-85 FDS-93 FDS-1807 FDS-2100 FDS-2107 FDS-2111 FDS-2117
FDS-78 FDS-90 FDS-1600 FDS-1808 FDS-2101 FDS-2110
Service Notes
This Field Maintenance Manual describes the correct service and repair procedures for Rockwell Single
Reduction Carriers. The information contained in this manual was current at the time of printing and
is subject to change without notice or liability.
You must follow your company safety procedures when you service or repair equipment. Be sure you
understand all the procedures and instructions-before you begin work on the unit.
Rockwell uses the following types of notes to give warning of possible safety problems and to give infor-
mation that will prevent damage to equipment:
&A WARNING:
A warning indicates procedures that must be followed exactly. Injury can occur if the procedure
is not followed.
ALCAUTION:
A caution indicates procedures must be followed exactly. If the procedure is not followed, damage
to equipment or components can occur. Personal injury can also occur in addition to damaged
or malfunctioning equipment or components.
a TORQUE:
The torque symbol is used to indicate fasteners that must be tightened to a specific torque value.
NOTE:
A note indicates an operation, procedure or instruction that is important for correct service.
Some procedures require the use of special tools for safe and correct service. Failure to use these special
tools when required, can cause injury to service personnel or damage to vehicle components.
This manual is written in Rockwell Universal Language System (RULS).

Copyright 1988 Rockwell International
Table of Contents
SUBJECT PAGE
1. Introduction ............................................................................ .
2. Disassembly
Remove Differential Carrier From Housing ..................................... .4
RemovetheDifferentialandRingGearFromCarrier.. ........................... ::::::::::::.5
Disassemble the Differential and Ring Gear Assembly ........................................ .8
Remove the Drive Pinion and Bearing Cage From Carrier .............................. .lO
Disassemble the Drive Pinion and Bearing Cage ..................................... : : : : : : .12
3. Prepare Parts for Assembly
Clean,lnspect& Repair Parts .......................................................... ..15
4. General Procedures
Use of Dri-Lot Fasteners and Rockwell Liquid Adhesive 2297-C-3747 or Loctite 277 ................. .. .20
Application of Rockwell Adhesive in Bearing Bores of the Differential .. ....... : : : : : : .21
Application of Silicone Gasket Material ................................................... .21
Install “Tight Fit” Yokes with Three-Piece Pilot Tool .................................. .22
Gear Set Information (Drive Pinion and Ring Gear Markings) ........................... : : : : : : .24
VehicleTowinglnstructions..............................................................2 5
5. Assembly
Assemble Drive Pinion, Bearings and Bearing Cage ........................................ .27
Adjust Preload of Pinion Bearings ....................................................... .31
Adjust Thickness of Shim Pack for Pinion Cage ............................................ .35
Install Drive Pinion, Bearing Cage and Shim Pack into Carrier ................................ .37
Assemble Differential and Ring Gear Assembly ............................................ .38
Rotating Resistance Check of Differential Gears .41
Install Differential and Ring Gear Assembly .................................................................................. : : : : .. .42
Adjust Preload of Differential Bearings .................................................... .43
Check Runoutof Ring Gear ........................................................................................................... .45
Adjust Backlash of Ring Gear . . . . ::.4 5
Check Tooth Contact Patterns of Gear Set . .47
InstallandAdjusttheThrustScrew.. . ............................................................................. ::::::::::..5 0
Install Carrier into Housing ............................................................. .51
6. Driver Controlled Main Differential Lock
Remove Differential Carrier from Housing ................................................. .54
Remove Differential and Gear Assembly .56
Install Differential Shift Assembly ............................................................................ : : : : : : : : : : : : : : .. .57
Install Carrier into Axle Housing ......................................................... .5g
Check the Differential Lock ............................................................ ..6 1
7. ILubrication .......................................................................... ..6 2
8. Fastener Torque Information
General Information .................................................................. ..6 4
Torque Charts .. .65-67
9. Adjustments and Specifications
......................................................................................................................... .. .&3
Copyrighted Material Page 1

s
.-0
8a Introduction
Standard Single Reduction Carriers drive pinion and ring gear set and bevel gears in the
differential assembly.
Without Diff. Lock
Rockwell single reduction standard carriers, Figure 1, A straight roller bearing (spigot) is mounted on the
are used in most Rockwell single axles, rear of head of the drive pinion. All other bearings in the
tandem axles and front drive steering axles. carrier are tapered roller bearings.
The single reduction carrier models are front mounted When the carrier operates, there is normal differential
into the axle housing. These carriers have a hypoid action between the wheels all the time.
Figure 1 Standard Carrier
Tapered Roller
/Bearings
Hypoid Drive Pinion

and Ring Gear
, Carrier
7-apered Roller
Bearing \ Straight Roller
Bearing
Ho”sing ~~
j”iiiii~:~
:::*::::gj:.:.
$$$$gi:::i:+::. Ro”er
Page 2 Copyrighted Material
s
Introduction 1 a
moved along the splines of the axle shaft toward the

Single Reduction Carriers with Driver
differential case. When the splines on the collar are
Controlled Main Differential Lock (Diff. engaged with splines on the differential case the axle
Lock) shafts and differential assembly are locked together.
Rockwell single reduction carriers with Differential When the carrier operates in the locked position,
Lock, Figure 2, have the same type of gears and there is no differential action between the wheels.
bearings as the standard type carriers. When the carrier is operated in the unlocked position,
there is normal differential action between the wheels
The differential lock is operated by an air actuated all the time.
shift assembly that is mounted on the carrier. When
the differential lock is activated, the shift collar is
shown With Differential Carrier With Diff. Lock

_ock Engaged n
HYPCIid Drive Pinion

and Ring Gear
Straight Roller Bearing
Axle Shaft
Tapered
Tapered Roller Bearing
Differential Case
\ Bevel Differential Gears

5
s
0
.m
Q)
v) 2 Disassembly
Remove Differential Carrier I Figure 4 .
From Axle Housing
IMPORTANT: If the vehicle is equipped with a driver
controlled main differential lock, see complete
instructions beginning on page 53. To tow a vehicle
see instructions on pages 25 and 26.
1. Raise the end of vehicle where the axle is
mounted. Use a jack or other lifting tool.
Ficlure 3.
A WARNING:
Do not work under the vehicle if supported by
jacks or lifting tools only. Jacks and lifting tools
can slip and cause injury.
A WARIVING:
Wear safe eye protection. Qo not hit the round
driving lugs on the head of axle shafts. Lugs can
break and cause injury.
A. Hold a l-1/2 inch diameter brass drift against

the center of the axle shaft, inside the round
driving lugs. Figure 5.
1Fisure 5 ,
Brass Hammer
2. Put jack stands under each spring seat of the axle

to hold vehicle in the raised position. Figure 3.
3. Remove the plug from bottom of axle housing and

drain lubricant from the assembly.
4. Disconnect the driveline universal joint from the

pinion input yoke or flange on the carrier.
Figure 4.
5. Remove the capscrews* and washers or stud

nuts* and washers from the flanges of both axle
shafts.
6. Loosen the tapered dowels* in the flanges of both
axle shafts as follows.
*Some Rockwell carriers do not have the parts described.Copyrighted Material
Page 4 Intended for CLARK dealers only
E
Disassembly 12
13. Carefully remove the carrier from the axle housing

NOTE: using the hydraulic roller jack. Use a pry bar that
A l-1/2 inch diameter brass hammer can be used as has a round end to help remove the carrier from
a drift. the housing.
B Hit the end of the drift with a large hammer

(five to six pounds) and the axle shaft and
tapered dowels will loosen.
A CAUTION:
When using a pry bar be careful not to damage the
A CAUTION;
Do not use a chisel or wedge to loosen the axle
carrier or housing flange. Damage to these surfaces
will cause oil leaks.
shafts and dowels. The chisel or wedge can

damage the hub, axle shafts and, if used, oil seals. 14. Remove and discard the carrier to housing gasket.
7. Remove the tapered dowels and both axle shafts 15. Lift the differential carrier by the input yoke or
from the axle assembly. flange and put the assembly in a repair stand.
Figure 7. Use a lifting tool for this procedure. Do
8. Place a hydraulic roller jack under the differential not lift by hand. A carrier stand can be made by
carrier to support the assembly. Figure 6. using the drawing on page 6.
Figure 7 _
Wood
Block
Repair
Stand
9. Remove all but the top two carrier to housing

capscrews or stud nuts and washers.
10. Loosen the top two carrier to housing fasteners

Remove The Differential And
and leave attached to the assembly. The fasteners Ring Gear From The Carrier
will hold the carrier in the housing.
11. Loosen the differential carrier in the axle housing.

Use a leather mallet to hit the mounting flange of
carrier at several points. NOTE:
Before you start work on the differential carrier in-
spect the hypoid gear set for damage. If the in-
NOTE: spection shows no damage, the same gear set can
Some carrier models have threaded puller screw be used again. Measure the backlash of the gear
holes in the mounting flange. Puller screws can be set and make a note of the dimension. Figure 8.
used to loosen and pull the carrier from the axle (See procedure on page 46, Steps 7 to 5.) Adjust
housing. If puller screws are used, clean the the backlash to the same dimension after the gear
threaded holes before the puller screws are set is installed into the carrier.
installed.
lS.After the carrier is loosened, remove the top two

fasteners. Copyrighted Material Page 5
A carrier stand, part number J 3409-01 is available
from Kent-Moore, Heavy-Duty Division, 29784 Little
Mack, Roseville, Michigan 48066-2298.
Carrier Stand
Plates 8’ Long x 3/4 Thick x l-114 Wide Handle 7” Long with Slot
with a Tongue to fit Slot in Bar in one end to fit Clamp Screw.
Drill 3/8 Hole thru
Haridle and Screw.
Screw 3-112”
Long x 518 Dia.
with Flats on end to
fit Handle and 2-l/2
Length of Thread Bar 2” Dia. x 9” Long
on other end. with one end Slotted
Shape and Size

Plug 4” Dia. x 7” Long with of Holes to fit
one end turned 3” Long Carrier.
to fit Pipe. Drill 2” Hole
\ Weld all around after
and Mill 3/18” Wide Slot 2”
pressing plug in Pipe.
from top.
23-112”
Center to Center
of PiDe.
4” Dia.
7
Chamfer end of Pipe /
for Welding. \
E
Disassembly 12
Figure 8 Figure 10
Thr
Thrust Screw
& Jam Nut
3. Rotate the differential carrier in the repair stand

until the ring gear is at the top of the assembly.
1. Loosen the jam nut* on the thrust screw*.
4. Mark one carrier leg and bearing cap for the pur-
pose of correctly matching the parts when you
2. Remove the thrust screw* and jam nut* from the assemble the carrier. A center punch and hammer
differential carrier. Figure 9. can be used to mark the parts. Figure 11.
Figure 9 Figure 11
NOTE: 5. Remove the cotter keys*, pins* or lock plates*

Some Rockwell carrier models have a thrust block*. that hold the two bearing adjusting rings in posi-
The thrust block will fall away from the ring gear in- tion. Use a small drift and hammer to remove pins.
Each lock plate is held in position by two
side the carrier when you remove the thrust screw. capscrews. Figure 12.
Figure 10.
*Some Rockwell carriers do not have the parts described.

Page 7
z
Z‘
Q 2 Disassembly
7. Remove the bearing caps and bearing adjusting
F:igure 12 rings from the carrier. Figure 14.
Figure 14 Bearing
Bearing Cap Adjusting Ring
Removing
i Cotter Key \
6. Safely lift the main differential and ring gear

assembly from the carrier. Put the assembly on a
work bench. Figure 15.
Figure 15
6. Remove the capscrews and washers that hold the

two bearing caps on the carrier. Each cap is held
in position by two capscrews and washers.
Figure 13.
9. Remove the thrust block* from inside the carrier.
Disassemble the Differential and

Ring Gear Assembly
1. If the matching marks on the case halves of the
differential assembly are not visible, mark each
case half with a center punch and hammer. The
purpose of the marks is to match the plain half
and flange half correctly when you assemble the
carrier. Figure 16.

Page 6
:
Disassembly 12
5. If the ring gear needs to be replaced, remove the

bolts*, nuts*, and washers* that hold the gear to
the flange case half.
6. If rivets* hold the ring gear to the flange case half,

remove the rivets as follows:
A. Carefully center punch each rivet head in the

center, on the ring gear side of the assembly.
B. Drill each rivet head on the ring gear side of

the assembly to a depth equal to the thickness
of one rivet head. Use a drill bit that is l/32 of
an inch smaller than the body diameter of the
rivets. Figure 18.
Finure 18
2. Remove the lock wire* capscrews* and washers*

or bolts*, nuts* and washers that hold the case
halves together.
a WAiNlNG:
Wear safe eye protection. Do not hit steel parts
with a steel hammer. Parts can break and cause
c;orrecr Wrong
C. Press the rivets through holes in the ring gear

and flange case half. Press from the drilled
injury. rivet head.
3. Separate the case halves. If necessary, use a
brass, plastic or leather mallet to loosen the parts. A CAUTION:
Do not remove the rivets or rivet heads with a
4. Remove the differential spider (cross), four pinion
gears, two side gears and six thrust washers from chisel and hammer. The chisel can damage the
inside the case halves. Figure 17. flange case ha/f. Figure 18.
Figure 17 7. Separate the case half and ring gear using a

press. Support the assembly under the ring gear
with metal or wood blocks and press the case half
Side through the gear. Figure 19.
Gear
fi‘gure 19
Thrust Washers
\
supports /

s
._
5cn 2 Disassembly
8. If the differential bearings need to be replaced, 2. Remove the nut and washer* from the drive pi-
remove the bearing cones from the case halves. nion. Figure 21.
Use a bearing puller or press. Figure 20.
3. Remove the yoke or flange bar.
4. Remove the yoke or flange from the drive pinion. If
the yoke or flange is tight on the pinion, use a
puller for removal. Figure 22.
Yoke Puller
Flange Puller
Kzz
Remove the Drive Pinion and
Bearing Cage From Carrier
1. Fasten a yoke or flange bar to the input yoke or
flange. The bar will hold the drive pinion in posi-
tion when the nut is removed. Figure 21.
Figure 21 A CAUTION:
Do not use a hammer or mallet to loosen and
remove the yoke or flange. A hammer or mallet can
damage the parts and cause runout or alignment
problems.
5. Remove the capscrews and washers that hold the

bearing cage in the carrier. Figure 23.
IFigure 23 Bearing Cage

5
Disassembly !!2
A WARNING:
8. Remove the drive pinion, bearing cage and shims
from the carrier. If the bearing cage is tight in the
carrier, use the following procedures to loosen the
cage. Figure 25.
injury.
6. Remove the cover* and seal assembly and

gasket* from the bearing cage. If the cover* is
A WARNING:
tight on the bearing cage, use a brass drift and with a steel hammer. Parts can break and cause
hammer for removal. Figure 24. injury.
Figure 24 A. Hit the bearing cage at several points around

Bearing the flange area with a leather, plastic or rubber
Cage
Cover and \ / mallet.
B. Some bearing cages have threaded puller

screw holes* in the mounting flange. Puller
screws can be used to loosen and pull a tightly
fitted cage from the carrier. If puller screws are
used, clean the threaded holes before the
puller screws are installed. Figure 26.
Figure 26 A
Gasket /
7. If the pinion seal is damaged, remove the seal

from the cover*. Use a press and sleeve or seal
driver. If a press is not available, use a screwdriver
or small pry bar for removal. Discard the pinion
seal.
NOTE:
If the carrier does not have a cover and seal
assembly the pinion seal will be mounted in the
outer bore of the bearing cage. Remove the seal
after the drive pinion is removed from the bearing
cage. A CAUTION:
Do not use a pry bar to remove the bearing cage
from the carrier. A pry bar can damage the bearing
Figure 25 , Drive Pinion
cage, shims and carrier.
and Bearing Cage
9. If the shims are in good conidtion, keep the shims

together for use later when the carrier is
assembled.
10. If shims are to be discarded because of damage,

first measure the total thickness of the pack. Make
a note of the dimension. The dimension will be
needed to calculate the depth of the drive pinion in
the carrier when the gear set is installed.
Copyrighted *Some Rockwell

Material carriers do not have the parts described.
Intended for CLARK dealers only Page 11
s
._
z
3 2 Disassembly
Disassemble The Drive Pinion 2. Sup,port the bearing cage under the flange area
with metal or wood blocks. Figure 28.
And Bearing Cage . 3. Press the drive pinion through the bearing cage.
Figure 28.
Figure 27 - (Pinion & Bearing Cage Assembly)
NOTE:
The inner bearing cone and bearing spacer or
Drive Pinion * Ora’
spacers will remain on the pinion shaft.
ALWARNING:
injury.
4. If a press is not available, use a leather, plastic or

rubber mallet to drive the pinion through the bear-
ing cage.
5. If the pinion oil seal is mounted directly in the

outer bore of the bearing cage, remove the seal at
\ \ I II (CUP& Cone) this time. Be careful that you do not damage the
mounting surfaces of the bearing cage. Figure
29.
Snap Ring JwK Spigot Brg.
If the seal is a one piece design (without mounting
flange), discard the seal.
If the oil seal is a triple-lip design (with flange),
inspect the seal for damage. If the surfaces of the
1. Put the drive pinion and bearing cage in a press. seal and the yoke or flange are smooth and not
The pinion shaft must be toward the top of the worn or damaged, you can use the seal again
assembly. Figure 28. when you assemble the carrier.
Figure 29
ALCAUTION:
Be careful when using a screwdriver or pry bar to
V Jpigotl Bearing
remove the seal. Do not damage the wall of bore.
Damage to the bore can cause oil leaks.
Page 12
Disassembly 12
6. If the pinion bearings need to be replaced, remove 8. If the spigot bearing needs to be replaced, put the
the inner and outer bearing cups from the inside of drive pinion in a vise. Install a soft metal cover
cage. Use a press and sleeve, bearing puller or a over each vise jaw to protect the drive pinion.
small drift and hammer. The type of tool used
depends on the design of the bearing cage. 9. Remove the snap ring* from the end of drive pi-
Figure 30. nion with snap ring pliers that expand.
Figure 32.
When a press is used, support the bearing cage
under the flange area with metal or wood blocks.
IFigure 32
Figure 30 Spigot Bearing
NOTE:
Some spigot bearings are fastened to the drive pi-
nion with a special peening tool. Figure 33.
Figure 33
7. If the pinion bearings need to be replaced, remove

the inner bearing cone from the drive pinion with a Peening
press or bearing puller. The puller MUST fit under Points
the inner race of the cone to remove the cone cor-
rectly without damage. Figure 31.
IFigure 31
Drive Pinion
Inner Bearing Cone .k;
Bearing Puller
\
“Some Rockwell carriers do not have the parts described.

2 Disassembly
c
0
._
E
to
10. Remove the spigot bearing from the drive pinion NOTE:
with a bearing puller. Figure 34. Some spigot bearings are a two-piece assembly.
Remove the inner race from the pinion with a bear-
Figure 34 ing puller. Remove the outer race/roller assembly
from carrier with a drift or a press. Figure 35.
Figure 35 Remove Outer

Race &
Roller Assy.
from Carrier
Remove Inner
Race from Pinion.
Page 14
Prepare Parts 5
for Assembly 1
Clean Ground and Polished 2. Before the axle is steam cleaned, close or put a
cover over all openings in the axle assembly. Ex-
Parts: amples of openings are breathers or vents in air
chambers.
1. Use a cleaning solvent to clean ground or polished
parts or surfaces. Kerosene or diesel fuel oil can
be used for this purpose. DO NOT USE Dry Parts That Have Been
GASOLINE.
Cleaned:
1. Parts must be dried immediately after cleaning and
g, WAR/W/G; washing.
Becareful when using cleaning solvents. Follow the
solvent manufacturer’s instructions for safe use to 2. Dry the parts using soft clean paper or cloth rags.
prevent injury.
3. Except for bearings, parts can be dried with com-
2. Use a tool with a flat blade if required to remove pressed air.
gasket material from parts. Be careful not to
damage the ground surfaces.
CAUTION:
3. DO NOT clean ground or polished parts in a hot Damage to bearings can be caused if dried by
solution tank, water, steam or alkaline solutions. rotating with compressed air.
Prevent Corrosion and Rust on

Clean Rough Parts:
Cleaned Parts:
1. Clean rough parts the same as cleaning ground
and polished parts. 1. Apply axle lubricant to cleaned and dried parts that
are not damaged and are to be assembled.
2. Rough parts can be cleaned in hot solution tanks
with a weak alkaline solution. 2. To store parts, apply a special material that
prevents corrosion and rust to all surfaces. Wrap
3. Parts must remain in hot solution tanks until com- them in a special paper that prevents corrosion
pletely cleaned and heated. and rust.
A WARNING:
Be careful when using,hot solution tanks and
Inspect Parts:
It is very important to inspect all parts carefully and
alkaline solutions. Follow the alkaline manufac- completely before the axle or carrier is assembled.
turer’s instructions for safe use to prevent injury. Check all parts for wear and replace damaged parts.
Replacement of damaged or worn parts now, will pre-
4. Parts must be washed with water until the alkaline vent failure of the assembly later.
solution is removed.
1. Inspect Tapered Roller Bearings:
Clean Axle Assemblies: Inspect the cup, cone, rollers and cage of all
tapered roller bearings in the assembly. If any of
1. A complete axle assembly can be steam cleaned the following conditions exist, the bearing MUST
on the outside to remove dirt. be replaced.

J
‘ Prepare Parts
g
Q 3 for Assembly
A. The center of large diameter end of rollers worn E. Bright wear marks on the outer surface of the
level with or below the outer surface. Figure 36. roller cage. Figure 38.
i‘gure 36
Worn Radius
F. Damage on rollers and on surfaces of the cup

Worn Surface and cone inner race that touch the rollers.
Figure 39.
B. The radius at large diameter end of rollers worn Figure 39 / Etching & Pitting
to a sharp edge. Figure 36.
C. A visible roller groove in the cup or cone inner
race surfaces. The groove can be seen at the
small or large diameter end of both parts.
Figure 37.
G. Damage on the cup and cone inner race sur-

faces that touch the rollers. Figure 40.
Spalling & Flaking
D. Deep cracks or breaks in the cup, cone inner

race or roller surfaces. Figure 37.

Prepare Parts s
for Assembly ! 3
2. Inspect Hyproid Drive Pinion and Ring Gear Sets: A. Inside surfaces of both case halves.
A. Inspect hypoid pinions and gears for wear or B. Both surfaces of all thrust washers.
damage. Gears that are worn or damaged
MUST be replaced. C. The four trunnion ends of the spider (cross).
A CAUTION:
Hypoid drive pinions and ring gears are machined
D.Teeth and splines of both differential side gears.
E. Teeth and bore of all differential pinions.

in matched sets. When a drive pinion or ring gear
of a hypoid set needs to be replaced, both drive &L CAUTION:
gear and pinion must be replaced at the same Always replace thrust washers, differential side
time. gears and pinion gears in sets. A higher stress on
parts and early failure of the assembly will occur if
3. Inspect the Main Differential Assembly: a new part is used with parts that are old or worn.
Inspect the following parts for wear or stress. Parts
that are damaged MUST be replaced. Figure 41. 4. Inspect Axle Shafts:
A. Inspect axle shafts for wear and cracks at the

Figure 41 flange, shaft and splines. Replace axle shaft if
required.
Repair or Replace Parts

General:
Replace worn or damged parts of an axle assembly.
The following are some examples to check for, repair
or replace.
1. Replace any fastener if corners of the head are

worn.
DIFFERENTIAL CASE HALVES 2. Replace washers if damaged.

Side Gear 3. Replace gaskets, oil seals or grease seals at the
and Thrust time of axle or carrier repair.
Thrust Washer 4. Clean parts and apply new silicone gasket material
where required when axle or carrier is assembled.
Figure 42.
Figure 42 Remove
DIFFERENTIAL GEAR NEST ASSEMBLY

J
‘ Prepare Parts
:
0
ii4 3 for Assembly
5. Remove nicks, mars and burrs from parts having

machined or ground surfaces. Use a fine file, india
CAUTION:
stone, emery cloth or crocus cloth for this purpose. Welding can be used when the crack or damaged
area is within the old weld material. Replace the
6. Clean and repair threads of fasteners and holes. axle housing if the crack extends into the metal
Use a die or tap of the correct size or a fine file next to the old weld. A housing that has damage in
for this purpose. the seam weld or cover weld because of overload
conditions can be repaired. A repaired housing
must be used in correct applications.
CAUTION:
Threads must be without damage and clean so that
accurate adjustments and correct torque values A WARNING:
can be applied to fasteners and parts.
Using wrong welding procedures or welding at
7. Tiahten all fasteners to the correct torque values. locations other than the three areas permitted by
Sge the chart on page 65 for torque values of Rockwell will make the heat-treated component
fasteners. Figure 43. weak. A weak component will cause poor or unsafe
operation of the axle and early failure. The foiiow-
v
ing procedure must be used.
i‘gure 43 \ \ 2. Welding Procedure
A. Drain the lubricant from the axle assembly.
B. Remove the axle shafts and differential carrier
from the axle housing.
\ Always use
Torque Wrenches
Becareful when using a cleaning solvent. Follow
the solvent manufacturer’s instructions for safe use
to prevent injury.
6. DO NOT repair rear axle housings by bending or C. Clean the damaged area inside and outside the
straightening. housing. Cleaning solvent can be used.
D. Grind the damaged weld to the base metal.
A WARNING:
Repair of axle housings by bending or straighten-
E. Warm the complete axle housing to a
temperature of 70° F - 80° F (21° C - 27O C) or
ing will cause poor or unsafe operation of the axle higher.
and ear/y failure.
F. Before you start welding, heat the damaged
area to be repaired to approximately 300° F
(1490 C).
Repair Axle By Welding: G. Use a 70,000 psi tensile weld material and the
correct voltage and amperage for the diameter
1. Rockwell International will permit repairing drive weld rod used. Examples of weld rods that can
axle housing assemblies by welding ONLY in the be used are E-7018 or ER-70S-3.
following areas:
A. Cover welds. A CAUTION:

if the f-7078 weld rod is used, the rod must be
B. Snorkel welds. kept dry. Electrodes that are not stored in the cor-
rect sealed containers ‘must be heated at 700° F
C. Housing seam welds between the suspension
(371O C) for one hour before welding. Wet eiec-
attaching brackets.
trodes must be dried at 780° f (82O C) for one to
two hours and then heated at 700° F (377OC) for
one hour before welding.
Page 18
Prepare Parts 5
for Assembly f 3
H. Fill in the Weld Gap as Follows:

Bending or Straightening
Drive Axle Housings:
A CAUTION;
Do not connect the ground cable at any point on
Rockwell International is emphatically opposed to
any attempt to correct or modify drive axle housings
the axle assembly that will put a bearing between by bending or straightening. All damaged drive axle
the ground cable and weld area. If a bearing is be- housings should be replaced.
tween the ground cable and weld, the bearing will
be damaged because of electricity arcing. A good Also, Rockwell will allow repair welding only in the
location to connect the ground cable is the spring following areas: cover welds, snorkel welds, and
mounting pad of the housing. housing seam welds between the suspension attach-
ing brackets. Repair welding should be performed
only if the crack/porosity is located within the weld
1. The snorkle weld MUST be a .375 inch (9.5 mm)
material.
fillet.
Replace any housing assemblies where cracks have
2. The opening in cover welds MUST be filled level worked into the parent metal. Also, any housings
with the old weld. that have seam weld or cover weld cracks, due to
known overloading of the axle, should not be repair
3. The opening in seam welds MUST be ground out welded.
A
to 70% of the wall thickness. The wall thickness
can be measured at the carrier opening of
housing. CA UT/O/V:
Bending, straightening, improper repair welding pro-
4. Clean the new weld area. Carefully remove all the cedures or repair welding at locations other than
rough weld material. those indicated above, may result in premature hous-
ing failure and affect the safe operation of the axle
5. Install the differential carrier and axle shafts. assembly.
6. Fill the axle assembly with the correct amount of For further information regarding Repair Welding,
lubricant. See page 62 or Rockwell Field refer to page 18.
Maintenance Manual No. 1 for information on
lubricants.
/VOTE:
To weld brackets or other components to the axle
housing, use the procedure in Rockwell Technical
Service Aid, TSA-2-95.

eneral
Procedures
Clean the oil and dirt from threaded holes. There
Use of Dri-Lot Fasteners and l- is no special cleaning required and it is not
Rockwell Liquid Adhesive necessary to remove the old Dri-Lot adhesive from
threads.
2297-C-3747 or Loctite 277
2. Apply four or five drops of Rockwell Liquid
Install New Dri-Lot Fasteners. Adhesive or Loctite 277 to threaded holes ONLY.
Make sure the adhesive is on the threads. Figure
1. Clean the oil and dirt from threaded holes. There 44.
is no special cleaning required.
1
2. Assemble parts using the new Dri-Lot fasteners.
A CAUTION:
A CAUTION:
Do not apply adhesives or sealants on new Dri-Lot
Do not apply adhesive to the fastener threads. Air
pressure in the hole will push the adhesive out as
the fastener is installed.
fasteners or in the threaded holes. If other
adhesives or sealants are used, the new Dri-lot 3. Tighten the fasteners to the required torque value
adhesive will not function correctly. for that size fastener. There is no special pro-
cedure or toraue value required. See the torque
3. Tighten the Di-Lot fasteners to the required chart on page 65. Figure 45.
torque valve for that size fastener. There is no 63
soecial Drocedure or toraue value reauired. See Figure 45
the torque chart on page.65.
43
NOTE:
There is no drying time required for Dri-ioc
fasteners.
Install Old Dri-Lot Fasteners using

Rockwell Liquid Adhesive 2297-C-3747 or \ Always use
Torque Wrenches
Loctite 277.
Figure 44 NOTE:
There is no drying time required for Rockwell Li-
quid Adhesive 2297-C-3747 or Loctite 277.
Check Torque Values of Dri-Lot Fasteners

not requiring removal.
4 to 5 Drops
on Threads CAUTION:
If Dri-Lot fasteners do not require removal from
components, check the fasteners for correct torque
value as follows:
Page 20
General .g~3
Procedures ii13
1. Apply the MINIMUM amount of torque required for Figure 46 Adhesive Bearing
that size fastener. See the torque chart on page
H Cap
65. The fastener MUST NOT rotate. Figure 45.
2. If the fastener rotates any amount, remove the r
1 II Carrier
+k=t
fastener from the component and apply adhesive
to the threaded hole. Follow the procedure for in- Leg
stalling old Dri-Lot fasteners.
-/I\
Remove Dri-Lot Fasteners.

If it is difficult to remove Dri-Lot fasteners from com-
ponents, the strength of Dri-Lot, Rockwell adhesive or
Loctite 277 can be decreased by heating. Use the
following procedure:
I I\
1. Heat the fastener for three to five seconds ONLY
NOTE:
The Rockwell adhesives will become hard (dry) in
and try to loosen the fastener with a wrench. DO
approximately two hours. The following two steps
NOT use an impact wrench to loosen the fastener
of the procedure must be done in two hours from
or hit the fastener with a hammer.
the time the adhesive was applied. If two hours
2. Repeat step 1 until the fastener can be removed. have passed since application, clean the parts
A
again and apply new adhesive.
CAUTION:
Donot exceed 350° F (+777O C) maximum. Heating
must be done slowly to prevent thermal stresses in 4. Install the main differential assembly, bearing cups
the other components. and bearing caps into the carrier. Use the normal
procedure, see page 42.
Application of Rockwell
Adhesive 2297-T-4180 or 5. Adjust preload of the differential bearings,
1199-Z-3250 in Bearing Bores backlash and tooth contact patterns of the gear set
as required using the normal procedures. See
for the Differential pages 43-51.
l Use adhesive 1199-z-3250 for SQ series axles.
l Use adhesive 2297-T-4180 for all other axles.
1. Clean the oil and dirt from outer diameters of bear- Application of Silicone Gasket
ing cups and bearing bores in the carrier and Material
bearing caps. There is no special cleaning
required.
2. Apply axle lubricant to the bearing cones and the NOTE:
inner diameters of the bearing cups of the main The following silicone gasket products can be used
differential. DO NOT get oil on the outer diameter on Rockwell components.
of the bearing cup and DO NOT permit oil to drip
on the bearing bores.
a. Dow Corning Silicone Rubber Sealant, No. 732
3. Apply a single continuous bead of the adhesive to Black.
the bearing bores in the carrier and bearing caps.
Apply the adhesive 360° around the smooth, b. General Electric No. RTV-1473 Black.
ground surfaces ONLY. DO NOT put adhesive on
threaded areas. Figure 46.
._ General
5
5 A
% 4 Procedures
c. From Rockwell International:

l/8 Inch Bead
. 40 pound containers, Part No. 1199-Q-2981
. Ten ounce tubes, Part No. 1250-X-388
. Three ounce tubes, Part No. 1199-T-3842
A WARNING:
Small amounts of acid vapor are present when ap
plying silicone gasket material. For this reason, be
sure there is good ventilation in the work area. If
the silicone gasket material gets in the eyes, flush
the eyes with water for 75 minutes. Have the eyes A CAUT/ON:
The amount of silicone gasket material applied
checked by a doctor.
must not exceed a 7/8 inch diameter bead. Too
much gasket material can block lubrication
passages.
1. Remove all old gasket material from both surfaces.
Figure 47. 5. Assemble the components immediately to permit
the silicone gasket material to compress evenly
between the parts. Tighten fasteners to the re-
quired torque value for that size fastener. There is
no special procedure or torque value required. See
Torque Chart on page 65.
Gasket Material
0
6. Wait 20 minutes before the assembly is filled with
lubricant.
NOTE:
The Rockwell adhesive and gasket products are
available from:
Rockwell /M&national Corp.
Florence Distribution Center
7975 Dixie Highway
Florence, Kentucky 47042
Installing Tight Fit Yokes using

the Three Piece Pilot Tool
Housing and Carrier Shown
2. Clean the surfaces where silicone gasket material NOTE:

will be applied. Remove all oil, grease, dirt and A three piece installation tool is required to
moisture. correctly install yokes with interference fit splines.
The yoke installation tools are not available from
3. Dry both surfaces. Rockwell International but can be purchased from
OTC Tool and Equipment Division, 655 Eisenhower
4. Apply a l/8 inch diameter continuous bead of the Drive, Owatonna, MN 55060. Specify the Rockwell
silicone gasket material around one surface. Also axle model when ordering. See the following list.
apply the gasket material around the edge of all
fastener holes in that surface. Figure 48.
Page 22
General 5 d
Procedures ii0
Axle Series Position OTC Tool Number Axle Series Position OTC Tool Number
H-172 D80T-4859-A RT-52-160* Forward Input D89T-4859-A

Forward Output D89T-4859-B
L-l 72 D80T-4859-A
Rear Input D89T-4859-A
P-l 74 D8OT-4859-A
RT-52-180* * Forward Input D80T-4859-B
R-l 55 D80T-4859-A Forward Output D80T-4859-A
R-255 D80T-4859-A Rear Input D89T-4859-A
R-l 70 D80T-4859-B RT-58-180* * Forward Input D80T-4859-B

Forward Output D80T-4859-A
R-270 D80T-4859-A Rear Input D89T-4859-A
s-1 70 D80T-4859- B SL-100 Forward Input D80T-4859-A
U-l 70 D80T-4859-B Forward Output D80T-4859-B
Rear Input D80T-4859-B
U-240 D80T-4859-A
SQ-100 Forward Input D80T-4859-A
U-270 D80T-4859-A Forward Output D80T-4859-A
U-280 D80T-4859-A Rear Input D80T-4859-A
W-280 D80T-4859-A SQR-100 Forward Input D80T-4859-A

RS-13-120* D89T-4859-B Rear Input D80T-4859-A
RS-15.120* D89T-4859-B SSHD D80T-4859-B
Forward Input
RS-15-210* D89T-4859-B Forward Output D80T-4859-A
Rear Input D80T-4859-A
RS-17-140* D89T-4859-B
STHD Forward Input D80T-4859-B
RS-17-220 * D89T-4859-B
RS-19-145* D89T-4859-B Rear Input D80T-4859-A
RS-20-230* D89T-4859-B SR-170 Forward Input D80T-4859-B
RS-21-145* D89T-4859-B
Rear Input D80T-4859-B
RS-23-160* D89T-4859-A
ST-1 70 Forward Input D80T-4859-B
RS-23-180* D89T-4859-A Forward Output D80T-4859-A
RS-23-240* D89T-4859-B Rear Input D80T-4859-B
RS-26-180* D89T-4859-A su-170 Forward Input D80T-4859-B

RS-30.180* D89T-4859-A Rear Input D80T-4859-B
RT-34- 145 * Forward Input D89T-4859-B SR-2701280 Forward Input D80T-4859-B
Forward Output D89T-4859-B Forward Output D80T-4859-A
Rear Input D89T-4859-B Rear Input D80T-4859-A
RT-40-145 * Forward Input D89T-4859-B ST-2701280 Forward Input D80T-4859-B
RT-44-145* Forward Input D89T-4859-B SU-2701280 Forward Input D80T-4859-B
RT-46.160* Forward Input D89T-4859-A SW-280 Forward Input D80T-4859-B
Rear Input D89T-4859-A Rear Input D80T-4859-A
RT-48-180 * l Forward Input D80T-4859- B SFDD-4640 Forward Input D80T-4859-B
Forward Output D80T-4859-A Forward Output D80T-4859-A
Rear Input D89T-4859-A Rear Input D80T-4859-A
*Axle models have metric size threads on drive pinions, Material

Copyrighted input shafts and output shafts.
**Metric threads only on drive pinions of Intended
rear/rearforaxles.
CLARK dealers only Page 23
‘s A General
Z
ifi L3
Procedures
A CAUTION: .
Do not install tight fit yokes on shafts using a ham-
A CAUTION:
Do not use the assembly yoke nut for installation
mer or mallet. A hammer or ma//et will damage the purposes. Use the nut that is supplied with the
yoke. three piece pilot too/.
1. Apply axle lubricant on the yoke seal. 7. Remove all parts of the pilot tool from the shaft.
(Pilot shaft, collar and nut).
2. Check all surfaces of the yoke hub for damage. If
necessary, polish the yoke hub with an india 8. Install the washer (if required) and yoke nut on the
stone, emery cloth or crocus cloth. shaft. Tighten the nut to the required torque value.
See the torque chart on page 65.
3. Install the pilot shaft on the input shaft of the @
assembly. Figure 49.
Figure 49
Gear Set Information (Drive
Pinion and Ring Gear Marks)
Lubricate Seal
NOTE:
Before a new gear set is installed in the carrier,
Check Yoke Hub read the following information. Always check the
gear set for correct marks to make sure the gears
are a matched set.
The location of the marks are shown in Figure 50.
Fiqure 50 Alternate Locations
3,4
’ Nut
/
, 1,2,3
4. Slide the yoke over the pilot shaft. Align the yoke
splines with the shaft splines.
1234m
, , 3
5. Put the collar on the pilot shaft and slide it against
the yoke.
1. Part Number
6. Install the nut on the pilot shaft and against the A. Examples of gear set part numbers: Conven-
collar. Tighten the nut against collar until the yoke tional ring gear, 36786. Conventional drive pin-
is completely in position on the shaft. Sometimes a ion, 36787. Generoid ring gear, 36786 K or
torque value of 200 lb.-ft. on the nut is required 36786 K2. Generoid drive pinion, 36787 K or
to install the yoke correctly. 36787 K2.
Page 24
General 5 d
Procedures i a
NOTE: NOTE:
The last digit in part numbers for Generoid gears is a The pinion cone variation number is not used when
letter or letter and number. checking for a matched gear set. The number is
used when you adjust the depth of the pinion in
the carrier. See the procedure for adjusting the
B. Location on Drive Pinion: End at threads. shim pack thickness under the pinion cage on
pages 3537.
C. Location on Ring Gear: Front face or outer
diameter. A. Examples of pinion cone variation numbers:
PC+3, PC-5, +2, -1, + .Olmm or -.02mm.
Figure 51.
2. Tooth Combination Number
A. Example of a tooth combination number: 5-37.

I Figure 51
NOTE:
A 5-37 gear set has a 5 tooth drive pinion and a 37
tooth ring gear.
B. Location on Drive Pinion: End at threads.

Pinion
diameter.
Cone
Variation
Number
3. Gear Set Match Number
Rockwell drive pinions and ring gears are available

only as matched sets. Both gears of a set have a B. Location on Gear Set: End of pinion gear head
match number. or outer diameter of ring gear.
A. Example of a gear set match number: M29.

Vehicle Towing Instructions :
NOTE: When towing or “piggybacking” a vehicle with the

A gear set match number has any combination of a wheels of one or both drive axles on the ground, it is
number or letter and number. possible to damage the axles or cause additional
damage if the wrong procedure is used before tow-
ing begins. Rockwell recommends that you use the
B. Location on Drive Pinion: End of gear head.
following procedure.

diameter.
4. Pinion Cone Variation Number

P General
sd
Q 0 Procedures
Before Towing: 4. Install a cover over the openings of both hubs to

retain the lubricant and keep dirt from entering
1. If the drive axle(s) are equipped with a main differ- the hub.
ential lock, shift the differential to the unlocked
(disengaged) position. The differential lock light in Before Operating the Vehicle:
the cab of the vehicle will go out.
1. Remove the covers from the hubs.
NOTE: 2. If the drive axle(s) are equipped with a main dif-
If the air supply to the differential lock is damaged,
the differential will unlock (disengage) when air ferential lock, shift the differential to the unlocked
(disengaged) position. Install the axle shafts with
pressure is lost.
two sets of splines and new gaskets in the cor-
2. Identify each axle shaft so that they can be rect locations as follows:
installed in the same location after repair is
A. Push the axle shaft and gasket into the hub
completed.
and housing until the shaft stops against the
3. Remove both axle shafts of drive axles that will shift collar.
remain on the ground while the vehicle is being
towed. Follow the procedures described in the B. Push down and in on the axle shaft flange and
rotate the shaft until the splines of the shaft
Disassembly section of this manual.
and collar are engaged.
NOTE: C. Push the axle shaft further into the housing
If the axle(s) are equipped with main differential lock, until the shaft stops against the differential
the left-hand front ax/e shaft and right-hand rear axle side gear.
shaft of tandem axles and the right-hand axle shaft
of single axles have two sets of splines. One set of D. Push down on the axle shaft flange and rotate
splines is engaged with the side gear and one set is the shaft until the splines of the shaft and side
engaged with the shift collar. It may be necessary to gear are engaged.
rotate the shaft when pulling it through the shift E. Push the axle shaft completely into the hous-
collar. Figure 51A (single or rear of tandem axle ing until the flange and gasket are flush
shown). against the hub.
Figure 51A RIGHTHANDSIDEOF 3. Install the other axle shafts at the locations from
DIFFERENTIAL CARRIER where they were removed. Follow the procedures
described in the Assembly section of this manual.
Shift Collar
in Locked 4. Check the lubricant level in the axles and hubs
Position where the axle shafts were removed. Add lubri-
cant if necessary. See the Lubrication section of
Actuator Assembly this manual for information.
and Shift Fork
Outer S&es-
Axle Shaft to
L Shift Collar
in Unlocked
Position
Shift Collar
Assembly 1
5
5
For information about the peen tool write to Rockwell C. Put the punch of the peen tool over the end of the
International, Communications Department, 2135 West pinion and spigot bearing. Apply the required
Maple Road, Troy, Michigan 48084. Figure 57. amount of force on the punch. Figure 58.
Figure 57
A CAUTION:
Punch - Do not align new points with grooves in end of
drive pinion or in old points. If the new peen points
are put in the wrong areas, the spigot bearing will
not be held correctly on the pinion.
D. Rotate the punch as many times as required for a

-Tube
minimum of five points. Repeat step C for each
point.
NOTE:
A. Put the drive pinion and the tube of the peen tool in If a three ball peen tool is used, rotate the tool
a press, spigot bearing toward the top. Figure 58. 180” (degrees).
B. Calculate the amount of force that will be required Installing and Staking the Two-Piece Spigot
on the peen tool. See specification and example Bearing on the Drive Pinion
calculation.
Figure 58 NOTE:
u- Press This procedure applies to some 160 Series single
rear axles and rear rear tandem axles. These axles
may also use a one-piece spigot bearing with a
tnstall and center the snap ring retainer.
Punch on the end
of Pinion The inner race of two-piece spigot bearings must
be staked in place on RS and RR-160 series rear
axles. Before you stake the pinion, you must heat
the pinion stem to soften it.
Spigot Bearing
NOTE:
Kent-More Kit J-39039 includes the staking tool,
temperature indicating liquid, heating shield and
plastigage needed for this job.
Put the Shaft

of Pinion into
Tube.

A. Apply two stripes of temperature indicating liquid on
the pinion stem from the top to the bottom.
A CAUTION:
Do not heat the pinion stem without the heat shield
Figure 59. Apply a green stripe to indicate 400°F in place. Also, do not overheat the pinion stem or
and a blue stripe to indicate 500°F. you will weaken the metal which can cause early
failure. Correct heating will take approximately
25-35 seconds, depending on how hot the torch is.
C. Light and adjust the torch until the white part of the
flame is approximately l/4 inch long. Keep the white
part of the flame approximately i/8 inch from the top
of the stem. Figure 61. Move the flame around the
outer diameter of the top of the pinion stem. The
green temperature indicating liquid will turn black
before the blue liquid does. Heat the stem until the
blue liquid turns black at a point in the middle of the
window.
Figure 61
B. Put the heating shield over the pinion stem so that

you can see the temperature indicating liquid White Part
through the hole in the shield. Figure 60.
Figure 60
I
/ Pinion \ Heating Shield
D. Remove the flame and the heat shield from the

pinion. Let the pinion air cool for 10 minutes. Use a
razor blade to remove the temperature indicating
liquid.
A CAUTION:
Do not press or hit directly on the new inner race in
step E or you will damage the bearing.
A WARNING:
To protect yourself from injury wear safety glasses
E. Use a press, if available, or a brass hammer to
install the new inner race. Use the old inner race as
a sleeve. The race is completely seated when you
when you do steps C-F: Wear heat resistant gloves cannot fit a 0.002 inch feeler gauge between the
while you do steps C and D. race and the pinion shoulder.
Assembly i 3
NOTE: Figure 63
If you cannot hold the races in place, try using the
staking tool instead of the old race to start the new 0 uter Bearing Bearing
race on the stem. But, use the old race to completely Cone Spacer
seat the new race.
NOTE:
In Step 6 you do not need to use the plastigage for
every stake. Just use it until you are sure you are
hitting the punch with the correct force.
F. Put the staking tool over the bearing race. Cut a Bearing
one inch piece from the green plastigage strip and Cage
put in between the punch and the staking tool.
Figure 62 - View A. Hit the punch with a two-
three pound brass hammer to upset the end of the
pinion stem. Then, remove the strip and measure its
thickness against the gauge on the wrapper that the
strip came in. The strip must not be less than 0.003
inch thick. This thickness indicates that you are
using enough force when you hit the punch. If the
strip is too thin, then you must hit the punch harder
so the stake will hold the race in place. Rotate the
tool and repeat this procedure until there are six
evenly spaced stake marks around the stem. NOTE:
Figure 62 - View B. The spacer or spacers control the preload
adjustment of the drive pinion bearings.
9. Install the outer bearing cone on pinion shaft against

the spacer. Figure 63.
NOTE:
DO NOT install pinion seal in bearing cage.
Continue with adjusting preload of pinion bearings.
Adjust Preload of Pinion Bearings

Specifications:
New pinion bearings - 5 to 45 lb.-in. (.56 to 5.08 N.m)
G. With a press or a soft mallet and sleeve, install the
torque.
outer race and roller assembly into its bore in the
Used pinion bearings in good condition - 10 to 30 lb.-
carrier. Use a sleeve that is the same size as the
in. (1.13 to 3.39 N.m) torque.
outer race and press the bearing until it is squarely
against the shoulder in the bottom of its bore.
Press Method
6. Apply axle lubricant on bearing cups in the cage and NOTE:
bearing cones. If a press is not available, or the press does not
have a pressure gauge, use, the yoke or flange
7. Install the drive pinion into the bearing cage.
method to adjust preload. See page 33.
8. Install the bearing spacer or spacers on pinion shaft A. Put the drive pinion and cage assembly in a
against the inner bearing cone. Figure 63. press, gear head (teeth) toward the bottom.

s
3‘
0 5 Assembly
Figure 64 Figure 65
Sleeve
---
Measure Diameter
of Cage
6. Install a sleeve of the correct size against the I. Use the following procedure to calculate the
inner race of the outer bearing. Figure 64. bearing preload (torque).
C. Apply and hold the correct amount pressure to Pounds pulled x Radius (inches) =
the pinion bearings. See chart 1. As pressure is lb.-in. preload x .113 = N.m preload OR
applied rotate the bearing cage several times so Kilograms pulledx Radius (centimeters)
=
that bearings make normal contact. kg-cm preload x .098 = N.m preload
D. While pressure is held against the assembly, Examples:
wind a cord around the bearing cage several Reading from spring scale = 7.5 pounds (3.4 kg)
times. Diameter of bearing cage = 6.62 inches (16.8 cm)
E. Attach a spring scale to the end of the cord. Radius of bearing cage = 3.31 inches (8.4 cm)
7.5 lb. x 3.31 in. = 24.8 in.-lb. preload x .113
F. Pull the cord with scale on a horizontal line. As
the bearing cage rotates, read the value in- = 2.8 N.m preload OR
dicated on scale. Make a note of reading. 3.4 kg x 8.4 cm = 28.6 kg-cm preload x .098
Figure 64. = 2.8 N.m preload
J. Ifthe preload (torque)of pinionbearingsis not
NOTE: withinspecifications,
do the followingprocedure
Do not read starting torque. Read only the torque then repeatsteps A to I.
value after the cage starts to rotate. Starting torque
will give a false reading. To increasepreload,install
a thinnerbearing
a thicker
spacer.To decrease preload,install
G. Measure the diameter of bearing cage where bearing spacer.
the cord was wound. Measure in inches or K. Check the bearing preload with the drive pinion
centimeters. Figure 65. and cage assembly installed in the carrier.
H. Divide the dimension in half to get the radius. Follow the procedures to adjust preload of pin-
Make a note of radius dimension. ion bearings, yoke or flange method.
CHART 1
Press Pressure Needed on Torque Value Needed on Pinion Nut
Thread Size of Bearings for Correct Preload. for Correct Bearing Preload.
Pinion Shaft pounds/tons (kg/metric tons) lb.-ft. (N.m)
7/8"-20 22,000Ill (9979110) 200-275 (271-373)
l "-20 30,000I 15 (13608I 13.6) 300-400 (407-542)
1 l/4"-12 L 54,000I27 (24494124.5) 700-900 (949-1220)
1 l/4"-18 54,000I27 (24494124.5) 700-900 (949-1220)
1 l/2"-12 54,000I27 (24494124.5) 800-1100 (1085-1491)
1 l/2"-18 54,000I27 (24494124.5) 800-1100 (1085-1491)
1 3/4"-12 50,000I25 (22680I22.7) 900-1200 (1220-1627)
2"-12 50,000I25 (22680122.7) 1200-1500 (1627-2034)
Assembly 13
Yoke or Flange Method C. Install the bearing cage to carrier capscrews.

Washers are not required at this time. Tighten
A. Install the input yoke or flange, nut and washer* the capscrews hand tight.
on the drive pinion. The yoke or flange MUST
be against the outer bearing. D. Fasten a yoke or flange bar to the input yoke or
flange. The bar will hold the drive pinion in posi-
NOTE: tion when the nut is tightened. Figure 68.
If the fit between the yoke or flange splines and
drive pinion splines are tight, use a press to install Figure 68
the yoke or flange. Figure 66.
If a press is not available, use the three piece pilot

tool for installation. See the procedure on page 22.
Figure 66 I I
7+-f- Press
Input
Flange
Shown
E. Tighten the nut on drive pinion to the correct

torque value. Figure 68.
See chart 1 on page 32. @
F. Remove the yoke or flange bar.

G.Attach a torque wrench on the drive pinion nut.
Rotate the drive pinion and read the value in-
dicated on torque wrench. Figure 69.
ALCAUTION:
Do not install tight fit yokes or flanges on shafts
using a hammer or ma//et. A hammer or mallet will
damage the yoke or flange.
B. Temporarily install the drive pinion and cage ue

assembly in the carrier. Do not install shims
under the bearing cage. Figure 67.
Figure 67
Page 33
5
L‘
isi
u) 5 Assembly
H. If the preload (torque) of pinion bearings is not
within specifications, remove the pinion and
cage assembly from carrier. Do the following
procedure then repeat steps A to G.
To increase preload, install a thinner bearing

spacer. Cover
To decrease preload, install a thicker bearing

spacer.
lO.After adjusting preload of pinion bearings, remove

the drive pinion and bearing cage from carrier.
Follow steps 1 to 5 on page 10. 12.If the pinion seal mounts directly into. the bearing
cage, install a new triple-lip seal as follows.
11. If the carrier has a cover and seal assembly over
the bearing cage, install a new seal into cover as A. The old triple-lip seal can be installed into the
follows. bearing cage if the seal is not worn or
damaged. See page 12.
A. Apply Lubriplate or grease used for wheel bear-
ings to the seal lips and cavities between lips. Figure 72
The Rockwell specification for grease is 0-617-A,
9pply Lubricant
O-61 7-B or equivalent. :o Seal Bore
B. Apply a sealing compound on the outer
diameter of seal.
C. Put the cover in a press, large diameter toward I

the top. Triple-Lip Seal
D. Support the cover under the small diameter

opening with metal or wood blocks. Figure 70.
Figure 70
I Press
I Pinion
lziizk
B. Apply the same lubricant used in the axle
housing to the outer surface of the seal and
the seal bore in the bearing cage. Figure 72.
E. Press the seal into cover until seal is flat

AL CA UT/ON:
Make sure that the seal lips are clean and free
against the bottom of bore. Use a sleeve or seal
from dirt and particles that will cause a leak
driver of the correct size that fits against the
metal retainer of seal. Figure 70. between the yoke and the seal.
C. On reused seals, apply Lubriplate or wheel
NOTE: bearing grease to the seal lips.
If a press is not available, use a ma//et and the D. Put the drive pinion and cage assembly in a
sleeve or driver to install the seal. Figure 71. press, seal bore toward the top.
A WARNING:
Wear safe eye protection. Do not hit steel parts or
E. Press the seal into bearing cage until flange of
seal is flat against the top of bearing cage. Use
a sleeve or seal driver of the correct size that
tools with a steel hammer. Parts or tools can break fits against the metal flange of seal. The
and cause injury. diameter of the sleeve or driver MUST be larger
than the diameter of the flange. Figure 73.
Page 34
Assembly g
s
5
Figure 73 F. After the triple-lip seal is installed, a gap of ap-
Press proximately .015 to .030 inch (.38 to .76 mm)
between the flange and bearing cage is normal.
Figure 75.
Sleeve Figure 75
.015-.030”
supports f (.38 - .76 mm)\
-;F-
+
Sleeve
Seal
(Shown without Bearings
and Pinion)
Check the gap with a feeler gauge at several

points around the seal. The gap must be within
.015 to .030 inch (.38 to .76 mm). The dif-
Drive ference between the largest and smallest gap
Pinion measurement MUST NOT exceed .OlO inch.
Adjust Thickness of Shim Pack for the Pin=
ion Cage (Depth of Pinion)
NOTE:
NOTE: Use this procedure if a new drive pinion and ring
If a press is not available, use a mallet and the gear set is installed, or if the depth of the drive pin-
sleeve or driver to install the seal. Figure74. ion has to be adjusted. Figure 76.
Figure 74 Figure 76
Bearing
Seal Shim Pack Cage
Driver Controls Depth
of Pinion
I
Carrier
ALWARNING:
Wear safe eye protection. Do not hit steel parts or
tools with a steel hammer. Parts or tools can break
and cause injury.
1. Measure the thickness of the old shim pack that 4. If the old pinion cone number is a minus (-), add
was removed from under the pinion cage with a the number to the old shim pack thickness that
micrometer. Record the measurement for later use. was measured in step 2.
Figure 77.
NOTE:
Figure The value calculated in step 3 or 4 is the thickness
of the standard shim pack, without a variation.
5. Look at the pinion cone (“PC”) variation number

on the new drive pinion that will be installed.
Record the number for later use.
6. If the new pinion cone number is a plus (+), add
the number to the standard shim pack thickness
that was calculated in step 3 or 4.
7. If the new pinion cone number is a minus (-), sub-
tract the number from the standard shim pack
thickness that was calculated in step 3 or 4.
2. Look at the pinion cone (“PC”) variation number NOTE:

on the old drive pinion that is being replaced. See The value calculated in step 6 or 7 is the thickness
Gear Set Information, step 4 on page 25 for ex- of the new shim pack that will be installed. See the
amples and location of the number. Record the following examples, Chart 2.
number for later use. If (“PC”) variation number
cannot be located, assemble gear set with shim Chart 2
pack thickness found in step 1. Figure78.
Examples: inches mm
Figure 78 1. Old Shim Pack Thickness .030 .76

Old PC Number, PC+2( +.05 mm)- .002 - .05
Pinion
Standard Shim Pack Thickness .028 .71
Cone
New PC Number, PC+5(+.13 mm)+ .005 + .13
Variation
Number
New Shim Pack Thickness .033 .84
2. Old Shim Pack Thickness .030 .76

Old PC Number, PC-2 (-.05 mm) + .002 + .05

New PC Number, PC+5(+.13 mm)+ .005 + 2
New Shim Pack Thickness .037 .94
NOTE: 3. Old Shim Pack Thickness .030 .76

The pinion cone number can be either 1,OOOths of Old PC Number, PC+ 2( +.05 mm) - .002 - .05
an inch or IOOths of a millimeter. See the following
examples. New PC Number, PC-5 (-.13 mm) - .005 - .13
PC+3, PC-3, +3 or -3 equal .003 inch. New Shim Pack Thickness .023 .58
PC+.O3, PC.03 mm, +.03 mm or -.03 equal .03
mm 4. Old Shim Pack Thickness .030 .76
Old PC Number, PC-2 (-.05 mm) + .002 + .05
To change inches to millimeters, multiply inches by
25.40 Standard Shim Pack Thickness .032 .81
To change millimeters to inches, multiply New PC Number, P&5(-.13 mm) - .005 - .13
millimeters by 0.039.
New Shim Pack Thickness .027 .68 i
3. If the old pinion cone number is a plus (+), sub-
tract the number from the old shim pack thickness IMPORTANT: Remember, that Rockwell drive pinions and
that was measured in step 2. ring gears MUST be replaced as matched sets.
Assembly E
s
5
8. Install the drive pinion, bearing cage and new shim 3. Install the drive pinion and bearing cage into the
pack into the carrier. carrier. If necessary, use a rubber, plastic or
leather mallet to hit the assembly into position.
Figure 80.
Install the Drive Pinion, Bearing
Figure 80 . Drive Pinion
Cage and Shim Pack into the and Bearing Cage
Carrier
NOTE:
If a new drive pinion and ring gear set is installed,
or if the depth of the drive pinion has to be ad-
justed, calculate the thickness of the shim pack.
See the procedure to Adjust Thickness Of Shim
Pack For The Pinion Cage on page 35.
1. install the correct shim pack between the bearing

cage and carrier. Figure 79.
2. Align the oil slots in the shims with oil slots in the
A
bearing cage and carrier. The use of guide studs
will help align the shims. Figure 79.
WARNING:
igure 79 Guide Studs with a steel hammer. Parts can break and cause
injury.
4. If used, install the cover* and seal assembly and

gasket* over the bearing cage. Figure 81.
NOTE: Bearing Cage’

Use a minimum of three shims in a pack. If the
pack is made from different thickness shims, install
the thinnest shims on both sides of the pack for 5. Align the oil slots in the cover* and gasket* with
maximum sealing. oil slot in the bearing cage.
‘Some Rockwell carriers do not have the parts described.

Page 37
83 Assembly
6. Install the bearing cage to carrier capscrews and

washers. Tighten capscrews to correct torque
Assemble the Main Differential
,_
value. See the toraue chart on oaae 65. Figure
62.
and Ring Gear Assembly
Figure 62
A CAUTION:
Do not press a cold ring gear on the flange case
half. A co/d ring gear will damage the case half
because of the tight fit. Metal particles between the
parts will cause gear runout that exceeds the
Rockwell specification of JO8 inch (0.2 mm)
1. Expand the ring gear by heating the gear in a tank

of water to a temperature of 160°F to 180°F (71OC
to 82OC) for 10 to 15 minutes.
A WARNING:
Wear safe clothing and gloves that will protect you
from injury when you touch the hot ring gear.
7. Install the input yoke or flange, nut and washer* 2. Safely lift the ring gear from the tank of water us-
on the drive pinion. The yoke or flange MUST be ing a lifting tool.
against the outer bearing.
3. Install the ring gear on the flange case half im-
mediately after the gear is heated. If the ring gear
NOTE: does not fit easily on the case half, heat the gear
If the fit between the yoke or flange splines and again. Repeat step 1.
drive pinion splines is tight, use the three-piece
pilot tool for installation. See the procedure on 4. Align fastener holes of the ring gear and flange
page 22. case half. Rotate the ring gear as needed.
AL CAUTION: 5. Install the bolts*, nuts* and washers* that hold the
Donot
ring gear to the flange case half. Install the bolts
install tight fit yokes or flanges on shafts from the gear side of the assembly. The bolt
using a hammer or mallet. A hammer or mallet will heads MUST be against the ring gear. Figure84.
damage the yoke or flange.
Figure 84
8. Tighten the pinion nut to the correct torque value.

See the torque chart on page 65. Figure 83.
Figure 83
Bolt Head
against Gear
6. Tighten the bolts* and nuts* to the correct torque

value. See the torque chart on page 65.
@
7. If rivets* are used to hold the ring gear to the
flange case half, install the rivets* as follows:
*Some
Copyrighted Rockwell carriers
Material do not have the parts described.
g
Assembly!
ALCAUTION: -
Do not beat rivets before installation. Use only cold
Figure 86
rivets to fasten the ring gear correct/y on the flange

case half.
A. Install the correct size rivets* in pairs opposite
each other from the case half side of the
assembly. The rivet* heads MUST be against
the flange case half. Figure 85.
Figure 85 3
Ring
Gear Check for
gap with
.003” Gauge
D. Check the flange case half and ring gear for the
problem that causes the gap. Repair or replace
parts.
E. After the parts are repaired or replaced,
assemble the ring gear on the flange case half.
Case Repeat the procedure on page 38, and steps A
Half to C on this page.
1
8. Install the bearing cones on both of the case
halves. Use a press and sleeve of the correct size.
B. Press the rivets* into position from the ring gear
Figure 87.
side of the assembly. Use a riveter machine and
apply the correct amount of pressure. See Chart
Figure 87
3 for rivet pressures.
:hatt 3
1
Sleeve
Diameter of
Press Pressure Needed to Install Rivets
Rivet Body
inch (mm) pounds I tons I kilograms / metric tons I

.438 (11.13) 44,000 I 22 19958 I 20
,500 (12.70) 60,000 I30 27216 I 27.2
S63 (14.30) 72,000 I 36 32659 I 32.7
.625 (15.88) 90,000 I 45 40824 I 40.8
A CAUTION:
The pressure on rivets must be held for approx-
imately one minute so that the rivet body will fill
the hole.
C. After the rivets are installed, check for gaps be-
tween the back surface of the ring gear and the
case flange. Use a .003 inch (.08 mm) feeler 9. Apply axle lubricant on the inside surfaces of both
gauge and check at four points around the case halves, spider (cross), thrust washers, side
assembly. Figure 86. gears and differential pinions.
If the gauge fits more than one half the distance
between the outer diameter of the flange and 10. Put the flange case half on a bench, ring gear
the pilot diameter of the gear, remove the ring teeth toward top.
gear. See the procedure on page 9 and the
following steps D and E. If the gap is less than
.003 inch (.08 mm), continue by following *Some Rockwell carriers do not have the parts described.
step 8. Copyrighted Material Page 39
5
Z‘
0 5 Assembly
11. Install one thrust washer and side gear into the Figure 90
flange case half. Figure 88.
Figure 88
Side Gear
-Thrust Washer
Flange Case Half
14.Put the plain half of the differential case over the

flange half and gears. Rotate the plain half as
needed to align the match marks. Figure 90 and
91.
Figure 91
A CAUTION:
The side gears in some carrier models have hubs
Plain
Case Half
of different lengths. Install the correct length side
gear into the flange case half.
12. Install the spider (cross), differentialpinions and
thrust washers into the flange case half.
Figure 89.
Figure 89
Spider,
shers
15. Install Dri-Lot fasteners into the case halves. See

the procedures on page 20 and the following steps
A and B.
A. Install four capscrews* and washers* or bolts*,

nuts* and washers* into the case halves. The
distance between the fasteners MUST be equal.
Tighten the fastners to the correct toraue value
13. Install the second side gear and thrust washer
in a pattern opposite each
over spider and differential pinions. Figure 90.
see torque chart on page 65.
:
Assembly i
Figure 92 B. Put the differential and ring gear assembly in

the vise.
C. Install the tool into the differential until the
splines of the tool and one side gear are engag-
ed. Figure 94.
Figure 94
Tool for
Checking
Resistance
B. Install the other fasteners into the case halves.

Tighten the fasteners to the correct torque
value. See the torque chart on page 65.
@
16.Check the rotating resistance of the differential
gears. Use the following procedure.
D. Attach a torque wrench to the nut of the tool
Rotating Resistance Check of Differential and rotate the differential gears. As the differen-
Gears tial gears rotate, read the value indicated on the
torque wrench. Figure 95.
Specification:
50 lb.-ft. (67.6 N.m) torque maximum applied to one
side gear. Figure 95
NOTE:
Make a tool for checking the rotating resistance of
the differential gears. The too/ can be made from
an axle shaft that matches the spline size of the
differential side gear. See Figure 93.
Figure 93
Approximetely
12 inches (304.8 mm)
E. If.. the torque value exceeds the specification,

disassemble the differential gears from the case
Weld kut to halves.
End of Shaft
F. Check the case halves, spider, gears and thrust
washers for the problem that causes the torque
END VIEW
value to exceed the specification. Repair or
replace parts.
A. Install soft metal covers over vise jaws to 17. After the parts are repaired or replaced, assemble
protect the ring gear. Figure 94. the parts and repeat steps A to F.
Page 41
5
E
‘
P 5 Assembly
6. Install both of the bearing adjusting rings into posi-
Install the Differential and Ring Gear
tion between the carrier legs. Turn each adjusting
Assembly ring hand tight against the bearing cup. Figure 98.
1. Clean and dry the bearing cups and bores of the Figure 98
carrier legs and bearing caps.
2. Apply axle lubricant on the inner diameter of the

bearing cups and on both bearing cones that are
assembled on the case halves.
3. Apply Rockwell Adhesive in the bearing bores of

the carrier legs and bearing caps. See the pro-
cedure on page 21. Figure 96.
7. Install the bearing caps over the bearings and ad-

justing rings in the correct location as marked
II before removal. Figure 99.
-
1
4. Install the bearing cups over the bearing cones

that are assembled on the case halves. Figure 97.
A WARNING:
with a steel hammer. Par& can break and cause
5. Safely lift the differential and ring gear assembly injury.
and install into the carrier. The bearing cups
MUST be flat against the bores between the car-
rier legs. Figure 97.
-
E
Assembly 15
8. Hit each bearing cap into position with a light Method 1.

leather, plastic or rubber mallet. The caps MUST
fit easily against the bearings, adjusting rings and 1. Attach a dial indicator on the mounting flange of
carrier. DO NOT FORCE THE BEARING CAPS IN- the carrier.
TO POSITION.
2. Adjust the dial indicator so that the plunger or
pointer is against the back surface of the ring
A CAUTION:
If bearing caps are not installed in correct loca-
gear. Figure 100.
tions, the bores and threads in caps will not match Figure 100
Dial Indicator
the carrier. You will have problems assembling the
caps on the carrier and damage to parts can OCCUT.
Do not force the bearing caps into position.
9. If bearing caps do not correctly fit into position,

check the alignment of match marks between caps
and carrier. Remove the caps and repeat steps 6
to 6.
10. Install the capscrews and washers that hold bear-
ing caps to the carrier. Tighten the capscrews by
hand four to six turns, then tighten the capscrews
to the correct torque value. See the torque chart
on page 65.
NOTE: dh CAUTION:
Do not install the cotter keys: pins* or lock plates* When you turn the adjusting rings, always use a
that hold the bearing adjusting rings in position. tool that engages two or more opposite notches in
Continue by adjusting the preload of differential the ring. A “T” bar wrench can be used for this
bearings, adjust backlash of the hypoid gear and purpose. If the tool does not correctly fit into the
check tooth contact patterns. notches, damage to the lugs will occur, Figure 101.
3. Loosen the bearing adjusting ring that is opposite
the ring gear so that a small amount of end play
shows on the dial indicator. Figure 101. Move the
differential and ring gear to the left and right with
Adjust Preload of Differential pry bars while you read the dial indicator. Use the
Bearings following step A or B.
Specifications: Figure 101

Preload of differential bearings - all carrier models -
15 to 35 lb.-in. (1.7 to 3.9 N.m) torque.
or
Expansion between bearing caps -
W-140 and RS-145 carrier models - .003 to .009 inch
(.08 to .22 mm)
All other carrier models - .006 to .013 inch
(.15 to .33 mm)
*Some Rockwell carriers do not have the parts described,

s
5 Assembly
._
G
zi
A. Use two pry bars that fit between the bearing Method 2.
adjusting rings and ends of the differential case.
The pry bars MUST NOT touch the differential A second method of checking preload is to measure
bearings. Figure 102. 6 the expansion between the bearing caps after you
tighten the adjusting rings. Use the following
Figure 102 procedure.
1. Turn both adjusting rings hand tight against the

differential bearings.
2. Measure the distance X or Y between opposite
surfaces of the bearing caps. Use a large
micrometer of the correct size. Figures 104 and
105. Make a note of the measurement.
B. Use two pry bars between the differential case

or ring gear and the carrier at locations other
than described in step A. The pry bars MUST
NOT touch the differential bearings. Figure 103.
4. Tighten the same bearing adjusting ring so that no

end play shows on the dial indicator. Move the dif-
ferential and ring gear to the left and right as
needed. Repeat step A or B. 3. Tighten each bearing adjusting ring one notch.
5. Tighten each bearing adjusting ring one notch 4. Measure the distance X or Y again. Compare the
from the zero end play measured in step 4. dimension with the distance X or Y measured in
step 2. The difference between the two dimensions
6. Continue by checking runout of the ring gear. is the amount the bearing caps have expanded.
Assembly 1
E
5
Example: Measurements of a Q-100 carrier. If runout of the ring gear exceeds specifications,
remove the differential and ring gear assembly
Distance X or Y before tightening adjusting rings from the carrier. See the procedure on page 5
= 15.315 inch (389.00 mm). and the following steps 5 and 6.
Distance X or Y after tightening adjusting rings =
15.324 inch (389.23 mm)
5. Check the differential parts including the carrier for
15.324 inch - 15.315 inch = .009 inch (.23 mm) the problem that causes the runout of gear to ex-
difference. ceed specifications. Repair or replace parts.
If the dimension is within specifications, continue 6. After the parts are repaired or replaced, install the
by checking runout of the ring gear. If the dimen- differential and ring gear into the carrier. See the
sion is less than specifications, repeat step 3 and procedure on page 42.
4 as needed.
7. Repeat preload adjustment of differential bearings.
Check Runout of Ring Gear

Specification: Adjust Backlash of the Ring
.008 inch (.20 mm) Gear
1. Attach a dial indicator on the mounting flange of Specifications:
the carrier. Figure 106. Ring gears that have a pitch diameter of less than
17 inches (431.8 mm).
Figure 106 Range of backlash setting - .008 to .018 inch
(.20 to .46 mm).
Rotate Ring Backlash setting for new gear sets - .012 inch
(.30 mm).
Ring gears that have a pitch diameter of 17 inches

(431.8 mm) or greater than 17 inches.
Range of backlash setting - .OlO to .020 inch
(.25 to .51 mm)
Backlash setting for new gear sets - .015 inch
(.38 mm)
Figure 107

pointer is against the back surface of the ring
gear.
3. Adjust the dial of the indicator to zero (0).
4. Rotate the differential and ring gear while you read

the dial indicator. The runout of the ring gear NOTE:
MUST NOT EXCEED .008 inch (.20 mm). Measure the outer diameter of ring gear for approx-
Figure 106. imate pitch diameter. Figure 107.
Page 45
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% 5 Assembly
If the old gear set is installed, adjust the backlash to NOTE:
the setting that was measured before the carrier was
Backlash is increased by moving the ring gear away
disassembled.
from the drive pinion. Figure 109.
If a new gear set is installed, adjust the backlash to Backlash is decreased by moving the ring gear
the correct specification for new gear sets. toward the drive pinion. Figure 110.
During the check of tooth contact patterns, the I7gure 109

backlash can be adjusted within specification limits, if
Tighten Adjusting Ring
needed, to change the location of the pattern. this side
1. Attach a dial indicator on the mounting flange of
the carrier. Figure 108.
Figure 108
\ I
Incrfase
Backlash
Loosen Adjusting Ring

this side
6. Loosen one bearing adjusting ring one notch then

tighten the opposite ring the same amount. See
Figures 109 and 110.
Figure 110

this side

pointer is against the tooth surface. Figure 108.
3. Adjust the dial of the indicator to zero (0). Tighten Adjusting Ring
this side
4. Hold the drive pinion in position.
5. While you read the dial indicator, rotate the dif-

ferential and ring gear a small amount in both
directions, against teeth of the drive pinion. If the
backlash reading is within specification, continue
by checking tooth contact patterns. If the backlash NOTE:
reading is not within specifications, adjust backlash When you adjust backlash, move the ring gear
as needed. Continue by following steps 6 and 7. ONLY. DO NOT move the drive pinion.
7. Repeat steps 2 to 6 until the backlash is within

specifications.
Assembly!
s
5
Check Tooth Contact Patterns Always check tooth contact patterns on the drive side
of the gear teeth. Figurel13.
of the Gear Set
General Information
Rockwell carriers can have a conventional hypoid
gear set or a GENEROID hypoid gear set. The tooth
contact patterns for each type of gear set are different.
Look at the part numbers to see what type of gear set
is in the carrier. See Figure 111 for the location of
part numbers.
Figure 111
Part Part
No. /No.
Part No. Option &?f-&& Tooth Contact. Patterns of Conventional
Hypoid and Generoid Hypoid Gear Sets
1. Adjust the backlash of a new gear set to either
Examples of part numbers for conventional gear sets. .012 inch (.30 mm) or .015 inch (.38 mm) depending
36786 for the ring gear. on the size of the ring gear. Adjust the backlash
36787 for the drive pinion. of an old gear set to the setting that was
measured before the carrier was disassembled.
See the procedure on page 45.
Examples of part numbers for GENEROID gear sets.
36786-K or 36786X2 for the ring gear. 2. Apply a marking compound to approximately 12
36787-K or 36787X2 for the drive pinion. gear teeth of the ring gear. Rotate the ring gear so
that the 12 gear teeth are next to the drive pinion.
Figure114.
In the following procedures, movement of the contact
pattern in the length of the tooth is indicated as,
toward the “heel’ or “toe” of the ring gear. Figure Figure 114
112.
Figure 112
3. Rotate ring gear forward and backward so that the

12 gear teeth go past the drive pinion six times to
get the contact patterns. Repeat if needed to get a
more clear pattern.

s
S
‘
Q 5 Assembly
Conventional Gears
Figure 115A Figure 116A Figure 117A

Good Hand Rolled Pattern High Pattern Low Pattern
Generoid Gears
Fiaure 1158 Figure 116B Figure 1178

Good Haid Roiled Pattern High Pattern Low Pattern
4. Look at the contact patterns on the ring gear When the carrier is being operated, a good pattern
teeth. Compare the patterns to Figures 115A or B, will extend approximately the full length of the
116AorBand117AorB. gear tooth. The top of the pattern will be near the
top of the gear tooth. See Figure 118A or B.
The Location of Good Hand Rolled Contact
The location of a good hand rolled contact pattern
Patterns.
for an old gear set MUST match the wear pattern
in the ring gear. The contact pattern will be
New Conventional and Generoid Gear Sets - smaller in area than the wear pattern
toward the toe of the gear tooth and in the center If the contact patterns require adjustment, continue
between the top and bottom of the tooth. See by following step 5 to move the contact patterns
Figures 115A and 115B. between the top and bottom of the gear teeth. If
the contact patterns are in the center of the gear
teeth, continue by following step 6.
Figure 118A Figure 118B

Good Pattern in Operation Good Pattern in Operation
Conventional Gears Generoid Gears
5i
Assembly 53
5. Change the thickness of the shim pack under

Figure 121 Move Pattern toward Toe
bearing cage to move the contact patterns be-
tween the top and bottom of the gear teeth. Use
this side
ttie following procedure.
4
Decrease _
NOTE:
A high contact pattern indicates that the drive pin-
ion was not installed deep enough into the carrier.
A low contact pattern indicates that the drive pin-
ion was installed too deep in the carrier.
Ic Tighten Adjusting Ring this side
A. Remove the drive pinion and bearing cage from
the carrier. See the procedure on page 10. B. Increase backlash to move the contact patterns
toward the heel of the ring gear teeth. Figure
B. To correct a high contact pattern, Figure 116A 122.
or 6 decrease the thickness of the shim pack
under the bearing cage. When you decrease the
Figure 122 Move Pattern toward Heel
thickness of the shim pack, the drive pinion will
Tighten Adjusting Ring
move toward the ring gear. Figure 119.
this side
To correct a low contact pattern, Figure 117A or
B increase the thickness of shim pack under the
bearing cage. When you increase the thickness
of the shim pack, the drive pinion will move
away from the ring gear. Figure120.
Incryase
Backlash
?gure 119 Figure 120
$_
Loosen Adjusting Ring this side
C. Repeat steps 2 to 4 and 6 until the contact pat-

terns are at the correct location in the length of
the gear teeth.
7. Install cotter keys*, pins*, or lock plates* that hold

the two bearing adjusting rings in position. Use the
following procedures.
Increase
Decrease
Shim Pack
Shim Pack A CAUTION:
If your carrier was built using cotter keys, lock
the adjusting rings only with cotter keys. If your
carrier was built using roll pins, reuse the roll
C. Install the drive pinion, bearing cage and shims
pins or lock the adjusting rings with cotter keys.
into the carrier. See the procedure on page 35. Do not force a roll pin into a cotter key hole.
D. Repeat steps 2 to 5 until the contact patterns A. Cotter keys* - Install cotter keys between lugs
are in the center between the top and bottom of of the adjusting ring and through the boss of the
the gear teeth. bearing cap. Bend the two ends of the cotter
key around the boss. Figure 123.
6. Adjust backlash of the ring gear within specifica-
tion range to move the contact patterns to the cor- B. Pins* - Install pin through boss of the bearing
rect location in the length of the gear teeth. See cap untii the pin is between lugs of the ad-
the procedure on page 45. justing ring. Use a drift and hammer to install
A. Decrease backlash to move the contact patterns the pin. Figure 123.
toward the toe of the ring gear teeth. Figure
121.
Page 49
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z
2 5 Assembly
C. Lock Plates* - Install lock plate on bearing cap 2. Put the thrust block*on the back surface of the
so that the tab is between lugs of the adjusting ring gear. The thrust block* MUST be in the
ring. Install the two capscrews that hold the lock center between the outer diameter of gear and dif-
plate to the bearing cap. Tighten the capscrews ferential case.
to correct torque value. See the torque chart on
page 65. Figure 123. 3. Rotate the ring gear until the thrust block* and
hole for thrust screw, in carrier, are aligned.
@ Figure 124.
4. Install the jam nut* on the thrust screw*, one half
the distance between both ends. Figure 125.
Figure 125
Threaded Holes in
Cap when Lock
Plate is used.
\rtllu -
-0
- *Shown
- with cotter
-‘‘.J
x1( &key installed.
Install and Adjust the Thrust

Screw* 5. Install the thrust screw* into the carrier until the
screw stops against the ring gear or thrust block”.
Specification: Figure 125.
Clearance between thrust screw or block and ring
gear - .025 to .045 inch (.65 to 1.14 mm). Loosen the 6. Loosen the thrust screw* l/2 turn, 180°. Figure
thrust screw l/2 turn, 180°. 126.
If the carrier does not have a thrust block*, start at
step 4. I
1. Rotate the carrier in the repair stand until the back

surface of ring gear is toward the top.
Figure 124 Thrust Screw 112 Turn
hrust
lock
Page 50
5
Assembly 1
7. Tiahten the iam nut* to the correct toraue value 3. Check for loose studs* in the mounting surface of
against the carrier. See the torque chart on page the housing where the carrier fastens. Remove
65. Figure 127. and clean the studs* that are loose.
4. Apply liquid adhesive to the threaded holes and in-
stall the studs* into axle housing. See the pro-
cedure on page 20. Tighten studs* to correct
torque value. See the torque chart on page 65.
@
5. Apply silicone gasket material to the mounting sur-
face of the housing where the carrier fastens. See
It-- Hold Thrust
Screw in Position the procedure on page 21. Figure 128.
Silicone Gasket Bead
IMPORTANT: To complete the assembly of axles

equipped with driver controlled main differential locks, 8. Install the carrier into the axle housing. Use a
see pages 57 through 61. Start with “Install Differen- hydraulic roller jack or a lifting tool.
tial Shift Assembly” page 57.
A CAUTION:
Do not install the carriers using a hammer or
mallet. A hammer or mallet will damage the mount-
ing flange of carrier and cause oil leaks.
7. Install nuts* and washers or capscrews and
Install Differential Carrier into washers in the four corner locations around the
Axle Housing carrier and axle housing. Tighten the fasteners
hand tight at this time. Figure 129.
A WARNING:
Be careful when using cleaning solvents. Follow the
solvent manufacturer’s instructions for safe use to
prevent injury.
1. Clean the inside of axle housing and the mounting

surface where the carrier fastens. Use a cleaning
solvent and rags to remove dirt. Blow dry the
cleaned areas with air. Also see the procedure on
page 15.
2. Inspect the axle housing for damage. Repair or

replace the axle housing. See the procedure on
pages 17 to 19. *Some Rockwell carriers do not have the parts described.
z
E
0 5 Assembly
-
8. Carefully push the carrier into position. Tighten the Figure 130
four fasteners two or three turns each in a pattern
opposite each other. See Figure 129.
Caoscrew Ga$ket
9. Repeat step 8 until the four fasteners are tightened
value. See the torque chart or Siud Nut
10. Install the other fasteners and washers that hold

the carrier in the axle housing. Tighten fasteners
value. See the torque chart
11. Connect the driveline universal joint to the pinion

input yoke or flange on the carrier.
12.lnstall the gaskets and axle shafts into the axle

housing and carrier. The gasket and flange of the
axle shafts MUST fit flat against the wheel hub. Axle Shaft \
Figure 130. Hub
13. Install the capscrews and washers that hold the

axle shaft to the wheel hub. Tighten capscrews to 15. Install the nuts* and washers on the studs*.
the correct torque value. See the torque chart on Tighten nuts* to the correct torque value. See the
page 65. torque chart on page 65.
0
14. If the wheel hubs have studs*, install the tapered
dowels* at each stud and into the flange ofthe ax-
le shaft. Use a punch or drift and hammer if
needed. *Some Rockwell carriers do not have the parts described.
Page 52
Driver Control1ed.i
Main Diff. Lock8
Driver Controlled Main Differential Lock
Figure 131
1. Sensor
2. Lock NutSwitch
- Sensor Switch 8.
9. Air Cylinder Tube
Piston 15. Cover Plug
16. Plug Gasket
3. Shift Shaft Spring IO. Piston “0” Ring 17. Washers
4. Shift Shaft 11. Cover Copper Gasket 18. Shift Collar
5. Shift Fork 12. Capscrew - Manual Actuation 19. Shift Fork Roll Pins
6. Spring Retaining Pin 13. Cylinder Cover
7. Flat Washer (or silastic as reqd.) 14. Cover Capscrews
Some Rockwell drive axle models have a driver con-

trolled main differential lock. This differential lock is
NOTE:
operated by a carrier mounted, air actuated shift unit. The Rockwell carrier models with driver controlled
When activated, the shift unit moves a sliding collar differential lock equipment are manufactured in
which is installed on the splines of the axle shaft. metric dimensions and sizes. When these carriers
When engaged, the collar locks the axle shaft to a are serviced, it is important to use the correct
second set of splines on the differential case. Figure metric size tools on the fasteners. See the metric
131. torque chart at the back of this manual.
Driver Controlled
6
! 0 Main Differential Lock
1. Remove the axle shafts before the vehicle is

towed. See the procedures on pages 25 and 26. A WARNING:
Do not start the vehicle engine and engage the
A CAUTION:
If the vehicle must be towed to a service facility
transmission with one wheel raised from the floor.
When the differential is in locked (engaged) posi-
tion, power will go to the wheel on the floor and
with the drive axle wheels on the ground, it is cause the vehicle to move.
necessary to remove the axle shafts before the
vehicle is towed. 3. Put a jack stand under the right-hand spring seat
to hold the vehicle in the raised position.
2. Install the axle shafts after the vehicle is towed.
See the procedure on page 26.
A WARNING:
Do not work under a vehicle supported only by
3. If the differential carrier must be removed from
jacks. Jacks can slip or tip over and cause injury.
the axle housing, use the following procedures.
4. Disconnect the driveline from the pinion input
yoke.
Remove Differential Carrier
5. Disconnect the vehicle air line from the differential
From Axle Housing lock actuator assembly.
Before the differential carrier can be removed or in- 6. Connect an auxiliary air supply to the differential
stalled, the differential lock MUST be shifted into and lock actuator assembly.
held in the locked (engaged) position. The locked
position gives enough clearance between the shift col-
lar and the axle housing to permit the removal or in-
stallation of the carrier.
NOTE:
If an auxiliary air supply is not available, continue
to “Manual Engaging Method” of locking the
differential.
NOTE:
If the axle shafts were removed for towing with the
differential in the unlocked (disengaged) position, in- 7. Apply and hold air pressure to the actuator
stall the right-hand axle shaft into the housing assembly. The air pressure will move the shift col-
before continuing. Follow steps 1 and 2 of %stall lar to engage with the splines on the differential
Axle Shafts After the Vehicle is Towed” on page 26. case half and lock the assembly.
To shift into the locked position, use either of the 8. Make sure that the shift collar has moved the full
following “Air Pressure” or the “Manual Engaging” distance on the splines of the differential case half.
methods. Rotate the drive pinion or the right-hand wheel un-
til the right-hand wheel makes one complete rota-
tion (forward or backward).
Air Pressure Method:
1. Remove the drain plug from the bottom of the Continue to hold the main differential in the locked
housing and drain the lubricant. position with air pressure until the carrier assembly
is completely removed from the axle housing.
2. Raise the right hand wheel of the drive axle off the
floor with a hoist or jack.
Driver Controlled s
Main Differential Lock 160
9. Remove the axle shafts from the housing. Follow 4. Install the plug and gasket into the bottom storage
Steps I-3 of “Remove Axle Shafts Before The hole in the cylinder cover.
Vehicle is Towed” on page 26.
10. Remove the carrier from the housing as described

NOTE:
The storage hole for the plug and gasket is the op-
in Steps 8 through 15 on page 5.
posite end of the storage hole for the manual
11. After the carrier is removed from the axle housing, engaging cap screw.
release the air pressure from the actuator
assembly.
5. Install the manual engaging capscrew into the
threaded hole in the center of the cylinder cover.
Manual Engaging Method:
6. Turn the manual adjusting capscrew to the right
If an auxiliary air supply is not available or if the until the head is approximately l/4 inch from the
differential carrier is to be stored for later use, use cylinder cover. DO NOT turn the capscrew beyond
this manual engaging method. Figure 132. its normal stop. The capscrew is now in the ser-
vice position and the main differential lock is com-
1. Follow Steps 1 through 5 of the “Air Pressure pletely engaged.
Method”.
Figure 132
POSITION OF CAP SCREW AND PLUG WHEN
A CAUTION:
There will be a small amount of spring resistance
MANUALLY LOCKING THE DIFFERENTIAL felt when you turn in the manual engaging
Top Side Storage Hole Air capscrew. If a high resistance is felt before
reaching the locked (engaged) position, STOP TURN-
ING THE CAPSCREW, or the cover and capscrew
threads will be damaged.
A high resistance on the capscrew indicates that

the splines of the shift collar and the differential
case half are not aligned or engaged. To align the
splines use the following procedure:
A. Rotate the drive pinion or right-hand wheel to

align the splines of the shift collar and case half
while you turn in the manual engaging
capscrew.
B. When the normal amount of spring resistance is
Gasket Bottom Side Storage Hole again felt on the capscrew, the splines are
for Plug and Gasket engaged. Continue to turn in the manual engag-
ing capscrew until the head is approximately l/4
inch from the cylinder cover.
2. Remove the plug and gasket from the hole in the
center of the cylinder cover.
3. Remove the manual engaging cap screw from the 7. Remove the carrier from the axle housing as
top storage hole in the cylinder cover. described in steps 8 through 15 on page 5.
Driver Controlled
Main Differential Lock
Remove Differential And Gear D. Remove the shift shaft from the shift fork. The
shaft may be loctited to the fork, use the
Assembly heating procedure to breakdown loctite. The
recommended procedure is similar to “Remove
1. To remove the differential lock sliding shift collar, Dri-Lock Fasteners” on page 21.
tap out the two retainer roll pins until they are level
with the inner face of the shift fork. Release the
differential lock if it is manually engaged. Figure E. Remove the shift shaft spring and flat washer.
133.
Figure 133
NOTE:
d Some models use silastic seal instead of the flat
washer in Step E.
F. Remove the shift fork.
NOTE:
A roll pin is installed in the shift shaft and is usec
as a stop for the shift shaft spring. It is not
necessary to remove this roll pin during a normal
disassembly.
3. Remove the cotter keys*, pins* or lock plates*

that hold the two bearing adjusting rings in posi-
tion. Use a small drift and hammer to remove
pins. Each lock plate is held in position by two
capscrews.
2. If required, remove the differential lock shift unit. 4. Match mark one bearing cap and one carrier leg
so that these parts will be assembled in the cor-
A. Remove the sensor switch and lock nut. rect positions. Remove the bearing cap
capscrews and washers, the bearing caps and the
B. Remove the four capscrews and washers that
adjusting rings.
hold the cylinder cover. Remove the cover and
copper gasket. Figure 134. 5. Lift the differential and gear assembly from the
carrier. Tilt the assembly as required to permit the
Figure 134 ring gear to clear the support for the pinion spigot
Capscrew & Washer Cover be&&g. Figure 135.
C. Remove the shift unit-cylinder and piston.

Remove the O-ring from the piston.

Driver Controlled 5
Main Differential Lock! 60
FURTHER DISASSEMBLY OF THESE CARRIERS IS 2. If the spring stop roll pin was removed from the
THE SAME AS AXLES WITHOUT THE DRIVER CON- head of the shift shaft, install the pin at this time.
TROLLED MAIN DIFFERENTIAL LOCK. TO CON-
TINUE DISASSEMBLY FOLLOW THE PROCEDURES
3. Apply Loctite 222 (Rockwell Part No.
2297-B-8112) to the threads of the shift shaft.
STARTING ON PAGE 8.
PREPARE PARTS FOR ASSEMBLY, AD- 4. Install the shift fork into its correct position in the
JUSTMENTS, AND CARRIER ASSEMBLY (UP TO carrier case. Figure 138.
THE POINT OF “INSTALL DIFFERENTIAL CARRIER
INTO AXLE HOUSING” ON PAGE 51) ARE ALSO
Figure 138
THE SAME FOR BOTH AXLES.
Install Differential Shift

Assembly
Install the differential shift assembly after the differen-
tial carrier is assembled and the gear and bearing ad-
justments are made. Parts of the shift assembly are
shown in Figure 136.
Figure 136 Electric
5. Hold the shift fork in position and install the shift

shaft spring into the shift shaft opening in the car-
rier, through the shift fork bore and into the bore
for the shift shaft spring. Figure 139.
Collarr Fork
1. Install the two roll pins into the ends of the shift
fork. Tap the pins into position until they are level
with the inner yoke face. Figure 137. Do not install
completely at this time.
Figure 137
,‘Shift Fork
Roll
Pin
Inner Yoke 6. Slide the shift shaft over the spring and install the
Faces shaft into the shift fork. Tighten to 20-25 lb. ft.
(27-34 N.m) torque.
@
7. Install the fiat washer (when used) or apply silastic
sealant (Rockwell Part No. 1199-Q-2981) to the
bottom of the cylinder bore. Figure 140.
Driver Controlled
6
\ 0 Main Differential Lock
install the O-ring into its groove on the piston. Figure 142
Lubricate the O-ring with axle lubricant. Install the /Cylinder Cover
piston into the air cylinder. Figure 140.
Figure
12.Hold the shift collar in the locked (engaged) posi-

Shift tion and tap in the two roll pins in the shift fork
ends until they are level with the outer yoke faces.
Figure 143.
9. Install the cylinder into the housing bore. Make Figure 143
sure that the pilot journal on the piston is against
its bore on the shift shaft. Figure 141.
Figure 141
Cvlinder
Shift
Collar
13. While the shift collar is still in the locked position,

put the sensor switch (with the lock nut loosely at-
tached) into its hole.
14. Connect a battery/bulb tester to the sensor switch

10. Install the copper gasket into its bore on the inside
and rotate the switch into its hole until contact with
of the cylinder cover. Put the cover in position over
the shift fork causes the light to go on. Turn the
the cylinder so that the air intake port will point up
switch one additional revolution and tiahten the
when the carrier is installed into the housing. In-
lock nut to 26-33 lb. ft. (35-45 N.m) to;que.
stall the cover with the four attaching capscrews
and washers. Tinhten to 7.4-8.9 lb. ft. (IO-12
\ N.m)
torque. Figures i36 and 142. NOTE:
# For carriers without the differential lock (Less Air
11. Slide the shift collar into the fork and engage the Shift), assemble the sensor switch plug and cover
shift collar splines with the splines of the differen- plate as follows:
tial case. Use the manual actuation capscrew to
1. Install the washer and plug into the hole for the
move the shift collar splines into the differential
sensor switch. Tighten the plug to 45-55 lb. ft.
case splines. See “Manual Engaging Method” on
(60-74 N.m). Figure 145.
page 60.
Driver Controlled z
Main Differential Lock1 60
2. Apply silicone gasket material to the cover plate 2. Inspect the axle housing for damage. If necessary,
mounting surface on the carrier. (See procedures repair or replace the housing. (See procedures on
on page 21). pages 17 to 19).
3. Install the four washers and capscrews. Tighten
the capscrews to 7.4-8.9 lb. ft. (lo-12 N.m). 3. Check for loose studs in the mounting surface of
Figure 144. the housing where the carrier fastens. Remove
e
and replace the studs where required.
Washers
4. Install the differential carrier into the housing. Use
one of the following procedures.
Air Pressure Method:

Cover Plate
(Apply Silicone A. Before the carrier is installed into the housing,
Gasket Material) install the right-hand axle shaft through the shift
collar and into the side gear. (The axle shaft is
being used as a spline alignment tool).
NOTE:
When the carrier is to be installed into the axle
housing, the shift collar must be he/d in the engag-
NOTE:
A similar tool can be made from a damaged right-
ed position. This can be done by keeping the air
band axle shaft by cutting off approximately 24
pressure applied to the shift cylinder (see ‘Air
inches from the spline end.
Pressure Method” on page SO), or by using the
manual engaging bolt (see “Manual Engaging
Method” on page 60). Failure to keep the differen- B. Align the splines of the shift collar and differen-
tial in the locked (engaged) position will make it tial case half by rotating the axle shaft tool or
impossible to install the carrier assembly into the drive pinion.
axle housing.
After the carrier is installed into the axle housing,

shift the differential info the unlocked (disengaged)
A WARNING:
Do not use your hands to hold the collar in posi-
position to permit the installation of the right hand tion. Injury can result when air pressure is applied
ax/e shaft. to the actuator.
C. Connect an auxiliary air supply to the actuator

Install Carrier Into Axle assembly.
Housing D. Apply and hold pressure to the actuator

assembly. The air pressure will move the shift
1. Clean the inside of the axle housing and the collar to engage the differential case half and
mounting surface where the carrier fastens. Use a lock the assembly.
cleaning solvent and rags to remove the dirt. Blow
E. If the shift collar has not moved the full distance
dry the cleaned areas with compressed air. (See
on the splines of the differential case half, rotate
procedures on page 15).
the axle shaft tool or the drive pinion one com-
plete rotation to the right or left.
A WARNING:
Be careful when using cleaning solvent. Follow the
F. Remove the axle shaft tool from the carrier.
solvent manufacturer’s instructions for safe use to

prevent injury.
Driver Controlled
6
1 0 lVlain Differential Lock
NOTE: A high resistance on the capscrew indicates that

the spfines of the shift collar and the differential
Continue to ho/d the main differential in the locked
case half are not aligned or engaged.
(engaged) position with air pressure until the car-
rier is completely installed in the axle housing. If Lift the shift collar as required and rotate to align
no air supply is available, use the “Manual Engag- the splines of collar and case half while you turn in
ing Method” on this page to lock (engage) the dif- the manual engaging capscrew. When the normal
feren tial. amount of spring resistance is again felt on the
capscrew, the splines are engaged. Continue to
turn in the manual engaging capscrew.
G. Apply silicone gasket material to the mounting
surface of the housing where the carrier fastens.
(See procedures on page 21). D. Install and fasten the carrier into the axle hous-
ing. Follow Steps G and H of the “Air Pressure
M. Install the carrier into the axle housina. Follow Method” on page 60.
steps 6-10 on page 51.
E. Remove the plug and gasket from their position.
I. Release the air pressure from the differential Remove the manual engaging capscrew from its
lock actuator and disconnect the auxiliary air service position.
supply.
J. Proceed to Step 5 on page 61. /VOTE:

When the manual engaging capscrew is removed
Manual Engaging Method: from the service position in the actuator, the main
differential lock becomes disengaged.
A. Align the splines of the shift collar and the dif-
ferential case half. This can be done by hand or
F. Clean the plug, gasket, cylinder cover, and
by installing the right-hand axle shaft through
threaded hole in the center of the cylinder
the shift collar and into the side gear. See Steps
A and B of the “Air Pressure Method” on this cover.
page. G. Install the plug and gasket into their operating
B. Install the manual engaging capscrew into the position in the cylinder cover. Install the manual
threaded hole in the center of the cylinder engaging capscrew into its storage position. See
cover. Figure 145.
C.Turn the manual adjusting capscrew to the right Figure 145 Top Side Storage Hole
until the head of the capscrew is approximately for Manual Engaging
l/4 inch from the cylinder cover. DO NOT turn
the capscrew beyond its normal stop. The
capscrew is now in the service position and the Manual
main differential lock is completely engaged. Engaging
Cap Screw
A CAUTION: Plug and

Gasket
There will be a small amount of spring resistance
felt when you turn in the manual engaging capscrew.
If a high resistance is felt before reaching the locked
(engaged) position, STOP TURNiNG THE
CAPSCREW, or the cover, fork and capscrew threads
will be damaged.
I ’ Pbsition
Bottom Side Storage Hole Ho’e
for Plug and Gasket
Driver Controlled O‘
Main Differential Lock!
H. Tighten the plug to 44-55 lb. ft. (60-75 N.m) tor- 4. Continue to drive the vehicle and put the dif-
que. Tighten the manual engaging capscrew to ferential lock switch in the locked (engaged)
22-28 lb. ft. (30-38 N.m). position. Let up on the accelerator to remove
the driveline torque and permit the shift. The
0
light must be on when the switch is in the lock-
5. Connect the vehicle air line to the differential lock ed position.
actuator assembly.
6. Install the electrical connection on the sensor NOTE:

switch located in the carrier, below the actuator If the indicator light remains “on” with the switch
assembly. in the unlocked position, the differential is still in
the locked position. Check to make sure that the
7. Install the right and left-hand axle shafts. Follow manual engaging capscrew was removed from the
the procedures in Steps 2 through 4 of “Before cylinder cover of the actuator assembly. See Steps
Towing” on page 26. E through H of “Manual Engaging Method” on this
page.
8. Remove the jack stand from under the drive ax-
le and lower the vehicle to the floor. Driver Caution Label
Figure 146
Check the Differential Lock

This vehicle D equipped with the
1. Shift the vehicle transmission to neutral and start ROCKWELL DRIVER CONTROLLED FULL LOCKING DIFFERENTIAL.
the engine to get the system air pressure to the

normal level.
Do not start the vehicle engine and engage the

transmission with one wheel raised from the floor.
When the differential is in locked (engaged) posi-
tion, power will go to the wheel on the floor and Check to see that the “Driver Caution” label is install-
cause the vehicle to move. ed in the vehicle cab. The caution label must be put
in a location that is easily visible to the driver. A
2. Put the differential lock switch (in the cab of the recommended location is on the instrument panel,
vehicle) in the unlocked (disengaged) position. next to the differential lock switch and lock indicator
light. Driver Caution labels (TP-86101) are available
3. Drive the vehicle at 5-10 MPH (8-16 kmph) and from Rockwell International, Troy, Michigan. Figure
check the differential lock indicator light. The light 146.
must be off when the switch is in the unlocked
position.

c
l
0
.m
H
cn Lubrication
NOTE:
For complete information on lubricating drive
axles and carriers, see Rockwell Field
Maintenance Manual No. 1.
See the following charts 4, 5 and 6 for standard infor-
mation on lubricants, schedules and capacities.
Chart 4
LUBRICANT CROSS REFERENCE (VISCOSITY) AND TEMPERATURE CHART
RockwellLubricant Description Cross Reference
Minimum Outside Maximum Outside
Specification Temperature Temperature
O-76-A Hypoid Gear Oil GL-5, S.A.E. 85W/140 - 12.2”C (+ 10°F) _ _ _**
O-76-B Hypoid Gear Oil GL-5, S.A.E. 8OWl140 - 26.1% (- 15°F) _ _ _**
O-76-D Hypoid Gear Oil GL-5, S.A.E. 8OWl90 - 26.1% (- 15°F) _ _ _**
O-76-E Hypoid Gear Oil GL-5, S.A.E. 75W/90 - 40°C (- 40°F) _ _ _tt
O-76-J Hypoid Gear Oil GL-5, S.A.E. 75W - 40°C (- 40°F) + 1.6”C (+ 35°F)
O-76-L Hypoid Gear Oil GL-5, S.A.E. 75W/140 - 40°C ( - 40°F) ___ l *
“There is no upper limit on these outside temperatures, but the axle sump temperature MUST NEVER EXCEED
+ 121°C (250°F)
Chart 5
LUBRICATION SCHEDULE
I
l Heavy-Duty On-Highway
l On and Oft Highway l Common Carrier On-Highway
l Off-Highway
Less than 60,000 miles More than 60,000 miles Less than 100,000 miles More than 100,000 miles
(96,000 Km) a year (96,000 Km) a year (160,000 Km) a year (160,000 Km) a year
25,000 to 30,000 miles 100,000 miles
Two Times A Year One Time A Year
(40,000 to 48,000 Km) (160,000 Km)
NOTE: If operation is continuous heavy-duty, check
lubricant each 1,000 miles (1,600 Km).
E
Lubrication 1a
CHART 6
LUBRICANT CAPACITIES
Use the following lubricant capacities as a guide only. The capacities are measured with the drive pinion in the horizontal
position. When the angle of the drive pinion changes, the lubricant capacity of the axle will change.
CAPACITY CAPACITY
AXLE MODEL AXLE MODEL
U.S. Pints I Liters U.S. Pints Liters
Sinale Drive Axles RS-23-180 39 18.6
RS-26-160 51 24.2
A-l 50 5.5 2.6
RS-26-180 38 18.3
B-l 00 10 4.7
RS-30-180 38 18.3
B-l 40 5.7
B-150 :‘5 1.7 Rear Axle Of Tandems
c-100 12.5 5.9
D-100 12.5 5.9 SDHD
D-l 40 12.5 5.9 (DHR rear) 16 7.6
E-100 15 7.1 SFHD
E-l 05 12.5 5.9 (FHR rear) 16.5 7.8
E-l 50 9 4.3 SHHD
F-100 13 (HHR rear) .26 12.3
F-106 13 kz SL-100
F-l 20 15 7:1 (LR-100 rear) 37 17.5
F-121 15 SLHD
F-140 14 zi (LHR rear) 32 15.1
FDS-75 14 6:s SC-1 00
FDS-85 15 7.1 (QQ~~O rear) 33 15.7
FDS-90 14 6.6
FDS-750 7 3.3 KJYJHHRprear) 31 14.7
FDS-1600 23 10.9
FDS-1800 35 16.6 p;T7;ar) 36 17
FDS-1805 35 16.6
G-161 21 9.9 (RR-170 rear) 43 20.3
H-100 20 9.5 SRHD
H-140 21 9.9 (RHR rear) 36 17
H-150 11 SSHD
H-162 20 z.: (SHR rear) 28 13.2
H-170 27* 12:8* ST-l 70
H-l 72 27 12.8 (TR-170 rear) 43 20.3
L-100 23 10.9 STHD
L-140 24 11.4 (THR rear) 28 13.2
L-155 24 11.4 su-170
L-l 72 27 12.8 (UR-170 rear) 43 20.3
M-172 27 12.8 SUHD
QT.140 24 11.4 (UHR rear) 28 13.2
Q-100 31 14.7 SW-170
Q-145 24 11.4 (WR-170 rear) 43 20.3
RL-170 46 22.7 RT-34-140
R-l 00 30 14.2 (RR-17-140) 35 16.9
R-140 28 13.2 RT-34-145
R-155 13.2 (RR-17-145 rear) 36 17.1
R-160 I: 13.2 RT-40-140
R-163 34 16.1 (RR-20-140) 35 16.9
R-l 70 43 20.3 RT-40-145
S-l 70 43 20.3 (RR-20-145 rear) 36 17.3
u-140 24 11.4 RT-44-145
u-170 43 20.3 (RR-22-145 rear) 35 16.9
W-l 70 43 20.3 RT-46-160
RS-13-120 15 7.2 (RR-23-160 rear) 43141 20.7119.5
RS-15-120 15 7.2 RT-52-160
RS-16-141 31 14.7 (RR-26-160 rear) 51 24.2
RS-17-140 32 15.4 RT-48-180
RS-17-141 31 14.7 (RR-24-180 rear) 39 18.6
RS-19-145 17.3 RT-52-180
RS-21-145 16.9 (RR-26-180 rear) 39 18.3
RS-23-160 43141 20.7119.5 RT-58-180
(RR-29-180 rear) 39 18.3
*Includes 1 pint (0.97 liter) for each wheel end and with drive
Intended for CLARKpinion
dealersangle
only at 3”. Page 63
Faste n er
TO
rque Info.
Torque Values for Fasteners Metric Fasteners
A. Measure the diameter of the threads in
General Information. millimeters (mm), dimension X. Figure 148.
1. The torque values in chart 7 are for fasteners that
have a light application of oil on the threads. Figure 148
2. If the fasteners are dry, increase the torque values
by ten percent (10%).
3. If the fasteners have a heavy application of oil on

the threads, decrease the torque values by ten
percent (10%).
4. If you do not know the size of the fastener that is

being installed, measure the fastener. Use the
following procedure.
American Standard Fasteners

A. Measure the diameter of the threads in inches,
dimension X. Figure 147.
Y I
Figure 147
I-4
X Dimension = (Example M8 or 8.mm)
Amount of Threads
in one inch. \ Y Dimension = Distance of IO Threads
B. Measure the distance of ten (10) threads, point

to point in millimeters (mm), dimension Y. Make
a note of dimension Y. Figure 148.
C. Divide dimension Y by ten (10). The result will

be the distance between two threads or pitch.
X Dimension = (Example l/2")

Example of a Metric size fastener is M 8 x 1.25.
The M 8 is the diameter of the fastener in millimeters
B. Count the amount of threads there are in one (mm) or dimension X.
inch (1.0 inch). Figure 147. The 1.25 is the distance between two threads or
pitch.
Example of an American Standard size fastener is
50 - 13.
The SO is the diameter of the fastener in inches or 5. Compare the size of fastener measured in step 4
dimension X. to the list of fasteners in chart 7 to find the correct
The 13 is the amount of threads in one inch (1.0 torque value.
inch).
Fastener s o
Torque Information.! 00
CHART 7
FASTENER TORQUE CHART
FASTENER THREAD TORQUE VALUE
SIZE lb-ft (N.m)
1. *Capscrew, Axle Shaft .31-24 18-24 (24-33)

so-13 85-115 (115156)
2. *Nut, Axle Shaft Stud PlainNut

.44-20 50-75 (68-102)
.50-20 75-115 (102-156)
.56-18 110-165 (149-224)
.62-18 150-230 (203-312)
Lock Nut
.44-20 40-65 (54-88)
.50-20 65-100 (88-136)
.56-18 loo-145 (136-197)
.62-18 130-190 (176-258)
* Some Rockwell carriers do not have the parts described.
‘s o Fastener
L
Q00 Torque Information
CHART 7 (Continued)
r FASTENER THREAD
SIZE
TORQUE VALUE
lb-ft (N.m)
3. Breather .38-l 8 20 minimum (27 minimum)
4. *Plug, Oil Fill (Housing) .75-l 4 35 minimum (47.5 minimun)
5. *Plug, Heat Indicator .50-l 4 25 minimum (34 minimum)

-
6. 1 Plug, Oil Drain .50-l 4 25 minimum (34 minimum)
7. Capscrew, Differential Case .38-l 6 35-50 (48-68)

.44-14 60-75 (81-102)
.50-l 3 85-115 (115-156)
.56-l 2 130-l 65 (176-224)
.62-l 1 180-230 (244-312)
Grade 10.9 Flange Head Ml2 x 1.75 85-l 03 (115-140)
Grade 10.9 Standard Hex Head Ml2 x 1.75 75-95 (100-130)
Grade 12.9 Standard Hex Head Ml2 x 1.75 105-125 (143-169)
Ml6 x 2 203-25 1 (275-340)
8. *Nut, Differential Case Bolt .50-l 3 75-100 (102-136)

.50-20 85-l 15 (115-156)
.62-l 1 150-l 90 (203-258)
.62-l 8 180-230 (244-312)
Ml2 x 1.75 74-96 (100-130)
9. *Nut, Ring Gear Bolt .50-l 3 75-l 00 (102-136)

.50-20 85-115 (115-l 56)
.62-l 1 150-190 (203-258)
.62-l 8 180-230
Ml2 x 1.25 66-81
Ml2 x 1.75 77-85
Flange Head Ml6 x 1.5 192-214 (260-290)
i Standard Hex Head Ml6 x 1.5 1go-225 (260-305)
10. Capscrew, Bearing Cap .56-l 2 110-145 (149-197)

.62-l 1 150-190 (203-258)
.75-l 0 270-350 (366-475)
.88-14 360-470 (488-637)
.88-9 425-550 (576-746)
Ml6 x 2 181-221 (245-300)
M20 x 2.5 347-43 1 (470-585)
M22 x 2.5 479-597 (650-810)
11. Nut, Housing to Carrier Stud -44-20 50-75 (68-l 02)

.50-20 75-115 (102-156)
.56-l 8 110-165 (149-224)
.62-18 150-230 (203-312)
12. Capscrew, Carrier to Housing .44-14 50-75 (68-l 02)

.50-13 75-l 15 (102-156)
.56-12 1 lo-165 (149-224)
.62-l 1 150-230 (203-312)
.75-l 0 270-400 (366-542)
Ml2 x 1.75 74-89 (100-120)
M16x2 181-221 (245-300)
Some Rockwell carriers do not have the parts described.
Fastener .E.o
Torque Information gE3
0
CHART 7 (Continued)
FASTENER THREAD TORQUE VALUE

SIZE lb-ft (N.m)
13. *Jam Nut, Thrust Screw .75-l 6 150-l 90 (203-258)

.88-l 4 150-300 (203-407)
1.12-16 150-l 90 (203-258)
M22 x 1.5 148-210 (200-285)
M30 x 1.5 236-295 (320-400)
14. Nut, Drive Pinion .88-20 200-275 (271-373)

1 .o-20 300-400 (407-542)
1.25-l 2 700-900 (949-l 220)
1.25-l 8 700-900 (949-l 220)
1.50-l 2 800-1100 (1085-1491)
1.50-l 8 800-1100 (1085-1491)
1.75-12 900-1200 (1220-1627)
M32 x 1.5 738-918 (1OOO- 1245)
M39 x 1.5 922-l 132 (1250-1535)
M45 x 1.5 996-1232 (1350-1670)
15. Capscrew, Bearing Cage .38-l 6 30-50 (41-68)

.44-l 4 50-75 (68-l 02)
.50-1.3 75-l 15 (102-156)
.56-l 2 11 O-165 (149-224)
.62-l 1 150-230 (203-312)
Ml2 x 1.75 74-96 (100-130)
16. *Plug, Oil Fill (Carrier) .75-l 4 25 minimum (34 minimum)

1.5-l 1.5 120 minimum (163 minimum)
M24 x 1.5 35 minimum (47 minimum)
17. * Capscrew, Lock Plate .31-18 20-30 (27-41)

M8 x 1.25 21-26 (28-35)
THE FOLLOWING FASTENERS AND TORQUE VALUES ARE FOR DIFF. LOCK CARRIERS ONLY
18. 1 Capscrew, Manual Actuation (Storage Position) 1 Ml0 x 1.5 1 15-25 (20-35) I
19. 1 Adapter, Air Cylinder Ml2 x 1.5 22-30 (30-40) I

20. 1 Capscrew, Air Cylinder Cover M6 x 1 7.4-8.9 (10-12) I
21. Capscrew/Plug, Air Cylinder Cover Ml0 x 1.5
(Operating Position) 15-25 (20-35)
(Storage Position) 15-25 (20-35)
22. Lock Nut, Sensor Switch Ml6 x 1 26-33 (35-45)
Some Rockwell carriers do not have the parts described.
v
s
0
.m
en 9 0 Adjustments and
Specifications
DRIVE PINION BEARINGS - PRELOAD PAGE
Specification: New bearings - 5 to 45 lb-in (.56 to 5.08 N.m) torque

Used bearings in good condition -
lo-30 lb-in (1.13 to 3.39 N.m) torque
31
Adjustment: Preload is controlled by the thickness of the spacer between bearings.
To increase preload install a thinner spacer
To decrease preload install a thicker spacer
DRIVE PINION - DEPTH IN CARRIER
Specification: Install the correct amount of shims between the bearing cage and carrier. To
calculate, use old shim pack thickness and new and old pinion cone numbers. 35-37
Adjustment: Change the thickness of the shim pack to get a good gear tooth contact pattern
HYPOID GEAR SET - TOOTH CONTACT PATTERNS (HAND ROLLED)
Specification: Conventional gear set -

Toward the toe of the gear tooth and in the center between the top and bottom of
the tooth
Generoid gear set -
Between the center and toe of the tooth and in the center between the top and
bottom of the tooth
Adjustment: Tooth contact patterns are controlled by the thickness of the shim pack between
the pinion bearing cage and carrier and by ring gear backlash
47-49
To move the contact pattern lower, decrease the thickness of the shim pack under
the pinion bearing cage
To move the contact pattern higher, increase the thickness of the shim pack under
the pinion bearing cage
To move the contact pattern toward the toe of the tooth decrease backlash of the
ring gear
To move the contact pattern toward the heel of the tooth increase backlash of the
ring gear
MAIN DIFFERENTIAL BEARINGS - PRELOAD
Specification: 15 to 35 lb-in (1.7 to 3.9 N.m) torque

OR
Expansion between bearing caps -
RS-140 and RS-145 carrier models - .003 to .009 inch (.08 to .22 mm) 43
All other carrier models - .006 to .013 inch (.15 to .33 mm)
Adjustment: Preload is controlled by tightening both adjusting rings after zero end play is
reached
Page 66
Adjustments and 5 0
Specifications 19
MAIN DIFFERENTIAL GEARS - ROTATING RESISTANCE PAGE
1 Specification: 50 lb-ft (68 N.m) torque applied to one side gear I 4’ I
RING GEAR - BACKLASH
Specification: Ring gears that have a pitch diameter of less than 17 inches (431.8 mm)
Range - .008 to .018 inch (.20 to .46 mm)
.012 inch (.30 mm) for a new gear set
Ring gears that have a pitch diameter of 17 inches (431.8 mm) or greater
Range - .OlO to .020 inch (.25 to 51 mm)
.015 inch (.38 mm) for a new gear set 45
Adjustment: Backlash is controlled by the position of the ring gear. Change backlash within
specifications to get a good tooth contact pattern.
To increase backlash, move the ring gear away from the drive pinion
To decrease backlash, move the ring gear toward the drive pinion
RING GEAR - RUNOUT
Specification: .008 inch (.20 mm) maximum
SENSOR SWITCH - INSTALLATION (CARRIERS WITH DIFF. LOCK ONLY)
Specification: Shift the differential to the locked position.

58
Tighten the sensor switch into the carrier until the test light comes on. Steps
Tighten the sensor switch one additional turn and tighten lock nut to correct torque 13&14
value.
SPIGOT BEARING - PEENING ON THE DRIVE PINION
Specification: Apply 3,000 kg (6,614 lb) load on a 10 mm or .375 inch ball.

2831
Peen the end of the drive pinion at a minimum of five points.
Softening of the pinion stem end by heating may be required. 30
THRUST SCREW OR THRUST BLOCK - CLEARANCE
Specification: .025 to .045 inch (-65 to 1.14 mm)

OR 50
Loosen the thrust screw l/2 turn after tightening the thrust screw, hand tight,
against the ring gear
Do not sell or distribute Page 69
GROUP 21
C500 Y 1809200-225S-225L-25OS-25OL-3OOS-3OOL-350
GROUP 2%PROP SHAFT
Prop Shaft Removal ........................................................ Section 2
Prop Shaft Overhaul ...................................................... Section 3
SM 575, July 97
‘ Copyrighted Material Prop Shaft
C500 Y2235 Group 21
SECTION I
TROUBLESHOOTING
SM575 Section Material

Copyrighted Tile Page July 97
1. Prop shaft bolts loose or 1. Inspect prop shaft bolts. If

damaged. damaged, replace. If loose,
tighten.
Excessive vibration.
2. Cross and bearing kit 2. Replace cross and bearing kit.
defective.
1. Prop shaft bolts loose or 1. Inspect prop shaft bolts. If

Thumping or banging damaged. damaged, replace. If loose,
noise when truck is tighten.
moving.
2. Cross and bearing kit 2. Replace cross and bearing kit.
defective.
Copyrighted
21-l-l Material
C500 Y2235 Group 21
SECTION 2
PROPSHAFT REMOVAL
Section Tile Page
ElfIRK Group 21, Prop Shaft
PROP SHAFT REMOVAL
1. Park truck on level surface and set parking brake. 5. Compress the spline assembly into the prop shaft
yoke assembly to remove prop shaft assembly from
2. Remove floor plates as shown. truck.
Note: Refer to Group 21, Section 3 for information
3. Remove capscrews and disconnect prop shaft on how to overhaul prop shaft.
assembly from companion flange of transmission.
6. When reinstalling prop shaft assembly, torque
4. Remove capscrews and disconnect prop shaft the mounting bolts to 90 - 100 Ibf-ft [122 - 135 Nom].
assembly from companion flange of drive axle.
SM 575, July 9
‘7 Copyrighted Material Prop Shaft Removal l 21-2-1
C500 Y2235 Group 21
SECTION 3
PROP SHAFT OVERHAUL
SM575 Section Title

Copyrighted Page
Material July 97
ElfWIt Group 21, Prop Shaft
UNIVERSAL JOINTS
INSPECTION, INSTALLATION AND REPLACEMENT TIPS
CROSS AND BEARING ASSEMBLY GREASE\F’TT’NG
CROSS AND BEARING ASSEMBLY /i. u)‘“;I -I$$

DUST CAP
GREASE FITTING
FELT SEAL I
YOKE AND SPLINE ASSEMBLY
SEAL RETAINER
SLIP YOKE ASSEMBLY
LOCKWASHER
4. Unscrew and remove dust cap. Remove seal
BOLT retainers and felt seals. Examine for serviceability. If
worn, replace with new.
Installation of a propeller shaft offers no serious me-
chanical problem. However, the following checks should 5. Separate the slip yoke and yoke and spline assem-
be made to insure satisfactory operation. blies but do not remove the cross and bearing assem-
blies at this time. Check the cross and bearing assem-
1. Wash all parts thoroughly in a Stoddard type blies for looseness. Because they are sealed units and
cleaning solvent. the condition of the cross and bearing cannot be easily
ascertained, temporarily reinstall each assembly in
2. Inspect the condition of the outer surfaces of the turn on the engine or transmission flange to check the
prop shaft assembly. No dents or other damage on condition of the center cross assembly. If a particular
shaft tubing should be allowed as these will tend to joint seems loose or flexes too freely, it should be
cause unbalance to the drive line. If severe enough, discarded due to the resulting unbalanced condition
these faults could very easily weaken the drive line to this may set up.
the point of failure under the normal operating load.
6. If required, replace the cross and bearing assembly
3. Slide the spline and sleeve yoke assemblies in and which can only be replaced as a unit. The cross and
out to check the condition of the spline. The splines on bearings cannot be replaced individually. Use the new
bothmatingfittingsshouldslidefreelywithaslight drag bolts provided to install the placement unit and torque
from the spline seal. Check the seal cap for damage. to 65 - 75 Ibf-ft [88 - lOZN=m].
If damaged, replace with new. Check the shaft for NOTE: All bolts used to assemble and mount the prop
twisting. If twisted, replace with new. shaft are grade eight. Never substitute bolts of lesser
grade.
SM 575, July 9
‘7 Prop Shaft Overhaul l 21-3-l
GROUP 22
C500 Y 18092009225S-225L-25OS-25OL-3OOS-3OOL-350
GROUP 22-WHEELS AND TIRES
Lifting, Jacking and Blocking ........................................ Section 1
Wheel and Tire Mounting .............................................. Section 2
Safe Handling of Multi-piece Rim Wheels ................... Section 3
SM 575, July 9
‘7 Copyrighted Material Wheels and Tires
C500 Y2235 Group 22
SECTION I
LIFTING, JACKING AND BLOCKING
Section Tile Page
ClRRK Group 22, Wheels and Tires
LIFTING, JACKING AND BLOCKING
Lifting or jacking any large piece of equipment such as

your fork truck presents obvious hazards. It must be
done with great care and forethought Consult the
truckweight tabulations in the Specifications Section of
this manual to ensure that your lifting equipment is of
adequate capacity. I
2. The rear of the truck may be lifted by the counter-

weight as shown. Chock the drive wheels before lifting
and be sure lifting equipment is of adequate capacity.
A WARNING
Check to see if the counterweight bolt
is in place and properly torqued before
lifting. Never attempt to lift the rear of
the truck with another fork truck.
1. The proper way to lift the front of the truck is by

rigging a chain fall or hoist to the upright as shown.
Chock the steer wheels before lifting. Place wheel
stands under the drive tires or solid blocking under the
base of the upright rails.
A WARNING
The Upright should be fully down be-
fore lifting.On uprights with negative
drop such as Marina trucks, clamp or
3. Place wheel stands under the steer tires as shown
chain the rails together so they cannot
or put solid blocking under the truck frame.
move.
If at all possible, remove the forks be- A WARNING

Takecaretoplaceblockuntertheframe
fore lifting the upright.
back far enough from the truck center
of gravity so that it is stably supported.
SM 575, July 9
‘7 Copyrighted Material Lifting, Jacking and Blocking l 22-l-l
C500 Y2235 Group 22
SECTION 2
WHEEL AND TIRE MOUNTING

ClRRK Group 22, Wheels and Tires
WHEEL AND TIRE MOUNTING
FOR DIRECTIONAL TREADS ONLY 3. Final torque all clamps in sequence shown to 190
- 210 Ibf-ft [257.4 - 284.5 Nom]. Do not over torque or
retorque after the above values have been achieved.
4. Step three must be repeated after truck has been

in service for one hour.
STEER DRIVE
STEER WHEEL RIM CLAMPING PROCEDURE
For 5/ ” Studs
4
1. Looking at top of tire when mounted on the truck.

Inside dual and steer tire are mounted with “V” pointing
forward. Outer dual has “V” pointing in the opposite
direction.
CLARK-HURTHDRIVE WHEEL RIM CLAMPING

PROCEDURE
1 3
2
1. Tire off floor for steps two and three.
2. Secure clamps evenly in position and draw up nuts

10 7 alternately in the sequence shown. Do not tighten
them to full torque. This permits rims to properly seat
on the bevel. Suggested pre-torque for step two: 40 -
60 Ibf-ft [54.3 - 81.3 Nom].
8 9
3. Final torque all clamps in sequence shown to 100
- 120 Ibf-ft [135.6 - 162.7 N=m]. Do not over torque or
retorque after the above values have been achieved.
4. Step three must be repeated after truck has been

4 in service for one hour.
1. Tire off floor fro steps two and three.
NOTE
2. Secure clamps evenly in position and draw up nuts This page covers all steer wheels and
alternately in the sequence shown. Do not tighten drive wheels used prior to lot 8518. For
them to full torque. This permits rims to properly seat drivewheelsusedonlot8518andabove
on bevel. Suggested pre-torque for steptwo: 100 - 150 on the Rockwell axle see the next page.
Ibf-f-t[135.6 - 203.4 N-m].
SM 575, July 9
‘7 Copyrighted Material Wheel and Tire Mounting l 22-2-l
Group 22, Wheels and Tires ClRRK
STEER WHEEL RIM CLAMPING PROCEDURE

For 3/4’* Studs
6 5
1. Tire off floor for steps 2 and 3.
2. Secure clamps evenly in position and draw up nuts

alternately inthe sequence shown. Do not tighten them
to full torque. This permits rims to properly seat on the
bevel. Suggersted pre-torque for step 2: 135 - 203 Nom
[lo0 - 150 Ibf-ft).
3. Final torque all clamps in sequence shown to 258

- 285 Nom [190 - 210 Ibf-ft]. Do not over torque or re-
torque after the avoce values have been achieved.
NOTE
This page covers all steer wheels and
drive wheels used prior to lot 8518. For
drivewheelsusedonlot8518andabove
on the Rockwell axle see the next page.
22-2-2 l Wheel and Tire Mounting Copyrighted Material SM 575, July 97

‘
ClZllW Group 22, Wheels and Tires
Rockwell Axle Wheels and Tires
Drive Wheel Torque Procedure

Tighten lug nuts to 50 Ibs-ft IN THE RECOM-
MENDED SEQUENCE SHOWN.
Continue to tighten all nuts in the same sequence.
Torque to 450-560 Ibf-ft (610-759 N’m).
Drive Axle End View
SM 575, July 9
‘7 Copyrighted Material Wheel and Tire Mounting l 22-2-3
C500 Y2235 Group 22
SECTION 3
SAFE HANDLING OF MULTI-PIECE RIM
WHEELS
Copyrighted
Section Material
Tile Page
ClflRU Group 22, Wheels and Tires
SAFE HANDLING OF MULTI-PIECE RIM WHEELS
A DANGER
For Your Safety and the Safety of Others
Before you do tire or rim maintenance,
read the OSHA rules regarding user
responsibility. Do not work on tires or
rims unless you have been trained in
the correct procedures. Read and un-
derstand all maintenance and repair
procedures on tires and rims. serious
injury or death can result if the safety
messages are ignored.
2. Check wheels and tires for damage every time you

“The Occupational Safety and Health Act (OSHA) check tire pressure. Make repairs when needed. Dirt
specifies required procedures for servicing multi-piece can get into cuts and cause damage to the tire tread.
rim wheels in 29 CFR Section 1910.177. It is the Remove debris from all cuts.
owners responsibility to comply with OSHA.
In accordance with OSHA, the owner must provide a

training program to train and instruct all employees
A WARNING
Before you loosen the wheel mounting
who service multi-piece rim wheels in the hazards
bolts or nuts, remove the air from the
involved and the safety procedures to be followed. Do
tire. Failure to remove the air from the
not let anyone mount, demount or service multi-piece
tire can result in injury.
rim wheels without correct training.
The owner should obtain and maintain in the service

areacurrent copies of the United States Department of
Transportation, National Highway Traffic Safety Ad-
ministration publications entitled Safety
‘ Precautions
for Mount and Demounting Tube-TypeTruckIBusTires’
and “Multi-Piece Rim/Wheel Matching Chart’ or other
similar publications applicable to the types of multi-
piece rim wheels being serviced.
The following instructions supplement the OSHA re-

quirements. In the event of any conflict or inconsis-
tency between these instructions and the OSHA re-
quirements, the OSHA requirements shall be control-
lina.
3. Remove valve core from valve stem.
4. After you remove air from the tire, then loosen and
remove the wheel bolts or nuts.
5. Remove the wheel.
1. When checking tire pressure always use a long

handled tire gauge and stay to one side.
SM 575, July 9
‘7 Copyrighted Material
Safe Handling of Split Rim Wheels l 22-3-i
Group 22, Wheels and Tires CIRRK
6. Remove lock ring. Remove wheel wedge. Re- 9. Check for cracks in the lock ring.
move tire from wheel. Cracks in the lock ring are caused by:
A. Deep rim tool marks.
B. Too much load on wheels.
C. Too much air pressure in the tires.
D. Using the wrong size tires.
7. Remove the rubber tube protector (flap). Repair

tire or tube as required.
10. Check for cracks between the stud holes in the

wheel disc.
Cracks are caused by:
A. Loose wheel lug nuts or bolts.
B. The wheel is not installed correctly.
C. The wrong size or type of parts were used.
If the wheel mounting parts are too tight, the studs or

bolts can break, causing cracks in the wheel disc
between the stud holes.
8. Check for cracks in the wheel. If the wheel mounting parts are too loose, damage to
Cracks in the wheel are caused by: parts and tire wear will result.
A. Deep rim tool marks.
B. Too much load on wheels.
C. Too much air pressure in the tires.
D. Using the wrong size tires.
22-3-2 l Safe Handling of Split Rim Wheels SM 575, July 9
‘7
ElfIRK Group 22, Wheels and Tires
11. Check wedge ring for wear or damage.
A CAUTION
Too much corrosion will cause wear
14. Clean wedge and lock rinos. Make sure the
seating surface&d bead seat areas are clean.
and damage to the wheel

wedge ring.
15. Apply paint to the tire rim with a brush or use an

aerosol can of metal primer.
12. Clean the wheels. Remove rust and dirt.
The parts must be clean and dry before you apply the
paint. Make sure to apply paint to the outside or tire
side of the rim. This is important because air is on the
metal surface of the tire side of the rim.
After the paint has thoroughly dried, apply lubricant on

the tire side of the rim base. Do not use a lubricant that
has water or solvent which will cause damage to the
rubber.
NOTE: Your Clark dealer can supply the correct lubri-
cant which contains a rust inhibitor.
13. Clean the tire bead seat area. Remove all rust and
rubber
SM 575, July 97
‘ Safe Handling of Split Rim Wheels l 22-3-
Group 22, Wheels and Tires ClRRU
_’
::
16. Put the tube into the tire. Put the rubber tube
protector (flap) over the tube. 19. Install the wheel wedge.
17. Install the tire onto the wheel rim, against the bead
seat areas.
20. Put the side ring over the rim and install the lock
ring as shown.
21. Connect air chuck and turn tire over with the valve
18. Put the wheel wedge over the rim. stem down. Put 3 P.S.I. [21 kPa] of air into tire.
22-3-4 l
Safe Handling of Split Rim Wheels SM 575, July 97
‘
EMRlC Group 22, Wheels and Tires
22. Turn wheel to other-side. Check to make sure lock

ring is in correct location.
24. Put the tire in an OSHA approved safety cage.

Follow the procedures on the next two pages whenyou
put air into your tires. If your air supply does not have
enough pressure to fill the tire, 100 P.S.I. [689.5 kPa],
to fill the tire, you can use a nitrogen cylinder to get the
correct tire pressure. Connect a nitrogen cylinder to
the valve stem with the use of an air chuck. TIRE IS
STILL IN SAFETY CAGE! Refer to pages 8 and 9 on
“How to adjust the regulator on the nitrogen cylinder”.
23. Use a mallet and hit the ring to make sure it isfully
installed.
A WARNING
Make sure the equipment used (nitro-
gen cylinder, gauges, regulator, hoses)
Disconnect the air chuck. are all in good condition. Make sure the
equipment is UL approved. Use the
correct regulator and hose for the pres-
sures that are necessary.
Use nitrogen only. Do not use oxygen

or any other gas to fill tires.
SM 575, July 9
Safe Handling of Split Rim Wheels . 22-3-5
Group 22, Wheels and Tires CWRK
TYPICAL TIRE FILLING PROCEDURE
SAFETY
GAUGE i
SHUTOFF
SING
IG
OF AIR
SUPPLY
Filling Tires With Air

All wheel and tire assemblies MUST be filled in a safety 3. At intervals, close the control valve and check the
cage. The air hose and components should be ar- pressure in the tire by reading the gauge. Do not put
ranged as shown. The hose must have an adapterthat too much pressure into the tire.
can be connected to the valve stem.
4. Continue to fill the tire to the correct capacity.
A
1. Attach an air hose to valve stem.
CAUTION
2. Open the control valve which will let compressed Put equal air pressure in both tires
air into the tire. of a dual assembly. Do not
put air into a tire that is
flat with first inspecting
it and wheel for damage.
22-3. l Safe Handling of Split Rim WheelsCopyrighted Material SM 575, July 9

‘7
CUWK Group 22, Wheels and Tires
RELIEF VALVE
MODEL 250V
l/Cinch NPT [6.35 mm] SAFETY CAGE
HUMPREY PRODUCTS (OSHA APPROVED)
P.O. BOX 2009 MEYERS TIRE SUPPLIES
KILGORE AT SPRINKLE ROAD 6400 EPWORTH BLVD
KALAMAZOO, MICHIGAN DETROIT, MICHIGAN
AIR PRESSURE GAUGE

MARSHALTOWN #23
160 P.S.I. [i ,103 kPa]
2.50 inch [63.5 mm] diameter
\
SHUT-OFF CONTROL
IMPERIAL #77E
l/4 [6.35mm] inch NPT
CLIP-ON AIR CHUCK
EQUIPMENT SOURCES LISTED FOR CONVIENCE ONLY. MAY BE OBTAINED FROM ANY REPUTABLE
SUPPLIER.
SM 575, July 97
‘
Safe Handling of Split Rim Wheels l 22-3-7
Group 22, Wheels and Tires elmu
How to Adust the Regulator On the Compressed Air Cylinder
1. Be sure cylinder is closed. Turn the regulator valve

counterclockwise until you can feel no resistance from
the regulator. This will adjust the regulator to a low 4. Turn the regulator valve clockwise until the regula-
pressure near zero. tor gauge reads the correct tire pressure. Fill the tire
with air.
1 Lx
2. Slowly turn the cylinder valve counterclockwise to
open position.
5. Turn the tankvalve clockwise and close the valve.
3. The tank gauge will now show tank pressure.
22-3-8 l
Safe Handling of Split Rim Wheels SM 575, July 97
‘
CMRU Group 22, Wheels and Tires
A WARNING
Use a long handled gauge so that your
hand does not go inside the cage or in
front of any component of a multipiece
wheel.
A soft tire on a truck (below 80 P.S.I. 1551.6 kPa]),

should always be completely deflated, removed from
the truck and placed in a safety cage for reinflation,
However, if it becomes absolutely necessary to add air
to a tire on the truck, the method illustrated below is the
safest way of doing so. Do this only in an area where
no other personnel could be struck by a flying lock ring.
A WARNING
Before you add air pressure to the tire,
make sure the lock ring is correctly
positioned in the rim and side ring. The
lock right can separate from the rim
with enough force to cause injury or
death.
6. Disconnect the air chuck from the valve stem.
Put a clip-on type air chuck on the compressed air

cylinder hose and attach it to the valve stem. Follow the
procedures previously outlined for adjustment of the
compressed air cylinder valves.
A
7. Turn the regulator valve counterclockwise to the
off position. WARNING
Use compressed air or nigrogen only
Use a tire pressure gauge to check the tire pressure.
to fill the tire. Do not use oxygen or
THE TIRE IS STILL IN THE SAFETY CAGE! If
other gas.
necessary, put more air into the tire. Do this as many
times as necessary to reach the correct tire pressure. *
SM 575, July 9
Safe Handling of Split Rim Wheels . 22-3-9
GROUP 23
C500 Y 1809200-225S-225L-25OS-25OL-3OOS-3OOL-350
GROUP 23-PARKING BRAKE
Mechanical Release of Parking Brake .......................... Section 2
SM 575, July 97
‘ Copyrighted Material Parking Brake
C500 Y2235 Group 23
SECTION I
TROUBLESHOOTING
Copyrighted
Section Material
Tile Page
Truck will not move

when shifted into gear 1. Parking brake set. 1. Release parking brake.
I
with engine running.
1. Air tank drain valve open. 1. Close air valve.

Parking brake will not
2. Air line broken or leaking. 2. Repair or replace air line.
release (no air pres-
3. Air governor defective. 3. Replace governor.
sure).
4. Air compressor defective. 4. Replace air compressor.
1. Lack of lubrication. 1. Lubricate slack adjusters and

brake cam shafts.
2. Service brake side of brake 2. Repair or replace brake
chamber sticking. chamber.
3. Brake chamber sticking due to 3. Clean brake chamber and
dirty or corroded linkage. brake linkage.
4. Broken brake shoe return 4. Replace spring.
spring.
5. Parking brake valve stuck on. 5. Repair or replace parking
brake valve.
C5OOY2235 Group23
SECTION 2
MECHANICAL RELEASE
OF PARKING BRAKE
Section Title Page
Group 23, Parking Brake
MECHANICAL RELEASE OF PARKING BRAKE

The air brake system on your truck is controled by a 3. Remove end-cover cap from center hole in head
pair of dual air brake chambers. Each chamber has a of brake chamber.
service brakesectionandaparkingbrakesection. The
service brake section expands the service brake shoes
in the wheels when air pressure is applied. The 4. Using a 3/4 inch wrench, unscrew release nut, flat
parking brake section is spring loaded “Automatic washer and release bolt from their storage pocket on
On’. It releases the wheel brake shoes when air side of brake chamber.
pressure is applied and expands them when air pres-
sure is absent by means of its internal spring. Thus, to
release the air brake for either removal of the brake
chamber assemblies or to tow the truck that lacks air
pressure, it is necessary to mechanically release the
parking brake. This is done in the following manner.
1. If possible, truck should be on a level, paved

surface. Chock all four wheels.
5. Insert release bolt into center hole of head and,

being sure formed end of bolt has entered hole in
piston inside the chamber, continue to insert bolt until
it bottoms out.
A CAUTION
2. Access to the brake chambers is most easily done If you are not absolutely sure of correct
frombeneaththe truck. Ifthis isnotpossible, theycan bolt-to-piston engagement, repeat this
step until you are sure.
be accessed from above after removing the floor
6. Turn release bolt 114turn clockwise and pull out

to lock formed end into position.
A CAUTION
If bolt does not lock into position in less
than a l/2 inch outward movement,
repeat steps 5 and 6 until you are sure it
does lock.
SM 575, July 9
‘7 Copyrighted Material Mechanical Release of Parking Brake . 23-2-l
Group 23, Parking Brake
7. Holdingboltlockedintopiston,installflatwasher
and release nut onto release bolt and turn down nut
against flat washer until finger tight.
8. Usinga3/4inchhandwrench@ONOTUSEAN
IMPACT WRENCH), turn release nut clockwise
until three inches of bolt extends above the nut as
shown. (A three inch wide strip of paper can be rolled
up and taped to use to measure the exposed bolt).
9. Toreac tivate the piggyback/spring brake from its

manually released position, reverse the order of steps
3 through 8.
10. Reinstall the release bolt, flat washer and release

nut into the storage pocket using 10 lbs-ft torque on
nut against the flat washer.
23-2-2 Copyrighted Material

. Mechanical Release of Parking Brake SM 575, July 97
‘
GROUP 24
C500 Y 180-2009225S-225L-2505925OL-3OOS-3OOL-350
GROUP 24-SERVICE BRAKE
Air Brake System ............................................................ Section 2
Air Brake Treadle Valve ................................................. Section 3
Air Brake Chambers ....................................................... Section4
Air Brake Compressor ................................................... Section 5
Rockwell Cam Brakes .................................................... Section 6
SM 575, July 97
‘ Copyrighted Material Service Brake
C500 Y2235 Group 24
SECTION I
TROUBLESHOOTING
Section Title Page
1. Air tank drain valve open. 1. Close drain valve.

No air pressure. 2. Air line broken or leaking. _ 2. Repair or replace air line.
3. Air governor defective. 3. Replace governor.
4. Air compressor defective. 4. Replace air compressor. I
I
1. System leakage. 1. Check all lines and connec-
IAir compressor fails to

maintain system. t-
2. Water in air tank.
tions for leaks. Tighten or
replace.
2. Drain water from tank.
3. Air compressor defective. 3. Replace air compressor.
, 1 ,
1. Fuse defective. 1. Replace fuse.
ILow pressure warning

buzzer not functioning.
2.
3.
4.
Buzzer defective.
Air pressure switch defective.
Wiring defective.
2.
3.
4.
Replace
Replace
Replace
buzzer.
air pressure switch.
defective section of
wirinn
E
1. Brake pads worn. 1. Replace brake pads.
I No brakes. 1
2. Defective brake valve c 2. Repair or replace brake valve
assembly. assembly.
I
1. Brake pedal linkage defective. 1. Repair or replace linkage.

Brake pedal hard to
2. Defective brake valve - 2. Repair or replace brake valve
compress.
assembly. assembly.
H
I 1. Low air Pressure. I 1 1. Check air reservoir pressure.
If low, check for system leak-
1 Excessive pedal travel. I- age. Repair any leaks.
2. Normal brake wear. 2. Adiust brakes or replace pads.
a
I I I
1. Incorrect brake adjustment or 1. Adjust brakes or replace pads.

worn pads.
2. Brake chamber defective. 2. Repair or replace brake
I 1
I chamber.
Copyrighted Material July 97

1. Lack of lubrication. 1. Lubricate slack adjusters and

brake cam shafts.
2. Brake chamber sticking. 2. Repair or replace brake
chamber.
3. Brake chamber sticking due to 3. Clean brake chamber and
Brakes do not release. -
dirty or corroded linkage. brake linkage.
4. Broken brake shoe return 4. Replace spring.
spring.
5. Parking brake valve stuck on. 5. Repair or replace parking
brake valve.
6. Air brake valve defective. 6. Repair or replace air brake
valve.
1. Brake shoe anchor pin tight in 1. Free up and lubricate pin.

shoe.
2. Weak or broken brake shoe 2. Replace spring.
return spring.
3. lnsuff icient brake shoe return 3. Adjust brakes.
clearance.
4. Loose brake spider. 4. Tighten brake spider.
5. Dirt embedded in brake linings. 5. Clean and replace linings.
6. Brake drums scored. 6. Repair or replace brake
drums.
Truck “creeps” in gear 1. Replace brake pads.

1. Brake pads worn.
with brake pedal - 2. Repair or replace air brake
2. Air brake valve defective.
depressed. valve.
July 97 Copyrighted
24-l Material
-2 SM575
C500 Y2235 Group 24
SECTION 2
AIR BRAKE SYSTEM

Group 24, Service Brakes ElmK
Section 2
Air Brake System
Park and Emergency Brake Valve -I __,,,,,.
Air Tank
.4--_
&?. Air 0,.
Pressure
.-A
- H’r urYer “!
.:,:.
~ Air Relay Valve : .‘.: .,
..‘ __
...$J.$ ..,,,,_,
::(
$
*
m<
,,
- R.H. Brake Pedal

Treadle Valve
L L.H. Brake Pedal
Treadle Valve Typical Illustration
Copyrighted Material Air Brake System . 24-2-l

SM 575, July 97
‘
Group 24, Service Brakes
InchingCycle
With L.H. Brake Pedal partially depressed, the Transmission Inching
Valve Actuates and theTransmission Pressure Plates partially disengage.
The truck can be inched forward at increased engine RPM providing
additional power for hydraulic functions..
ency
rol
I
Left .. I E- ::. Right

Brake
Chamber
I I : .. .. I I I ’
w
/
.’‘
Pressure
y;;phg
-- ______
y..-____
r -----~---p----l~---&--~ R
v
I I
Ij 0”
Plug
’ 0 n--Plug I
“’ “’
I
u
Epg’ I I ,L(‘,
I I
l- ----- ---
Bra$Fzdal
1
Hyr L&es
dy
Air Lines Used
ncmy v a vc
to perform
Inching Function
Transmission Inching Valve
24-2-2 l Air Brake System Copyrighted Material SM 575, July 97

‘
lnchmg Cycle Completed, Brakmg Yrovided

Further depression of the L.H. Brake Pedal stops the Inching Cycle and
provides normal braking operation. The Relay Valve operates allowing
the Transrnission Pressure Plates to fully disengage.
..’ ”
r
I
I
I
I
L -----
HE!? ,cFt;es
J
Air Lines Used
to perform
.:. Braking Function
e
SM 575, July 9
‘7 Copyrighted Material Air Brake System l 24-2-3
R. H. Brake Pedal Operation ., ..”

Airwytr{er
The R.H. Brake Pedal is used for normal brake operation. ;;,:
,I..
‘ “.’
Safet Valve
n (OptYonal)
---L+-
r
_--_
Heav Lines
IndYcate
Air Lines Used
to net-form
I
Transrnissio~ inching Valve

‘7
r
Air Dryer (with Safety Valve)
(Optional)
Air
Compressor
Inlet
/
Air Reservoir R.H. Service Brake Pedal

(Treadle Valve)
n
Plug
Air Pressure JL ..
R.H.
Brake
Chamber
\ cz DeClutch Cylinder
Outlet (Trans. Control Cover)
Switch
inlet Outlet
) _I
Quick
& Release
Emergency Valve
Brake
Control L.H. inching
Valve &
Service Brake Pedal \
(Treadle Valve)
\-2%5-j
SM 575, July 97
‘ Copyrighted Material Air Brake System - 24-2-5
Air Intake (Air Cleaner)
Inlet
24-2-6 Air Brake System

l Copyrighted Material SM 575, July 97
‘
Group 24, Service Brakes ElIIRK
“Park”
Emergency
Brake Valve
L.H. Brake
-rOafib V&/P Quick Release Valve
Valve 8’ Brake-d
Inching Valve,S.Z-“-*’
(Transmission Conrtol Cover)
L Air Compressor & Governor
l Low Air Pressure Warning Control
Typical lllustratiol
SM 575, July 97
‘ Copyrighted Material Air Brake System l 24-2-7
pical Illustration

‘7
C5OOY2235 Group 24
SECTION 3
AIR BRAKE TREADLE VALVE
SM575 Copyrighted
Section Material
Tile Page July 97
Group 24, Service Brake
Section 3
Air Brake Treadle Valve
Valve Actuator
Mounting Flange
Treadle Valve
SM 575, July 9
‘7 Copyrighted Material Air Brake Treadle Valve l 24-3-l
Group 24, Service Brake CUIRK
-6
8
12
602-
Typical illustration
24-3-2 l Air Brake Treadle Valve SM 575, July 97
‘
ClflRK Group 24, Service Brake
Disassembly found on mating surfaces. Do not use emery cloth

or files. Be sure all parts are clean and dry. Parts
1. Place valve assembly in padded vise with may be cleaned in a Stoddard type cleaning solvent
retainer ring (1) facing up. and wiped dry with a clean cloth.
A WARNING A WARNING
Internal components are When using air pressure to
under approximately 50 dry parts, wear eye protection
pounds of spring pressure. and protective clothing.
When disassembling allow Reduce air pressure to 30 PSI
parts to separate slowly. (207 kPa). Debris removed
with air pressure can cause
2. Remove retainer ring (1) and remove valve
injury.
assembly. Allow parts to separate slowly.
3. Remove and discard preformed packing (7) A CAUTION
seat (6). Cleanliness is of extreme
importance. Be certain all
4. Remove caps crew (2), bevel washer (3), and parts areciean and dry before
diaphragm (4). reassembly.
5. While depressing valve seat (6), remove spring
(5). Reassembly
6. Separate valve seat (6) from valve inlet (11) 1. Using Dow Coming 55-M pneumatic grease
and remove preformed packing (9) and spring (or equivalent), coat piston bores, metal-to-
(8). Discard preformed packing. metal moving surfaces, and all preformed
packings.
7. Remove valve retainer (10).
2. Place body (20) in padded vise with retainer
A WARNING
ring (1) groove faced downward.
Internal components are
under approximately 50 3. Install spacer (16), spring seat (15), washer
pounds of spring pressure. (14) and capscrew (13) on piston (18). Torque
When disassembling allow capscrew to 50 lb. in. (5.7 N*m).
parts to separate slowly.
4. Install preformed packing (17) on piston (18),
8. Depress piston assembly and remove retainer then place spring (19) and piston body (20).
(12). Allow parts to separate slowly.
A WARNING
9. Remove piston assembly and spring ( 19) from Internal spring pressure
body (20). generates 50 pounds of force
during assembly. Be sure
10. Remove and discard preformed packing (17)
retainers or retaining rings
from piston (18). are seated correctly before
11. Remove capscrew (13), washer (14), spring releasing pressure on spring.
seat (15), and spacer (16) from piston (18).
5. While depressing piston (18) install retainer
(12) on valve body (20) making sure that
Cleaning & Inspection prongs snap over groove.
Check parts for nicks, burrs, or scratches. If found,
6. Install spring (5), diaphragm (4), washer (3),
replace part with new. Old packings should be and capscrew (2) in valve seat (6).
discarded and new ones installed in theirplace. Use
acrocus cloth toremove any burrs, nicks or scratches 7. Install preformed packing (9) and valve re-
tainer (10) on valve inlet (11).
SM 575, July 97
‘ Intended for CLARK dealers only Air Brake Treadle Valve l 24-3-3
Group 24, Service Brake C1RRU
24-3-4 l Air Brake Treadle Valve SM 575, July 97
‘
CIRRK Group 24, Service Brake
8. Install spring (8) and valve inlet (11) on valve
seat (6).
9. Compress valve inlet (11) and valve seat (6)
until spring (5) snaps and holds the assembly
together.
10. Install preformed packing (7) on valve seat
(6).
11. Place valve assembly in body (20).
A CAUTION
Internal spring pressure
generates 50 pounds of force
during assembly. Be sure
retainers or retaining rings
are seated correctly before
releasing pressureon spring.
12. Depress valve assembly, and install retaining

ring (1) making sure that ring snaps in groove.
SM 575, July 97
‘ Air Brake Treadle Valve l 24-3-5
C500 Y2235 Group 24
SECTION 4
AIR BRAKE CHAMBERS
SM575 Section Tile

Copyrighted Page
Material July 97
CMRK Group 24, Service Brake
Section 4
Air Brake Chambers
Typical Illustrations
Pisb
Nav
Maintenance of the Air Brake Chambers

1. Check to be sure the End Cover Cap is securely in place, and replace with a new one at once if
damaged or missing.
A WARNING
Do not work on the brake chambers while they are in the truck. Do not remove Clamp Rings
(A & B) for any purpose at any time, as serious injury may result from sudden release of the
power spring. Follow the instructions outlined in Group 23, Section 2 and remove the brake
chambers for service.
2. Inspect Upper Clamp Rings (A&B) to be sure it is securely in place and damage-free. If any damage
is seen or suspected, the chamber must be removed and serviced in this manual.
3. Inspect all exterior surfaces for signs of damage, corrosion and/or rust. If any of these are seen or
suspected, cautiously remove complete assembly for service.
4. Check tightness of Hex Nuts (C) on mounting bolts. Refer to following page for torque specifica-
tions.
5. Inspect air lines, hose and fittings attached to chamber. Replace any damaged or leaking parts.
6. Inspect Piston Rod to be sure it is working free, not bent, binding or misaligned to chamber bottom
by more than +/-3” in any direction. If misalignment is seen, make corrections by repositioning
chamber on mounting bracket and/or by shimming slack adjuster to the right or left on camshaft.
7. Inspect Yoke Assembly being sure the Yoke Pin is present and locked into place with Cotter Pin.
Replace any damaged, worn or missing parts. Be certain Yoke Jam Nut is tightened securely.
8. Inspect the External Breather Tube to be sure both flexible Elbows are in place. The connector tube
should be engaged into each elbow a minimum of l/2-inch.
SM 575, July 97
‘ Copyrighted Material Air Brake Chambers l 24-4-l
Group 24, Service Brake C1RRU
ind Cap -
4 A WARNING AWARNING
Do not remove this “%mOWt3
LOADED””
clamp. Chamber is To manually release brake:
Refer to Group 23, Section 2
“Mechanicaly Releasing Brake”
Rekease Bolt -\ Nut & Washer
S3-40 N-m
I
vlaximum) Diaphragm
Piston & Rod

Assembly
L Chamber
Service
Assembly
Jam Nut-
Torque L Torque NOTE
25-35 Ib.ft. 100-l 15 Ib.ft.
(33-47 N-m) (135156 Nom) Donotinstallflatwasherbetween
Yoke chamber and mounting bracket.
Cut-A-Way
Typical Illustration Typical Illustration
24-4-2 l Air Brake Chambers Copyrighted Material SM 575, July 97

‘
ClRRlc Group 24, Service Brake
Spring Release Bolt bolt fully engages piston. Repeat

procedure in you are unsure.
Illustrated procedures are listed
in Group 23, Section 2,
“Mechanically Releasing
Brake”.
/ r Breather Tube \
Insert formed end of release bolt through

access hole in upper chamber and completely
into piston until bolt bottoms out.
NOTE
Be certain bolt locks into piston
with less than 0.5” (12.7 mm) of
outward movement. Repeat bolt
locking procedure until you are
certain bolt has locked in place.
Rotate release bolt 114 turn clockwise and

pull outward until formed end engages pis-
for ton.
(Spring Release Bolt)
Hold the release bolt in position and hand-
rypical Illustration thread washer and nut onto bolt until seated
Chamber Service against top of chamber.
Move truck to a flat level surface. Fully lower

A CAUTION
Do not allow more than 3.00”
carriage. Shut engine down. Chock front and rear
(76.2 mm) of release bolt
of drive axle wheels. Attach warning tags to steer-
threads to extend beyond nut
ing hand wheel stating “Brakes are inoperative. Do and/or an excess of 50 Ib.ft.
not start engine or operate truck” (68 N-m) torque on nut at any
A WARNING time. Internal damage can
occur preventing correct
Depressurize air system before release of spring brake
disconnecting or removing any chamber.
part of the air brake system. Se-
vere injury or death can result if Tighten nut until clevis attaching pin in yoke
components are removed while is free to rotate. See illustration above. The
system is still pressurized. yoke connects to the brake arm of the service
l Remove nut, washer, and spring release bolt brake.
from storage pocket located on side upper Remove and discard cotter pin from clevis
chamber. Refer to the illustration above. pin.
l Remove end cap from access hole in upper Remove clevis pin and separate yoke from
chamber assembly. Refer to illustrations on brake arm (slack adjuster).
opposite page.
Remove nuts, washer and brake chamber
NOTE from mounting bracket.
When inserting release bolt into
chamber piston, be certain that
SM 575, July 97
‘ Copyrighted Material Air Brake Chambers l 24-4-3
Group 24, Service Brake CMRI
Ind Cap -
WA
1
WARNING AWARNING
Do not remove this ""SPOOKY
LOADED,""
clamp. Chamber is To manually release brake:
ielease Bolt Kit sorina loaded.
Refer to Group 23, Section 2
“Mechanicaly Releasing Brake”
Rekease Bolt -1
- Nut & Washer
Beather
imergenc)
-Tube
Emer ency Power
Chamber
Kit
Cham%Ier Spring7
qssembly
Bolt
&
Nut
Torque 1
X5-30 Ib.ft. 1Clamp Ring 1
33-40 N-m
Maximum)
Piston & Rod

Assembly
Service
Er
Chamber.
Assembly Return Spring
Chamber
-7 y Nut&Washer
L Service
Chamber
Assembly
Jam Nut-----/
Torque L Torque
100-115 Ib.ft. NOTE
25-30 Ib.ft.
(135-156 N-m)
Do not install flat washer between
chamber and mounting bracket.
Cut-A-Way
Typical illustration Typical Illustration
24-4-4 . Air Brake Chambers Copyrighted Material SM 575, July 97

‘
ClflRK Group 24, Service Brake
Disassembly
IMPORTANT
Prior to disassembly,
measure and record the
following measurements.
l Measure distance from bottom of chamber to

end of threaded piston rod. Record measure-
ment.
l Measure distance from bottom of chamber to
center of opening in clevis for the clevis pin.
Record measurement. Remove clevis. L
AWARNING
Do not remove upper Meakurekents
chamber assembly Clamp I I
Ring as serious injury can
result from sudden release
of internal power spring. The
clamp ring is spot welded to
deterremoval. Donotremove ---
it. i-upperClamp1 Typical Illustration
* Match mark upper chamber to lower chamber - Breather Tube
for correct installation.

l Remove breather tube.
A WARNING
Internal components are
under approximately 50 Ibs
(23 kg) of spring pressure.
When disassembling allow
parts to separate slowly.
l Position brake chamber with threaded rod

pointing downward (as shown). Apply pres- Bench
sure to the upper chamber and remove lower

clanlp ... . allow upper and lower chambers to Reassembly
slowly separate.
Install new repair kit. Torque fasteners to specifi-
l Remove diaphragm. cations shown in illustration on opposite page.
l Remove piston rod and spring from chamber.
Installation
Inspection
l Install brake chambers to mounting brakes
Check cylinder shell for dents, hose or pipe con-
and torque the mounting nuts to specifications
nections for damage and wear that could result in
shown in illustration on opposite page.
leakage. Check the diaphragm for wear or damage.
Check cylinder linkages for damage or binding l Back off slack adjusters until they can be
and alignment balance on L.H. R.H. brakes. Re- connected to the brake chamber rods.
place all parts that are unfit for further service.
SM 575, July 97
Group 24, Service Brake ClflRK
Brake Chamber Typical Illustration
Brake Adjustment
l Rotate adjuster for a stroke of l-inch (25.1
mm +/-0), see below.
l Adjust both L.H. & R.H. brakes to the same
specification.
vice Brake Arm
,::~
.
/ If
.::::::::
.:.:.:.:.:
::::::::::
Stroke
II-Inch
1c
\--- - mm\
------ 175-A
4))
“““I
::::y$
@
- _ :.:.:.:.:.:_
..:.::::::::::::::::::::::::~:.,..
............... ......a... --%. . . . . . . . . .
...........................................
..:.:.
.‘:
\ h-
/@
R.H. Brake Chamber
24-4-6 l Air Brake Chambers Copyrighted Material SM 575, July 97

‘
Group 24, Service Brake
Power
Spring Normal Service Brake
Since the service section
and spring brake section
are isolated from each
other by seals, the spring
brake cannot interfere with
the operation of the normal
service brake.
Parking Brakes
A manual control in the
operator’s compartment
releases air pressure
within the spring brake to
provide parking or
emergency application.
Normal Driving
Air pressure within the
system holds spring brakes
released.
“Stroke Alert” J u
Mounting Indicator
Face Groove
IJ-:z
Brakes OFF Propew&&dJuud

(Not Applied)
A WARNING
Brake Adjustments are made at the Slack Adjusters.
No foundation brake adjustment can be made at the
piggyback/spring brake chamber or at the service
brake chamber.
All “stroke adjustments” must be made at the slack-

adjuster.
SM 575, July 97
C500 Y2235 Group 24
SECTION 5
AIR BRAKE COMPRESSOR
Section Tiile Page
ElfMU
Section 5
Air Brake Compressor
Typical Illustratic m
Important
Keep Breather Clean
SM 575, July 97
‘
Air Brake Compressor l 24-5-l
GENERAL DESCRIPTION let valve open, airpasses back andforththrough the

The compressor is a one cylinder, valve between the cylinder block and atmosphere
recirocating piston, engine lubricated air compres- eliminating the compression of air. When system
sor. It is availablewith either air or water cooled air pressure is reduced to the desired minimum the
cylinder head and either base or flange mount governor will exhaust the air pressure to the
configurations. Withthe exception of the cylinder unloader pin. The pin then releases the inlet valve
head casting, all air cooled compressor compo- and compression of air resumes.
nents are identical tothe water cooled compressor
components. The compressor’s rated capacity is General Maintenance Procedure
8.5 cubic feet per minute (CFM) at 1250 RPM. The air compressor requires no specific
The compressor is comprised of five major periodic maintenance for the warranty
components; cylinder head assembly (which con- periodbeyond assuring a clean unrestricted inlet air
tains all valving), cylinder block, crankcase, one supplyandcleanlubricatingengineoil.Theairfilter
piece crankshaft supported at both ends with bear- should be cleaned or replaced when the filter
ings, and an aluminum piston and rod assembly. causes a restriction exceeding 20 inches of water.
The restriction should be measured at the compres-
sor inlet between the filter and aircompressor while
the compressor is pumping.
AIR COMPRESSOR OPERATION
If the compressor fails to maintain ad-
Compression equate air pressure or provides excessive pressure
the governor and unloader components should be
When the piston travels down in the cylin- inspected. The unloader is serviced by removing
der bore, air pressure opens the inlet valve and air the unloader screw on the top of the cylinder head.
isdrawn into the cylinder bore. As the piston starts Ifwear, or damage is evident, an unloaderrepairkit
upward the inlet valve closes. As the piston is available.
approaches the top of its stroke, the pressure in the
cylinder will exceed that of the exhaust cavity and DISASSEMBLY PROCEDURE
reservoir, thereby causing the exhaust valve to
open and expel the compressed air. When the Beforedisassembly, cleanthecompressor’s
piston starts back down, the exhaust valve closes exterior using a S toddard type cleaning solvent and
and will not permit the compressed air to return to a stiff brush.
the cylinder bore. The intake and compression
stroke is then repeated.
Unloaded (Not Compressing Air)

The aircompressor turns continually when-
ever the engine is running. However, air compres-
sion is controlled by a governor. When airpressure
in the systemreservoirreaches a desiredmaximum
the governor is actuated. Actuation permits system
pressure to be applied to the unloader assembly.
Inresponse to systempressure, theunloader
pin in the cylinder head moves to hold the inlet
valve off its seat to the open position. With the in-
244-2 ’ Air Brake Compressor Copyrighted Material SM 575, July 9

‘7
A WARNING
A compressor should never be disassembled while mounted to the engine.
A CAUTION
Cover or plug all openings to prevent contamination.
A CAUTION
Do not use solvents containing chemicals injurious to aluminum alloy.
Never use gasoline, fuel oil or kerosene as a cleaning solvent.
A WARNING
Always provideadequateventilation of theworking are during the useof solvents.
The compressor crankcase, cylinder block, Unloader Removal

and cylinder head are designed to be assembled in
NOTE
different ways to meet carious installation require-
The unloader can be serviced
ments. Mark these parts to insure each part is
without removing the compressor
reassembled in its proper position.
from the engine.
Governor Removal 1. Remove the unloader cover and the washer seal
The air governor may be mounted directly to (1 l/4” hex screw), on top of cylinder head.
the cylinder head or remotely mounted with a line 2. Remove unloader pin, o-ring and spring.
leading from the governor to the cylinder head. If
3. Discard thewasher, seal and spring. Remove the
remotely mounted, disconnect and remove the
o-ring from the pin and discard the o-ring.
unloader line from the cylinder head.
4. Clean machine surfaces and inspect for damage.
A direct mount governor is removed by two
screws. Remove the gasket between the governor and 5. For unloader installation instructions refer to
“Cylinder Head Assembly”.
cylinder head. Clean both gasket surfaces and inspect
each for damage.
Cylinder Head Removal
Air Cleaner Removal 1. With a 9/l 6” wrench remove the four hex head
bolts holding the head to the block.
Inlet air may be provided through an air
cleaner mounted directly to the compressor cylinder 2. Tap head gently with a brass or plastic mallet to
head or through a hose to the engine air cleaner. loosen, if necessary.
If the engine air cleaner is used, remove the 3. Lift head assembly off block.
hose and hose fitting from the cylinder head.
4. Discard gasket and clean the gasket surface.
Direct mount air cleaner is removed by the
two mounting screws. Remove the aircleaner gasket. Cylinder Head Disassembly
Clean the gasket surfaces and inspect for damage.
1. Place the cylinder head on a table or in a soft-
SM 575, July 9
‘7 Copyrighted Material Air Brake Compressor l 24-5-3
jawed vice and remove the 1 l/4” hex unloader Piston & Connecting Rod Removal
cover bolt. Service the unloader as described
l
1. Turn the crankcase on its side to expose the
previously.
connectingrodtocrankshaftbolts.Flangemount
2. Turn the head bottom side up. Remove the and some base mount compressors will have a
exhaust valve seat using a 3/4”allen wrench. bottom cover plate which must be removed.
Remove the valve, spring and copper washer.
2. Slowly rotate the crankshaft so that the connect-
Discard the copper washer. Exhaust valve stop
ing rod is at the bottom of its stroke.. Use a 12
is pressed in place and SHOULD NOT BE
point, S/16” or l/4” socket to remove the rod and
REMOVED.
cap bolts.
3. Remove the inlet valve cage using. Remove the
3. Lift the piston and connecting rod through the
valve, spring and copper washer. Discard the
top of the crankhouse.
copper washer.
Piston & Connecting Rod

Disassembly
1. Remove buttons from piston wrist pin holes.
2. Donotremovepistonwristpinfrompistonsince
damage to the piston may occur with the press
fit design. The piston and rod must be replaced
as an assembly if either part is damaged.
3. Remove the piston rings f?om the piston with a
ring expander.
%lbn
wht PAI
Cnmprerrinn
Rings PI
Cylinder Block Removal

1. Remove the four 3/8” bolts and lo&washers
holding the cylinder block to the crankcase.
Crankshaft Bearing Cap Removal
2. Tap the block off the crankcase and piston.
1. Remove the bolts securing the bearing cap to the
Remove and discard gasket.
crankcase.
A CAUTION 2. Tap the cap gently with a brass or plastic mallet
Be extremely careful to avoid to loosen. Remove cap fi-omcrankcase.. Discard
scratching machined surfaces.
gasket. Clean gasket surfaces.
3. Pull the block off the crankcase and piston. 3. On compressors having rear ball bearings, re-
Remove and discard gasket. Clean machined move the seal and spring.
surfaces and inspect for damage.
24-5-4 l Air Brake Compressor Copyrighted Material SM 575, July 9

‘7
Crankshaft Removal Inspection - Cylinder Head

Ifvisual
inspection shows that the crankcase Components
or crankshaft is damaged, the compressor should be 1. Examine cylinder head for cracks and damaged
replaced with a new or remanufactured unit. threads. The head gasket surface must be free of
A CAUTION nicks and gouges. Replace the head if damaged.
Removal of crankshaft may 2. Inspect the inlet valve disc and exhaust valve
cause main bearing damage. disc for wear. Replace the valves, if cracked
Therefore, inspection while pitted or grooved in excess of .005 deep on either
assembled is recommended. side.
3. Check for inlet valve spring and exhaust valve
Cleaning, Inspection and Repair spring for loads at specified heights. Inspect for
1. Wash all parts in cleaning solvent. Blow dry wear between adjacent spring and coil.
with compressed air. 4. Examine the inlet valve cage for damage and
A WARNING wear. Measure the valve guide diameter and the
distance from the top of the cage to the valve
When using air pressure, wear
eye protection and protective stop. Examine the inlet valve seat for damage.
clothing. Reduce air pressure Measure from the valve seatingsurface to the
to 30 PSI (207 kPa). Debris surface that contacts the valve cage..
removed with pressure can
cause injury. 5. Examine the exhaust valve seat for damage and
wear. Measure the valve guide diameter and the
2
‘. Clean carbon deposits from the cylinder heads distance from the top of the valve seat to the
interior surfaces. Clean all interior air and water valve seating surface..
passageways.
6. Examine the exhaust valve stop for damage,
3. Remove carbon from piston crowns and ring looseness or wear. Measure the distance from
grooves. Carbon in ring grooves can be removed the valve end of the stop to the face of the
by using a piece of a broken ring as a tool. cylinder head. If the exhaust valve stop is loose,
4. Blow out all drilled passageways with com- worn, damaged or does not meet the specified
measurement from the valve stop surface to the
pressed air to insure they are open.
cylinder head surface, the head assembly must
A WARNING be replaced.
Use proper eye cover when
7. Examine the unloader seal bore diameter for
using compressed air.
scoring or pitting. Check unloader pin for dam-
5. Remove old gasket material sealer from gasket age. Measure the lenght of the unloader pin.
surfaces. 8. Check the unloader spring for load at the speci-
A CAUTION fied height.
Do not usesolventscontaining
chemicals injurious to Piston, Connecting Rod and
aluminum alloy. Never use Bearings
gasoline, fuel oil or kerosene
as a cleaning solvent. 1. Examine piston for scoring, cracks, or other
damage. Replace as needed.
SM 575, July 97
‘ Copyrighted Material Air Brake Compressor l 24-5-5
2. Measure the outside diameter at a 90 degree NOTE

angle to the piston pin bore. Piston to bore The connecting rod and rod cap
clearance should not exceed 008 (0.20 mm). If must be replaced as a unit.
clearance exceeds .008 in. (.020 mm) replace the
pisaton and rod assembly. The block must be Cylinder Block
replaced or bored 0.020 oversize. Oversize
pistons at 0.020 in. are available. 1. Examine cylinder block for cracks. Replace if
damaged.
NOTE
When measuring outside piston 2. Examine cylinder bore for scratches, scoring
diameter, make sure measurement and pitting. Check bore for out-of-round or
is taken 90 degrees from piston pin taper. If out-of-round more than 0.0005 inch or
bore. Measurements in line with tapered more than 0.0015 inch from top to
the wrist pin are less accurate.. bottom of bore, the block must be rebored or
honed oversize, or replaced with a new cylinder
3. Check the fit of the piston pin in the piston and block.
connecting rod. If play in excess of .005 is
3. If bore is within the tolerance, honing to a 30
detected between the pin and piston , or pin and
degress crosshatch pattern within 20-35 AA
connecting rod, the entire piston and rod assem-
surface fmish is recommended. Service piston
bly must be replaced.
is available 0.020 inches oversize if thebore is to
4. Check the fit of compression and oil rings in the be machined oversize.
piston ring grooves. Place rings in piston ring
grooves and measure side clearance.. Place Crankshaft and Bearings
rings in the cylinder bores and measure end gap.
1. A bent or twisted crankshaft cannot be repaired.
Clearance between ring and ring groove, and
If connecting rod journals are scored beyond
ring gap must be within limits listed in the
repair or worn beyond the “Specifications,”
“Specifications” section. If clearance or gaps are
replace with a new crankshaft or regrind jour-
not within these limits, new rings must be
nals. Service insert bearings are available at
iIlSta.lld.
0.010 and 0.020 inches (0.25 and 0.51 mm)
NOTE undersize.
Whenever a complete compressor
2. If the main bearing journal on a compressor,
teardown is accomplished, new
which has a sleeve main bearing, is scored
rings are recommended.
excessively or worn beyond “Specifications,” it
5. Examineconnectingrodbearinginsertsforscor- must be replaced. No undersize main bearings
ing, pitting or excessive visible wear. Check fit are available.
ofrodbearingsoncrankshaftjoumals.Clearance 3. Thread, keyway, and all ground and machined
between bearing and crankshaft journals must surfaces must not be mutiliated or worn.
be between 0.005 and 0.0021 inches. If damage
is evident or clearance does not meet the speci- 4. Examine ball bearings for worn or damaged
fied dimensions, new inserts must be installed. balls; rotate bearing by hand to detect roughness.
If wear, roughness ordamage is evident, bearing
6. Check clearance between side of connecting rod must be replaced.
bearing cap and crankshaft. If clearance exceeds
0.010 inches, new rod and bearing cap must be
installed
244-6 l Air Brake Compressor Copyrighted Material SM 575, July 9

‘7
Crankshaft Bearing Cap NOTE

Special parts, in addition to
1. Examine crankshaft rear &uing cap and re-
standard parts, are available for
place if worn or cracked.
overhauling each compressor.
2. On compressor with a sleeve-type rear bearing, Included are 0.020 inch oversize
check the inside diameter of the rear bearing piston and rings, cylinder block
against the dimension in the “Specifications” with 0.020 inch oversize cylinder
section. Replace the bearing cap assembly if the bore, and 0.010 and 0.020 inch
bearing is worn excessively. undersize bearing inserts.
3. Compressors with a ball type rear bearing have
a seal and spring in the rear bearing cap. Crankcase and Breather Cap
a Check the wear of the seal where it contacts 1. Press a new oil seal into front of the crankcase,
the crankshaft. The seal must be replaced if apply a sealer on the seals outer rim and engine
grooved more than 0.005 inch (0.3 1 mm). Mea- oil to thelip. The spring side of the seal must face
sure outside diameter of seal ring. If diameter is the inside of the crankcase when installed. The
not within “Specifications,” the seal ring must be seal case should be flush to .005 inch (0.031
replaced. mm) below the surface of the crankcase.
b Check the oil seal aspring for load at as- 2. Place a new gasket on the rear bearing end cap.
sembled height. Spring must conform to “Speci- Install the sealing ring over the spring in the end
fications. ” cap and lubricate with engine oil.
3. Slide the rear bearing end cap over the ball
Crankcase bearing, taking care that the seal and spring
1. Examine the crankcase for cracks anddamage to remains in position.
gasket surfaces. Replace if necessary.
A CAUTION
2. Inspect studs in crankcase, ifused. Replace any Do not over-tighten bolts.
bent or damaged studs.
4. Pull bearing cap into position by alternately
3. Measure the main bearing bore diameters to tightening the four attaching bolts. Torque to
insure they are within “Specifications.” If not, 120- 160 in. lbs.
replacement of the crankcase is required.
5. Crankshaft should revolve freely after assem-
Air Cleaner Assembly bling cap.
1. Unscrew the air cleaner assembly cover and Cylinder Block

remove the air cleaner element. Replace the
element if dirty, crushed, damaged, or if resis- 1. Place a new gasket between the block and
tance to flow when pumping exceeds 20 inches crankcase and set the block on the crankcase.
of water. Assemble the four mounting bolts to 15 ft. lbs.
Increase the bolt torque to 25-30 ft. lbs. in
2. Replace the air cleaner cover or base if either is sequence around the block.
bent, crushed or damaged.
Piston and Connecting Rod
Compressor Assembly
Assembly
Coat crankshaft, bearings, connecting rod bearings,
1. Placeplasticbuttonsintopistonattheendsofthe
piston, pin and cylinder block bore with engine oil
piston pin.
before reassembling.
SM 575, July 9
‘7 Copyrighted Material Air Brake Compressor l 24-5-7
2. Install one compression ring in each of the top Cylinder Head Assembly
three groves. Compression rings must be in-
1. Invert cylinder head and insert new copper
stalled with top up.Top is identified by either the
washers into both ports.
letter “N” or a dot near the end gap of the ring.
2. Insert exhaust valve spring, exhaust valve and
3. Install the piston oil ring in the bottom groove
exhaust valve seat. Using a 3/4” Allen wrench,
below the pin. Oil rings may be either one or
tighten exhaust valve seats to 70-90 ft. lbs.
three piece designThree piece oil rings are
installed by placing the center expander in that
3. Insert inlet valve seat, inlet valve, inlet valve
groove first, followed by the rails on each side..
spring and inlet valve cage.
The oil ring has no top or bottom.
NOTE
4. Stagger ring gaps 120 degrees.
The inlet and exhaust valves must
5 Press the connecting rod bearing inserts into the be centered to avoiddamage. Insure
connecting rod and rod gap. that both valves are free while
6. Coat both rod bearings with engine oil and torquing each assembly to 70-90
temporarily attach rod cap with arrows aligned. ft. lbs.
4. Tighten inlet cage to 70-90 ft. lbs.

Piston and Connecting Rod
Installation 5. Turn the head over and insert unloader spring.
Assemble the o-ring on the unloader pin.
1. Lubricate the cylinder wall, piston and rings
with engine oil. 6. Apply Dow-Corning #33 lubricant to the seal
forming a 11/16 in. diameter ball. Insert the
2. Remove the rod cap and bearing from the con- unloader pin into the head. Place the unloader
necting rod. washer on the unloader cover. Assemble these
3. Load the connecting rod through the top of the two items to the head as a unit compressing the
cylinder block. Compress the piston rings and unloaderspringandholddownuntiltheunloader
press the piston into the block until the top of the cover thread engages the cylinder head. Tighten
piston is flush with the top of the block. cover to approximately 30 ft. lbs. torque.
4. Turn the assembly over and position the con-

Cylinder Head Installation
necting rod on the crankshaft journal making
sure bearing inserts are in place. 1. Place a new head to block gasket on the cylinder
block.
Lubricate the rod journal with engine oil.
2. Place the head on the gasket assembling the four
5. Install connecting rod bearing cap and insert,
head bolts.
aligning the arrows on the bearing cap and rod.
Install the connecting rod bolts. 3. Tighten the head bolts to 18-22 ft. lbs.
Tighten to 185-225 in. lbs. torque.. 4. Retighten the head bolts to 27-33 ft. lbs.
6. On flange mount compressor, replace the gasket Head-mounted governor:

and assemble the bottom plate. 1. Attach the governor to the head with two screws.
Tighten the four hex head bottom cover bolts to Use a new gasket.
1 lo- 150 in. lbs. torque. Remote-mounted governor:
1. Install governor assembly and bracket in place..
2. Install the unloader line..
24-5-8 l Air Brake Compressor Copyrighted Material SM 575, July 97

‘
C500 Y2235 Group 24
SECTION 6
ROCKWELL AXLE
CAM BRAKES
This section covers the brakes used on the

Rockwell Drive Axle used on trucks built to lot
number 8518 and above.
For information on brakes used priorto lot 8518,
refer to the Clark-Hurth Planetary Drive Axle in
Group 20, Section 4 of this manual.
Section Tile Page
Service Notes
This Maintenance Manual describes the correct service and repair procedures for Rockwell cam
brakes. The information contained in this manual was current at time of printing and is subject to
change without notice or liability.
You must follow your company procedures when you service or repair equipment or components.
You must understand all procedures and instructions before you begin to work on a unit. Some
procedures require the use of special tools for safe and correct service. Failure to use special tools
when required can cause serious personal injury to service personnel, as well as damage to
equipment and components.
Rockwell uses the following notations to warn the user of possible safety problems and to provide
information that will prevent damage to equipment and components.
A WARNING
A warning indicates a procedure that must be followed exactly. Serious personal injury can
occur if the procedure is not followed.
Ig CAUTION
A caution indicates a procedure that must be followed exactly. If the procedure is not followed,
damage to equipment or components can occur Serious personal injury can also occur in
addition to damaged or malfunctioning equipment or components.
This symbol is used to indicate thatfasteners must be tightened to a spectjic torque value.
@
NOTE
A NOTE indicates an operation, procedure or instruction that is important for proper service. A
NOTE can also supply information that will help to make service quicker and easier.
A Asbestos and Non-Asbestos Fibers Warnings

Some brake linings contain asbestos fibers, a cancer and lung disease hazard. Some
brake linings contain non-asbestos fibers, whose long-term eflects to health are
unknown. Use caution when you handle both asbestos and non-asbestos materials, as
described on page 2 of this manual.
Training Videos To order videos, send a purchase order or

check for $20 for each video to: Rockwell
Rockwell offers the following VHS videos: Literature Distribution Center, c/o Vispac,
Rockwell Cam Brake Maintenance Inc., 35000 Industrial Road, Livonia, MI
(Video 90233) 48150. Phone orders are also accepted by
Automatic Slack Adjuster Installation and calling 8 10-435-8689.
Maintenance (Video 90234)
New Generation Automatic Slack Adjuster
(Video T-9443V)
Table of Contents
PAGE
ASBESTOS AND NON-ASBESTOS FIBERS WARNINGS .. . .. . ... . .. .. .. . .. .. . .. .. .. .. ... . .. .. ... ... ... ..2
1. Introduction .................................................................................................................................... 3
P Series Brakes ............................................................................................................................. 3
Q Series and Q Plus Brakes ......................................................................................................... 3
T Series Brakes ............................................................................................................................ 4
2. Disassemble Brakes ........................................................................................................................ 5

Remove Wheel Components ........................................................................................................ 5
Remove Brake Shoes ................................................................................................................... 6
Remove Camshaft and Slack Adjuster ......................................................................................... 8
3. Prepare Parts for Assembly ........................................................................................................... 9

Clean Parts ................................................................................................................................... 9
Inspect Parts ................................................................................................................................. 9
4. Assemble Brakes .......................................................................................................................... 12

Install Camshaft ......................................................................................................................... 12
Replacement of Q Series Camshafts With Q Plus Camshafts in All Front and Drive Axle
16.5” Q Series Brakes ............................................................................................................ 13
New Q Plus Camshaft and Return Spring for 16.5 x 5” and 6” Front Q Series Brakes.. ........ ..13
Install Brake Shoes .................................................................................................................... 14
Installation of the Rockwell Slack Adjuster.. ............................................................................ .17
Adjust the Brake ........................................................................................................................ 20
5. Reline Brakes ................................................................................................................................ 22
6. Lubrication ................................................................................................................................... 23
7. Visual Inspection of the Brake System ....................................................................................... 25
8. Recommended Periodic Service .................................................................................................. 26
9. Federal Roadside Brake Adjustment Inspection ...................................................................... 27

Truck, Tractor, or Tractor and Trailer Combination ................................................................. .27
Trailer Only ................................................................................................................................ 28
10. Torque Chart ................................................................................................................................ 29
11. Q Series and Q Plus Brake Conversion Kits ............................................................................. 30
12. Cam Brake Tips ........................................................................................................................... 31
A ASBESTOS WARNING 9. Work areas should be cleaned by industrial vacuums with HBPA
filters or by wet wiping. Compressed air or dry sweeping should
Recommended Procedures for Reducing Asbestos Dust, a Cancer never be used for cleaning. Asbestos-containing waste, such as
and Lung Disease Hazard. For All Rockwell Brake Linings with dirty rags, should be sealed, labeled and disposed of as required by
Asbestos. EPA and OSHA regulations. Respirators should be used when
emptying vacuum cleaners and handling asbestos waste products.
1. Because some brake linings contain asbestos, it is important that Workers should wash before eating, drinking, or smoking, should
people who handle brake linings know the potential hazards of shower after work, and should not wear work clothes home. Work
asbestos and the precautions to be taken. Exposure to airborne clothes should be vacuumed after use and then laundered, without
asbestos dust can cause serious and possibly fatal diseases; shaking, to prevent the release of asbestos fibers into the air.
namely, asbestosis (a chronic lung disease) and cancer, principally
lung cancer and mesothelioma (a cancer of the lining of the chest
or abdominal cavities). The risk of lung cancer among asbestos
workers who smoke is much greater than that among non-smokers. NON-ASBESTOS
Symptoms of these diseases are not usually seen until 1.5to 20, or
more, years after the first exposure to asbestos. A FIBER WARNING
2. OSHA has set the maximum allowable level for asbestos at Most recently manufactured brake linings no longer contain
0.2 fibers of asbestos per cubic centimeter of air (0.2 f/cc) as an asbestos fibers. In place of asbestos, these linings contain a variety
eight-hour time weighted average and at 1.0 fiber per cubic of ingredients, includiig glass fibers, mineral wool, aramid fibers,
centimeter (1 .O f/cc) averaged over a 30-minute sampling period. ceramic fibers, and carbon fibers. At present, OHSA does not
There is scientific debate whether even these levels will eliminate specifically regulate these non-asbestos fibers, except as nuisance
all risk of asbestos-related disease. Therefore, workers doing brake dust. Medical experts do not agree about the possible long-term
work should take steps to minimize exposure to asbestos to the risks from working with and inhaling non-asbestos fibers. Some
extent possible. experts nonetheless think that long-term exposure to some non-
asbestos fibers could cause diseases of the lung, including
3. Areas where brake work is done should be separate from other pneumoconiosis, fibrosis and cancer. Therefore, Rockwell
operations if possible. OSHA requires that the following sign be recommends that workers use caution to avoid creating and
posted at the entrance to areas where exposures exceed either breathing dust when working on brakes that contain non-asbestos
0.2 f/cc (as an eight-hour time weighted average) or 1.0 f/cc fibers.
(averaged over a 30-minute sampling period).
1. Whenever possible, work on brakes in a separate area away
DANGER: ASBESTOS from other operations.
CANCER AND LUNG DISEASE HAZARD
2. Always wear a respirator approved by NIOSH or MSHA during
AUTHORIZED PERSONNEL ONLY
all brake service procedures. Wear the respirator from removal of
RESPIRATORS AND PROTECTIVE CLOTHING the wheels through assembly.
ARE REQUIRED IN THIS AREA
3. Never use compressed air or dry brushing to clean brake parts or
4. During brake servicing, the mechanic should wear an air assemblies. OSHA recommends that you use cylinders that
purifying respirator with high-efficiency filters approved by enclose the brake. These cylinders have vacuums with high
NIOSH or MSHA for asbestos dust. (Disposable dust masks are no efficiency (HBPA) filters and worker’s arm sleeves. But, if such
longer allowed by OSHA.) The respirator should be worn during equipment is not available, carefully clean parts and assemblies in
all procedures, starting with the removal of wheels and including the open air.
reassembly.
4. Clean brake parts and assemblies in the open air. During
5. OSHA recommends that enclosed cylinders equipped with disassembly, carefully place all parts on the floor to avoid getting
vacuums with high-efficiency (HEPA) filters be used in brake dust into the air. Use an industrial vacuum cleaner with a HBPA
repairs. Under this system, the entire brake assembly is placed filter system to clean dust from the brake drums, backing plates
within the cylinder and the mechanic works on the brake through and other brake parts. After using the vacuum, remove any
sleeves attached to the cylinder. Compressed air is blown into the remaining dust with a rag soaked in water and wrung until nearly
cylinder to clean the assembly, and the dirty air is removed from dry.
the cylinder by the vacuum.
5. Grinding or machining brake linings. If you must grind or
6. If such an enclosed system is not available, the mechanic must machine brake linings, take additional precautions because contact
carefully clean the brake assembly in the open air. During with fiber dust is higher during these operations. In addition to
disassembly, all parts should be carefully placed on the floor to wearing an approved respirator, do such work in an area with
minimize creation of airborne dust. Dust should first be cleaned exhaust ventilation.
from the brake drums, brake backing plates and brake assemblies
using an industrial vacuum cleaner equipped with a HEPA filter 6. Cleaning the work area. Never use compressed air or dry
system. After vacuum cleaning, any remaining dust should be sweeping to clean the work area. Use an industrial vacuum with a
removed using a rag soaked in water and wrung until nearly dry. I-IBPA filter and rags soaked in water and wrung until nearly dry.
Dispose of used rags with care to avoid getting dust into the air.
7. Compressed air or dry brushing should never be used for Use an approved respirator when emptying vacuum cleaners and
cleaning brake assemblies. handling used rags.
8. If grinding or other machining of brake linings is necessary, 7. Worker clean-up. Workers should wash their hands before
other precautions must be taken because exposure to asbestos dust eating, drinking or smoking. Do not wear your work clothes home.
is the highest during such operations. In addition to use of an Vacuum your work clothes after use and then launder them
approved respirator, there must be local exhaust ventilation such separately, without shaking, to prevent fiber dust from getting into
that worker exposures are kept as low as possible. the air.
8. Material safety data sheets on this product, as required by

OSHA, are available from Rockwell.
Section 1
Introduction
Rockwell Cam-Master@ brakes are air actuated, Figul
cam operated, two shoe brakes with each shoe
mounted on a separate anchor pin. The brakes are
available with automatic or manual adjustment
and can be assembled with spring brakes.
There are four types of Cam-Master brakes:
P Series@‘,Qm Series, Q Plus and T Series.
P Series Brakes
Rockwell P Series brakes are available in
16.5 inch and 18 inch diameters with 7 inch wide
cast shoes with 0.75 inch tapered brake lining.
Figure 1. 15” Q PLUS BRAKE
16.5” Q SERIES and Q PLUS BRAKE
Figure
The Q Plus brake is the same as the Q Series
brake except for the following differences:
New Q Plus shoe design

Thicker linings
Heavy-duty return spring
New camshaft
The trailer axle version of the
16.5 inch x 7 inch Q Plus brake uses a heavy-
duty, bolt-on camshaft bushing.
16.5” P SERIES BRAKE WITH CAST SHOES
Q Series and Q Plus Brakes

The Q Series brake is similar to the P Series
brake, but has open anchor pin ends on the shoes
to permit “Quick Change” service. The Q Series
brake also has two shoe retainer springs in
addition to the shoe return spring, as well as
different design anchor pins. Q Series brakes are
available in 16.5 inch diameter with 5,6,7,8,
8.625 and 10 inch widths with 0.75 inch tapered
brake lining. 15 inch Q Plus brakes are available
in 4,5,6,7 and 8.625 inch widths with 0.75 inch
tapered brake lining. Figure 2.
Section 1
Introduction
A 15 x 4 inch Q Series brake is available for front, T Series Brakes
non-drive axle applications. Figure 3. The
15 x 4 inch Q Series brake has one shoe return The T Series brake was for smaller capacity axles
spring and one shoe retainer spring. The anchor and was available in 15 inch diameter with
pins are different from other Q Series brakes, but 3.5 inch and 4 inch widths with 0.438 inch thick
the shoes still have the “Quick Change” feature. lining. Figure 4.
The shape of the rollers and the shape of the cam
head are also different from other Q Series brakes. NOTE
The current 15 x 4 inch Q Series and Q Plus
Figure 3 brakes are designed to be used in applications
where T Series brakes were used. T Series brake
parts are NOT interchangeable with Q Series or
Q Plus brake parts.
Figure 4
15” Q SERIES BRAKE
The 15 inch Q Plus brake offers the same features

as the 16.5 inch Q brake. Compared to the
standard 15 inch Q Series brake, the 15 inch
Q Plus is different due to the following features: 15” T SERIES BRAKE
I Q Plus I Q Series I
l Double web shoe l Single web shoe
l Cast spider l Stamped backing

plate
l 1.5 inch, 28-spline l 1.25-.24 inch, 28-

camshaft spline camshaft
I l 1.75 inch offset I l 1.5 inch offset I
l 0.75 inch tapered l 0.458 inch strip

block lining lining
Section 2
Disassemble Brakes
A WARNING
Some brake linings contain asbestos fibers,a
Figure 5
01
cancer and lung disease hazard. Some brake
linings contain non-asbestos$bers whose long- 0
term effects are unknown. Caution should be
exercised in handling both asbestos and non-
asbestos materials as described on page 2. NEW STYLE
OLD STYLE (PRY OUT
(REMOVE) TO DISENGAGE)
Remove Wheel Components
A WARNING A CAUTION
You must remove or disengage the paw1 before
To prevent serious eye injury, always
wear safe
rotating the manual adjusting nut, or you will
eye protection when performing maintenance or
damage the paw1 teeth. A damaged paw1 will not
service.
allow the slack adjuster to automatically adjust
the brake clearance. Replace damaged pawls
A WARNING
Do not work under a vehicle supported only by
before putting the vehicle in service.
jacks. Jacks can slip or fall over and cause A. Disengage or remove the paw1 assembly
serious personal injury. as required. Figure 6.
1. Use a jack under the axle being serviced to B. Use a wrench to turn the manual adjusting
raise the vehicle. nut until the brake shoes are fully
retracted.
2. Install jack stands under each comer of the
C. Remove the screwdriver so the paw1 (new
vehicle to hold it in position.
style) snaps back into engagement; or
reinstall the paw1 assembly (old style).
A WARNING
When you work on a spring chamber, carefully
follow the service instructions of the chamber NUT \ \\ \ \
manufacturer. Sudden release of a compressed
spring can cause serious personal injury.
3. If the brake has spring chambers, carefully
cage and lock the spring so that the spring
cannot actuate during disassembly.
4. Fully release the slack adjusters so that the
shoes retract and the drums will clear the
linings.
NOTE
Old style pawls on Rockwell automatic slack
adjusters must be removed to prevent damage
when adjusting the brake. New style “pull”
\
DISENGAGE
PAWL
pawls are spring loaded. Pry out “pull” pawls at

least 1132 inch to disengage the teeth and
prevent damage. When you remove the pry bar,
the paw1 will engage automatically. Figure 5.
Page 5
Section 2
Disassemble Brakes
NOTE Figure 8 TRAILER
AXLE BRAKE
For complete maintenance instructions on the
Rockwell automatic slack adjuster, see Rockwell
Maintenance Manual No. 4B, “Automatic Slack
Adjuster.”
5. Use standard procedures to remove the wheels
LOCK
and drums from the axle.
PINS
Remove Brake Shoes

P Series Brakes
+FF5’-j~
Figure 7 shows the current anchor pin 3116” Q/32’
arrangement for P Series brakes. Older brakes =4 x
‘-
may include additional parts. 2. Remove the top anchor pin with a brass drift.
Figure 9.
Figure 7 BUSHING
1225-B-496 Figure 9
I SNAP RING
ANCHOR PIN
1259-N-1132
1259-M-1131
STAMPED SHOE)
(.OSO”)
A WARNING
3. Rotate the top shoe to release the tension on
the return spring and remove the shoe.
with a steel hammer. Pieces can break off and Figure 10.
cause serious personal injury.
1. Remove any anchor pin snap rings, washers,
retainers, felts, seals or set screws, as needed.
IFigure 10
NOTE
Some trailer axle P Series brakes have anchor
pins that are held in place with lock pins. A tool
to drive out the lock pins can be made from a
steel rod, as shown in Figure 8.
Section 2
Disassemble Brakes
4. Remove the bottom anchor pin (see step 2) Figure 13
and remove the second shoe.
5. If necessary, remove the rollers. Figure 11.
Figure 11
4. Rotate the bottom shoe to release the tension

on the two retaining springs. Remove the
16.5Inch Diameter Q Series springs and brake shoes. Figure 14.
,
Brakes and All Q Plus Brakes
1. Push down on the bottom brake shoe and pull
on the roller retaining clip to remove the
bottom cam roller. Figure 12.
Figure 12
15 Inch Diameter Q Series Brakes

1. Push down on the bottom brake shoe to give
clearance and remove the bottom cam roller.
2. Lift the top brake shoe and remove the top
2. Lift the top brake shoe and pull on the roller cam roller.
retaining clip to remove the top cam roller. 3. Remove the brake shoe return spring.
3. Lift the bottom shoe to release the tension on 4. Rotate the bottom shoe to release the tension
the brake return spring. Remove the spring. on the retaining spring. Remove the spring
Figure 13. and brake shoes.
Page 7
Section 2
Disassemble Brakes
T Series Brakes 2. Remove any snap rings, washers and spacers
from the camshaft.
1. Disassemble the retainers and springs from
3. Remove the two clevis pins from the clevis on
the anti-rattle rods.
the air chamber push rod.
2. Push down on the bottom brake shoe to give
4. Remove the slack adjuster from the camshaft.
clearance and remove the bottom cam roller.
5. Pull the camshaft from the spider and bracket.
3. Lift the top brake shoe and remove the top
cam roller. 6. Use the correct size driver to remove the
bushings from the spider and the bracket.
4. Remove the anchor pin snap rings and the
anchor pins. Figure 15
5. Remove the brake shoes.
Remove Camshaft and

Slack Adjuster
NOTE
Rockwell recommends that you check the
bushings at every reline.
1. Check the up-and-down and side-to-side end

play of the camshaft to determine if you must
replace the camshaft bushings. Figure 15. If
the total movement is more than 0.030 inch
(0.76 mm), replace the bushings.
Section 3
Prepare Parts for Assembly
Clean Parts Prevent Corrosion on Cleaned
Parts
A WARNING Apply brake lubricant to cleaned and dried parts
To prevent serious eye injury, always wear safe
that are not damaged and are to be immediately
assembled. Do not apply brake lubricant to the
service.
brake linings or the brake drums.
A WARNING
If you use cleaning solvents, hot solution tanks
If parts are to be stored, apply a special material
that prevents corrosion and rust to all surfaces. Do
or alkaline solutions incorrectly, serious not apply the material to the brake linings or the
personal injury can occur. To prevent injury, brake drums. Store the parts inside special paper
follow the instructions supplied by the or other material that prevents corrosion and rust.
manufacturer of these products. Do not use
gasoline to clean parts. Gasoline can explode
and cause serious personal injury.
Inspect Parts
It is important that you carefully inspect all parts
Clean Ground or Polished Parts before assembly. Check all parts for wear or
damage. Repair or replace them as required.
Use a cleaning solvent, kerosene or diesel fuel to
clean ground or polished parts and surfaces. Do 1. Check the spider for expanded anchor pin
not use gasoline. holes and for cracks. Replace damaged
Do not clean ground or polished parts in a hot spiders and anchor pin bushings.
solution tarik or with water, steam or alkaline 2. Check the camshaft bracket for broken welds,
solutions. These solutions will cause corrosion of cracks and correct alignment. Replace
the parts. damaged brackets.
3. Check anchor pins for corrosion! and wear.
Clean Rough Parts Replace damaged an&or pins.
Rough parts can be cleaned with solvents or in hot 4. Check brake shoes for rust, expanded rivet
solution tanks with a weak alkaline solution. Parts holes, broken welds and correct alignment.
must remain in the hot solution tanks until they Replace a shoe with any of the above
are completely cleaned and heated. When the conditions.
parts are removed from the hot solution tank,
wash them with water until the hot solution is On 16.5 inch brake shoes only: Anchor pin
removed. holes must not exceed 1.009 inches in
diameter. The distance from the center of the
Dry Parts After Cleaning anchor pin hole to the center of the roller hole
must not exceed 12.779 inches. Replace any
Dry the parts immediately after cleaning. Dry shoe whose measurements are not to
parts with clean paper or rags, or compressed air. specifications.
5. Check the camshaft for cracks, wear and
corrosion. Check the cam head, bearing
journals and splines. Replace damaged
camshafts.
Page 9
Section 3
6. Check the slack adjusters:
AA CAUTION
You must remove or disengage the paw1 before
A. For slack adjusters with “quick connect”
type clevis, check the gap between the rotating the manual adjusting nut, or you will
clevis and the collar. If the gap exceeds damage the paw1 teeth. A damaged paw1 will not
0.060 inch (1.52 mm) replace the clevis. allow the slack adjuster to automatically adjust
the brake clearance. Replace damaged pawls
B. Check the clevis pins and the bushing in
before putting the vehicle in service.
the arm of the slack adjuster. Replace the
pins if they are worn. Replace the bushing D. Check Rockwell automatic slack adjusters
if its diameter exceeds 0.531 inch by rotating the adjusting nut to the left
(13.5 mm). with a pound inch torque wrench. Figure
17. Turn the gear 360 degrees
C. For manual slack adjusters, rotate the (22 rotations of the adjusting nut).
adjustment nut on the worm shaft to make
l For a new or rebuilt slack adjuster, the
sure that the worm drive is free. Figure
torque MUST remain less than 25 lb-in
16. Replace the slack adjuster if the worm
for 360 degrees.
drive does not operate correctly. Do not
repair a manual slack adjuster. l For an in-service slack adjuster, the
torque MUST remain less than 40 lb-in
Figure 16 for 360 degrees.
l If the torque value exceeds the
specifications, the slack adjuster is not
ADJUSTMENT
NUT
working correctly. Disassemble, inspect
and repair the slack adjuster. See
Rockwell Maintenance Manual No. 4B
for complete information.
Figure 17
Section 3
7. Check the drums:
Figure 18
A. Check the brake drums for cracks, severe
heat checking, heat spotting, scoring,
pitting and distortion. Replace drums as
required. Rockwell recommends that you
do NOT turn or rebore brake drums
because it decreases the strength and heat
capacity of the drum.
B. Measure the inside diameter of the drum
in several locations with a drum caliper or
internal micrometer. Figure 18. Replace
the drum if the diameter exceeds the
specifications supplied by the drum
manufacturer.
A WARNING
Do not operate the vehicle with the brake drum 8. Check dust shields for rust and distortion.
worn or machined beyond the discard dimension Repair or replace damaged shields as
indicated on the drum. The brake system may necessary.
not operate correctly. Damage to components
and serious personal injury can result.
Page 11
Section 4
Assemble Brakes
A WARNING
Some brake linings contain asbestos fibers, a
linings contain non-asbestos fibers whose long-
term effects are unknown. Caution shot& be
exercised in handling both asbestos and non-
asbestos materials as described on page 2.
NOTE
To help avoid shorter lining life, Rockwell
recommends that you replace springs, rollers, Figure 21
anchor pins and cam bushings at each reline.
A WARNING
service.
Install Camshaft
1. Tighten all the spider bolts to the correct
torque as shown in Figure 19.
u
3. If the camshaft bracket was removed, install

the gasket and bracket on the spider. Tighten
the capscrews to the correct torque. See the
Torque Chart on page 29.
4. Put the cam head thrust washer on the
camshaft. Apply 0-617-A or -B chassis grease
to the camshaft bushings and journals. Install
the camshaft through the spider and bracket so
that the camshaft turns freely by hand.
Figure 22.
Figure 22
2. Use a seal driver to install new camshaft seals

and new bushings in the spider and the
camshaft bracket. Figure 20. Install the seals
with their lips toward the slack adjuster.
Figure 21.
Section 4
Assemble Brakes
Replacement of Q Series NOTE
Camshafts With Q Plus You can use the new offset-center bar spring
with the hammerclaw Q camshaft.
Camshafts in All Front and
Drive Axle 16.5 Inch Q Series Figure 24
Brakes
A WARNING
service.
Rockwell has implemented a replacement of the
Q Series camshaft with the Q Plus camshaft in all New Stvle:
Standard Cl f&s Cam
16.5 inch Q Series brakes. Q Series brake
installation and maintenance procedures are not New Style
affected by the replacement. Offset Spring
2258-Y-l 273
New Q Plus Camshaft and Shoe Return Spring Installation

Return Spring for 16.5 x 5 Inch
Install the new offset shoe return spring with the
and 6 Inch Front Q Series open end of the spring hooks toward the camshaft.
Brakes Figure 25.
Figure 25
A WARNING
Do not use the straight-center bar shoe return
spring with the Q Plus camshaft. The shoe spring
can inteqere with the camshaft and affect braking
per$ormance. Serious personal injury can result.
Rockwell has replaced the hammerclaw Q Series
camshaft and the straight-center bar shoe return
spring (Figure 23) with a standard Q Plus
camshaft and an offset-center bar shoe return
New Installation
spring (Figure 24).
Figure 23 Spring must be installed with

the open end of the hook
toward the cam head. Spring
(P/N 2258-Y-l 273)
4l Old Style:
Hammerclaw Q Series Cam
Old Style
Straight Spring
Copyrighted
2258-R-642 Material Page 13
Section 4
Assemble Brakes
Install Brake Shoes
NOTE
When you install the brake shoes, lubricate the brake components as described in Section 6.
16.5Inch Q Series and All Q Plus Brakes
A CAUTION
You can install a Q Plus camshaft in a 16.5 inch Q brake. (For easy ident@cation, all Q Plus shoes are
stamped with “Q Plus” in the shoe table. All camshafts have “‘QPlus” forged in the roller pocket.)
However, DO NOT install a Q camshaft in a Q Plus brake for the following reasons:
l A Q Series camshaft does not provide enough clearance between the Q Plus lining blocks and the
brake drum. Brake drag and overheating can affect lining life.
l A new drum may notfit over Q Plus shoes when used with a standard Q Series camshaft.
Chart A (below) identifies the differences between Q Series and Q Plus components. Chart B (page 15)
specifies the only allowable combinations of 16.5” Q Plus and Q Series camshafts, shoes and return
springs.
CHART A
6.5” X 7” Q SHOE
PART NUMBER
LOCATED HERE
LOCATEDHERE
USED WITH SPIDER
Section 4
Assemble Brakes
CHART B
Camshafts Shoes Return Springs
Q Plus Q Plus Heavy-duty (blue)
Q Plus Q Series Standard
Q QS eries Standard
1. Put the upper brake shoe in position on the top 3. Pull each brake shoe away from the cam to
anchor pin. Hold the lower brake shoe on the permit enough space to install the cam rollers
bottom anchor pin and install two new brake and retainers. Press the ears of the retainer
shoe retaining springs. Figure 26. together to permit the retainer to fit between
the brake shoe webs. Figure 28.
2. Rotate the lower brake shoe forward and

install a new brake shoe return spring. Install 4. Push the retainer into the brake shoe until its
the open end of the spring hooks toward the ears lock in the holes in the shoe webs.
camshaft. Figure 27. Figure 29.
Figure 29

Section 4
Assemble Brakes
15 x 4 Inch Q Series Brakes 4. Use a brass drift to install the anchor pin. If
necessary, align the flat or groove on the pin
_. If removed, assemble the anchor pins, with the holes in the spider and bushing.
washers and nuts to the spider. Tighten the
anchor pin nuts to 325-375 lb-ft 5. Install the anchor pin washers, felts, seals,
(441-509 Nom). c) retainers and snap rings as required. If
required, install the lock pins or lock screws
2. Install the retainer spring on the shoes and and tighten the screws to lo-15 lb-ft
install the shoes on the anchor pins. Figure (13.6-20.3 Nom). c)
30. Hold the bottom shoe in position and
install the return spring. 6. Install a new shoe return spring on the brake
shoes. Figure 31. Put the upper shoe in
Figure 30 position over the spider and repeat steps 4 and
RETAINER 5 above.
SPRING
ROLLERS =+=4&
-
T Series Brakes
3. Pull each shoe away from the cam to permit
enough space and then install the cam rollers. 1. If removed, assemble the anchor pins,
washers and nuts to the backing plate. Tighten
the anchor pin nuts to 185-350 lb-ft
P Series Brakes
(251-475 Nom). c)
1. Install the anchor pin bushings. If necessary, 2. Install the anti-rattle rods, then, install the
align the holes in the bushings with the holes brake shoes on the anchor pins and anti-rattle
in the spider. rods.
2. Install new cam rollers and roller retainers. 3. Install the anchor pin,snap rings and the
3. Put the lower brake shoe in position on the springs and retainers on the anti-rattle rods.
spider. 4. Pull each shoe away from the cam to permit
enough space and then install the cam rollers.
A WARNING
Wear safe eye protection. Do not hit steel parts 5. Install a new shoe return spring on the brake
with a steel hammer. Pieces can break off and shoes.
cause serious personal injury.
Section 4
Assemble Brakes
Installation of the Rockwell Figure 32 HANDED UNHANDED
Automatic Slack Adjuster
NOTE
For complete instructions on how to install
Rockwell automatic slack adjusters, refer to
Maintenance Manual No. 4B, ‘Automatic Slack
Adjusters.”
There are two different automatic slack adjuster
designs: handed and unhanded. For most
applications, install a handed automatic slack .
51 F@B
adjuster so that the paw1 faces inboard on the
vehicle.
The paw1 can be on either side or on the front of
the slack adjuster housing. Figure 32. OLD SlYLE NEW STYLE
NOTE 1. If the automatic slack adjuster gear does not

have a grease groove and lubrication holes,
Install the slack adjuster so that you can remove
apply anti-seize compound to the automatic
the old-style paw1 or disengage the new-style
slack adjuster and cam or powershaft splines.
“pullpawl” when you adjust the brake.
Use Rockwell lubricant O-637, Southwest
SA 8249496 or equivalent.
Old-Style Pawls
2. Install the slack adjuster on the camshaft or
You must remove old-style pawls during service.
the powershaft.
Figure 32A.
3. If necessary, install spacing washers and the
New-Style “Pull Pawls” snap ring until there is a maximum clearance
of 0.062 inch (1.57 mm) between the washer
New-style “pull pawls” are spring loaded. Pry the and the snap ring.
“pull pawl” at least l/32 inch to disengage the
teeth. Figure 32B. When you remove the pry bar,
the “pull pawl” will re-engage automatically.
New-style “pull pawls” can replace old-style
pawls.
NOTE
Most Rockwell automatic slack adjusters
manufactured after January 1990 have
lubrication holes in the gear splines. Do not
operate the actuator before installing the slack
adjuster. Some of the lubricant can pump
through the holes and onto the splines.

Section 4
Assemble Brakes
A CAUTION A CAUTION
You must remove or disengage the paw1 before Do not reuse clevis pin retainer clips when you
rotating the manual adjusting nut, or you will remove them to service the automatic slack
damage the paw1 teeth. A damaged paw1 will not adjuster or chamber. Always replace used
allow the slack adjuster to automatically adjust retainer clips with new ones each time you
the brake clearance. Replace damaged pawls service the automatic slack adjuster or chamber.
before putting the vehicle in service. Discard used clips. When removed for service,
4. Remove or disengage the pawl. Turn the clevis pin retainer clips can be bent or “gapped
manual adjusting nut to align the holes in the apart” and can lose retention.
slack adjuster arm and the clevis. Figure 33. A bent retainer clip that is reused on the large
clevis pin can dislodge porn the clevis pin. Brake
Figure 33
application can be affected if the clevis pin
l\i
works its way out of the automatic slack adjuster.
A bent retainer clip that is reused on the small
clevis pin can dislodge and affect the automatic
adjustment of the automatic slack adjuster if the
small retainer clip and clevis pin are lost.
6. Apply anti-seize compound to the two clevis
pins. Install the clevis pins through the clevis
and the slack adjuster and install the cotter
pins or clevis pin retainer clips to hold the
clevis pins in place. Figure 34.
7. Adjust the brake.
Figure 34
5. Rotate the slack adjuster by hand to make sure
that nothing prevents the slack adjuster from CLEV’S LARGE CLEWS PIN
rotating when the brakes are applied. The \ AND
chart below shows the maximum stroke that I
you should check for clearance for each size
chamber.
Size of Chamber Maximum Stroke LARGE CLEWS PIN

RETAINER CLIP
(Square Inches) Available (Inches) P/N 2257-D-i 174
I a
12 I l-3/4 I
/
SMALL CLEWS SMALL CLEWS PIN
I 16 I 2-l/4 I
PIN AND
RETAINER CLIP
RETAINER CLIP
P/N 2257-C-l 173
20
I 24 I 2-l/4 I
Section 4
Assemble Brakes
NOTE 3.750” & 3.812”
There are three different Rockwell automatic BRKT. OFFSET
slQck adjuster installation templates for cam
brakes. Make sure you use the correct template.
See the chart that follows.
Rockwell Automatic
Slack Adjuster Templates
IForm
Number I
41
TP-4786 Truck & Tractor Cam Brake Brown
6.00”
6.50”
SLACK ADJ.
SIZE
I
* 0.125”
BSAP
Manual Slack Adjusters 5.00” 2.75”

5.50” 2.75”
If the clevis was not replaced, install new clevis 6.00” 2.75”
pins. Apply rust preventive grease (Rockwell 6.50” 2.62”
specification O-637) to the pins before

CORRECT POSITION OF MANUAL AND
installation.
AUTOMATIC SLACK ADJUSTER
3.750” AND 3.812” OFFSETS ONLY
Brake Slack Adjuster Position (FOR OTHER BRACKET OFFSETS,
(BSAP) REFER TO THE VEHICLE
MANUFACTURER’S SPECIFICATIONS)
The correct Brake Slack Adjuster Position
(BSAP) for both an automatic slack adjuster and a
manual slack adjuster is the same. When you
install either an automatic or manual slack
adjuster, verify that the BSAP matches the chart
in Figure 35.
Page 19
Section 4
Assemble Brakes
Adjust the Brake 1. For Rockwell Automatic Slack Adjusters:
Disengage or remove the paw1 as required.
Turn the adjusting nut until the linings touch
A CAUTION the drum, then, turn the adjusting nut l/2 turn
You must remove or disengage the paw1 before in the opposite direction.
rotating the manual adjusting nut, or you will
damage the paw1 teeth. A damaged paw1 will not For Manual Slack Adjusters: Turn the
allow the slack adjuster to automatically adjust adjusting nut until the linings touch the drum.
the brake clearance. Replace damaged pawls Then, turn the nut in the opposite direction for
before putting the vehicle in service. one or two clicks so that the linings just clear
the drum. Rotate the drum to check for
clearance.
Q Plus Camshaft Used in a
Q Series Brake 2. Measure the distance from the center of the
large clevis pin to the bottom of the air
chamber. Figure 37.
NOTE
The Q Plus camshaft has deeper roller pockets Figure 37
than a Q Series camshaft. You may notice a
MEASURE THIS DISTANCE
larger gap between the lining blocks and the
BRAKES OFF-BRAKES ON
drum after the brake shoes and return springs
are assembled (Figure 36). The excess gap will
be eliminated when the brake has been properly
adjusted.
Figure 36 The initial lining to drum clearance

with a Q Plus camshaft is increased
with both shoes fully retracted.
\
3. Use a pry bar to move the slack adjuster so

that the linings are against the drum. Measure
the same distance again. The difference
between this measurement and the
measurement in step 2 is the “free stroke.”
4. Turn the adjusting nut until the “free stroke” is
between S/8 - 3/4 inch (15.9-19.1 mm).
5. Check the adjustment. Apply the brakes and
hold the pressure. With the pressure at 85 psi,
again measure the distance from the center of
the large clevis pin to the bottom of the air
chamber.
Section 4
Assemble Brakes
6. The difference between the measurements in 7. Release or install the paw1 assembly and
step 2 and step 5 is the adjusted chamber tighten the capscrew to 15-20 lb-ft
stroke. Turn the adjusting nut so that the (20-27 Nom). li)
adjusted stroke is as short as possible, but not
so short that the “free stroke” is too short and
A WARNING
the linings drag. The adjusted stroke MUST
When you work on a spring chamber, carefully
NOT be greater than the dimensions shown in
follow the service instructions of the chamber
Figure 38. manufacturer. Sudden release of a compressed
Figure 38 spring can cause serious personal injury.
MAXIMUM STROKE AT WHICH BRAKE 8. If the brake has spring chambers, carefully
MUST BE ADJUSTED? 80-90 PSI release the spring.
(550-620 kPa) AIR PRESSURE IN THE AIR 9. Test the vehicle to make sure that the brake
CHAMBER. CLAMP TYPE
system operates correctly before you put the
AIR CHAMBER.
vehicle into service.
CHAMBER STROKE LENGTH
TYPE (SIZE) NOT TO EXCEED:
9 l-3/8 inches (34.9 mm)
12 l-3/8 inches (34.9 mm)
16 l-3/4 inches (44.4 mm)
20 l-3/4 inches (44.4 mm)
24 l-3/4 inches (44.4 mm)
30 2 inches (50.8 mm)
36 2-l/4 inches (57.1 mm)
*NOTE: The U.S. Department of Transportation

(DOT), Federal Highway Administration has
issued the above specijications for cam brakes.
Copyrighted Material Page 2 1

Section 5
Reline Brakes
A WARNING
sometimes used. When combination friction
lining sets are used, the lining blocks must be
Some brake linings contain asbestos fibers, a
installed in the correct locations on the brake
shoes.
linings contain non-asbestos fibers whose long-
term effects are unknown. Caution should be
exercised in handling both asbestos and non- A WARNING
asbestos materials as described on page 2.
Vehicle brake systems require the correct lining service.
material to perform as originally designed. The
type of lining material that is specified is based on NOTE
several technical considerations and DOT braking Always follow the instructions supplied with the
performance regulations. Always use the lining replacement combination linings for correct
material specified by the vehicle manufacturer. installation. The primary linings must be
Always reline both wheels of a single axle and all installed on the primary shoe. The ftrst shoe past
four wheels of a tandem axle at the same time. the cam in the direction of wheel rotation is the
Always install the same linings and drums on primary shoe. The primary shoe can be either at
both wheels of a single axle and all four wheels of the top or the bottom position, depending on the
a tandem axle. It is not necessary that the front location of the cam. If the cam is behind the
and rear axles have the same linings and drums. axle, the top shoe is the primary shoe. If the cam
is in front of the axle, the bottom shoe is the
Combination Linings primary shoe. Figure 39.
Combination lining sets with different friction

ratings on the primary and secondary shoes are
Figure 39 RIGHT WHEEL ROTATION

WHEEL ROTATION WHEEL ROTATION
/$ggz&
CAM BEHIND /% CAM IN FRONT

OF AXLE
LEFT WHEEL ROTATION

WHEEL ROTATION
WHEEL ROTATION
CAM IN FRONT w
CAM BEHIND
OF AXLE AXLE
IL7
Page 22
Section 6
Lubrication
Camshaft Bushings 15 x 4 Inch Q Brake Spider and
Retainer Clips
NOTE
1. Use 0-617-A or O-6 17-B (multi-purpose
Rockwell recommends that you install new
chassis grease).
camshaft bushings whenever you install a new
camshaft or relined brake shoes. 2. When the brake is disassembled, or when
necessary, lubricate the clips and the spider
1. Use 0-617-A or 0-617-B (multi-purpose where they touch the brake shoes.
chassis grease).
2. Use the following schedule: Camshaft Splines and Clevis Pins
Q or Q Plus brake - on-highway 1. Use O-637 (rust preventive grease). Do NOT
application: Every 100,000 miles mix this grease with other greases. This
(160,000 km). compound is also available from the
Southwest Petro-Chemical Division of Witco
P Brake - on-highway application: Every Chemical Corp., 1400 S. Harrison, Olathe, KS
50,000 miles (80,000 km) or every six 66061 as “Corrosion Control,” part number
months. SA 8249496.
Off-highway application: At least every 2. Lubricate when the brake is disassembled or
four months, when the seals are replaced or when necessary.
when the brakes are relined. Lubricate more
often for severe duty. Lubrication Anchor Pins
frequencies can be determined by
inspecting the internal parts and lubricant 1. Use 0-617-A (NLGI Grade l), 0-617-B
every two weeks for the first four-month (NLGI Grade 2), O-645 (NLGI Grade 2) or
period. At each inspection, look for O-692 (NLGI Grades 1 and 2) greases.
hardened or contaminated grease or for the 2. When the brake is disassembled, or when
absence of grease. necessary, lubricate the anchor pins where
3. Lubricate through the fitting on the bracket or they touch the brake shoes.
the spider until new grease flows from the
inboard seal. Shoe Rollers
1. Use 0-617-A or O-6 17-B (multi-purpose
A CAUTION chassis grease).
When grease flows from the seal near the cam
2. When the brake is disassembled, or when
head, replace the seal. Remove any grease from
necessary, lubricate the rollers where they
the cam head, rollers and linings. Grease on the
touch the brake shoes. DO NOT get grease on
linings can increase stopping distances.
the part of the roller that touches the cam
4. For the bushings at the slack adjuster end of head.
trailer camshafts, lubricate until grease flows
from around the bushing.

Section 6
Lubrication
Automatic Slack Adjuster 2. Use the following schedule that gives the
most frequent lubrication:
1. The following chart shows the greases to use
in Rockwell automatic slack adjusters. Use l Your fleet’s chassis lubrication schedule.
these greases or their equivalent. l The chassis manufacturer’s chassis
lubrication schedule.
OPERATING TEMPERATURE
l A minimum of four times during the life of
-40°F (-40°C) and
Below -40°F (-40°C: the linings.
Above
3. Lubricate through the grease fitting until new
Clay-Base Greases Synthetic Greases
grease flows from around the inboard splines,
l Rockwell Spec 0-616-A l Rockwell Spec O-645
(Part Number (Part Number or, from the paw1 assembly.
A-1779-W-283) 2297-X-4574)
l Shell Darina EP- 1 l Mobilgrease 28 (Military:
l Texaco Thermatex EP- 1 l Mobiltemp SHC 32
l Texaco Hytherm EP- 1 (Industrial)
l Aralub 3837
l Tribolube-12 Grade 1
Lithium-Base
Greases
l Rockwell Spec O-692
l Amoco Super Permalube
#2
9 Citco Premium Lithium
EP-2
n Exxon Ronex MP-2
l Kendall L-427 Super
Blu #2
l Mobilith AW- 1
l Sohio Factran EP-2
Section 7
Visual Inspection of the Brake System
For safe operating conditions and longer 6. Always follow the specifications supplied by
component life, make these visual inspections the vehicle manufacturer for the correct lining
before the vehicle is put into service: to be used. Vehicle brake systems must have
the correct friction material and these
1. Check the complete air system for worn hoses requirements can change from vehicle to
and connectors. With air pressure at 100 psi, vehicle.
brakes released and engine off, loss of tractor
air pressure must not exceed two psi a minute. 7. The return springs must retract the shoes
Total tractor and trailer loss must not exceed completely when the brakes are released.
three psi per minute. Replace the return springs each time the
brakes are relined. The spring brakes must
2. Check to see that the air compressor drive belt retract completely when they are released.
is tight. Air system pressure must rise to
approximately 100 psi in two minutes. 8. The “AL” factor is air chamber area
multiplied by slack adjuster length. Figure 41.
3. The governor must be checked and set to the The “AL” factor must be equal for both ends
specifications supplied by the vehicle of a single axle and all four ends of a tandem
manufacturer. axle.
4. Both the tractor and trailer air systems must
Figure 41 m
match the specifications supplied by the
vehicle manufacturer.
5. Both wheel ends of each axle must have the
same linings and drums. All four wheel ends
of tandem axles also must have the same
linings and drums. It is not necessary for the
front axle brakes to be the same as the rear
driving axle brakes. Figure 40.
Figure 40
TANDEM AXLES FRONT AXLE AL FACTOR = “A” x “L” -

“A” = AIR CHAMBER AREA
-v It “L” = LENGTH OF SLACK ADJUSTER
+
-0
c I
ID
BOTH WHEEL ENDS OF EACH AXLE MUST

HAVE IDENTICAL DRUMS AND LINING
Page 25
Section 8
Recommended Periodic Service
1. Brake Adjustment - when the air chamber 5. Drums - check at reline.
stroke exceeds the limits shown in Figure 42. 6. Major Inspection - at each reline.
Figure 42 7. Complete Overhaul - at every second reline
or as required.
MAXIMUM STROKE AT WHICH BRAKE
MUST BE ADJUSTED4 SO-90 PSI A schedule for the periodic adjustment, cleaning,
(550-620 kPa) AIR PRESSURE IN THE AIR inspection and lubrication of the brake equipment
CHAMBER. CLAMP TYPE AIR must be made according to experience and the
CHAMBER. type of operation.
CHAMBER STROKE LENGTH Brakes must be adjusted as frequently as required
TYPE (SIZE) NOT TO EXCEED: for correct operation and safety. The adjustments
9 l-3/8 inches (34.9 mm) must give correct clearance between the lining
12 l-3/8 inches (34.9 mm) and drum, correct pushrod travel and correct
16 l-3/4 inches (44.4 mm) balance between the brakes.
20 l-314 inches (44.4 mm)
24 l-3/4 inches (44.4 mm)
30 2 inches (50.8 mm) A CAUTION
36 2-l/4 inches (57.1 mm) Do not let brake lining wear to the point that the
rivets or bolts touch the drum. Damage to the
*NOTE: The U.S. Department of Transportation drum will occur.
(DOT), Federal Highway Administration has NOTE
issued the above specijications for cam brakes.
Correctly adjust wheel bearings before adjusting
NOTE the brake.
The adjusting bolt on some manual slack Brakes must be cleaned, inspected, lubricated and
adjusters can reach the limit of its adjustment adjusted every time the wheel hubs are removed.
before the linings are completely worn. To get
During a major overhaul, the following parts must
additional adjustment, do the following:
be carefully checked and replaced with genuine
A. Completely retract the brakes. Rockwell Replacement Parts if required:
B. Remove the slack adjuster.
1. Backing plates or spiders for distortion and
c. Turn the camshaft to force the brake shoes loose bolts
apart. Install the slack adjuster so that its
arm is one spline closer to the clevis than 2. Anchor pins for wear and correct alignment
before. 3. Brake shoes for wear at anchor pin holes or
D. Adjust the brake. roller slots
2. Lubrication - lubricate the brake and slack 4. Camshaft and camshaft bushings for wear
adjuster according to the schedules on page 5. Shoe return springs must be replaced
26.
6. Brake linings for grease on the lining, wear
3. Minor Inspection - at each lubrication. and loose rivets or bolts
4. Brake Reline - when the thickness of the 7. Drums for cracks, deep scratches or other
lining is l/4 inch (6.3 mm) at its thinnest damage.
point.
To help ensure maximum lining life, Rockwell
recommends that springs, rollers, and anchor pins
be replaced at each reline.
Section 9
Federal Roadside Brake Adjustment Inspection
5. Release the brakes. nailer Only
6. Calculate the adjusted chamber stroke of each
1. Connect an auxiliary air system to the
brake:
SUPPLY or EMERGENCY port of the trailer
A. Subtract the dimension that was measured air system.
in step 2 from the dimension measured in
step 4. 2. Increase the air pressure to100 psi
MlNlMUM to release the spring chambers.
B. The difference between the two
dimensions is the adjusted chamber 3. With the brakes NOT APPLIED, measure the
stroke. The adjusted chamber stroke distance from the bottom of the air chamber to
MUST NOT BE GREATER THAN THE the center of the large clevis pin on all the
STROKE LENGTH SHOWN IN brakes. Figure 43A. Record each dimension.
FIGURE 44 for that size air chamber. 4. Connect a second auxiliary air system to the
C. If the adjusted chamber stroke you SERVICE port of the trailer air system.
measured is greater than the maximum
5. Increase the air pressure of the second air
stroke shown in Figure 44, inspect the
system to 85 psi to apply the service brakes.
slack adjuster. Refer to the manufacturer’s
instructions. If Rockwell automatic slack 6. Repeat step 3 and measure WITH THE
adjusters are used, refer to Rockwell SERVICE BRAKES APPLIED. Figure 43C.
Maintenance Manual No. 4B, “Automatic Record each dimension.
Slack Adjuster.” 7. Calculate the adjusted chamber stroke of each
brake:
Figure 44
A. Subtract the dimension that was measured
MAXIMUM STROKE AT WHICH BRAKE in step 3 from the dimension measured in
MUST BE ADJUSTED? 80-90 PSI step 6.
(550-620 kPa) AIR PRESSURE IN THE AIR
CHAMBER. CLAMP TYPE AIR B. The difference between the two
CHAMBER. dimensions is the adjusted chamber
stroke. The adjusted chamber stroke
CHAMBER STROKE LENGTH MUST NOT BE GREATER THAN THE
TYPE (SIZE) NOT TO EXCEED: STROKE LENGTH SHOWN IN
9 FIGURE 44 for that size air chamber.
l-3/8 inches (34.9 mm)
12 C. If the adjusted chamber stroke you
16 measured is greater than the maximum
20 stroke shown in Figure 44, inspect the
24 slack adjuster. Refer to the manufacturer’s
30
2 inches (50.8 mm) instructions. If Rockwell automatic slack
36
2-l/4 inches (57.1 mm) adjusters are used, refer to Rockwell
Maintenance Manual No. 4B, “Automatic
Slack Adjuster.”
*NOTE: The U.S. Department of Transportation
(DOT), Federal Highway Administration has
issued the above specifications for cam brakes.
Section 10
Torque Chart
FASTENER TORQUE CHART FOR CAM-MASTER BRAKES
HOLD DOWN CLIP (21
(SoMb MCDbLS) CAM BRACKET MOUNllNG (4) PUSH ROD LOCK NUT (1)
.250’-28 Thread 0”Thd 25’1Th d
105-135 lb-in (12-15 N.m) 12~?b-ftr~?22-163 N.m) 25-g lb-ft~34~N.m)
Grade 5 = 65100 lb-ft (88-136 N.m)
.500”-20 Thread
\ .625’-18 Thread 20-30 lb-R (27-41 N.m)
r SHIELD MOUNTING (4) Or (61 Plain Nut =150-180 lb-R (203-258 N.m)
(r=Mb MCDbLS Lock Nut = 130-185 Ibft (178-224 N.m)
.312”-18 Thread)
12-20 lb-ft (16-27 N.m) \\
.375’-16 Thread ADD CAMSHAFT SPACING WASHERS so
Grade 8 = 30-50 lb-ft (41-68 N.m) THAT SLACK ADJUSTER FL2LlzNED
Grade 5 = 2535 lb-R (34-47 N.m) WITH AIR CHAM
\\
ANCHOR PIN SET SCREW (2)
.-.-
375”-16 .- Thread
-_-
10 lb-R (14 N.m) MINIMUM \ /
..-- ._ . ..._.._
185350 lb-ft (250-474 N.m)
(15 X 4 Q-BRAKE ONLY)

325-375 lb-ft (441-508 N.m)
BRAKE MOUNTING BOLTS ’

Grade 8 bolts with lock nuts andtwo
hardened washers on each bolt.
GREASE FITTING (1)
Bolt (SGM’= MmbLS)
Size Torque l/8” D seal
3-5 lb-ft (r -7 N.m)
7/16”-26 60-75 Ibft (81-102 N.m)
l/2”-20 85115 lb-ft (115156 N.m) I
9/l r-18 130-i 65 Ibft (176-224 N.m) I
5/8’-18 180-230 lb-ft (244312 N-m) ADD CAMSHAFT SPACING WASHERS TO
PROVIDE 0.060’ MAXIMUM END PLAY
AIR CHAMBER MOUNTfNG (2)
SPRING
Chbr. Size 9 12 16 20 24 30 36 CHAMBER
Bendix 20-30 lb. ft. 30-45 lb. ft. 45-65 lb. ft. 65-85 lb. ft.
(27-41 Nom) (41-61 Nom) (61-B Nom) (s-115 Nom)
Midland 35-50 lb. ft. 70-100 lb. ft.

(48-68 N=m) (95-136 Nom)
MGM 35-40 lb. ft. 100-115 lb. ft.

(48-54 N*m) (136-156 Nom)
Anchorlok 110-115 lb. ft with hex nut and washer

(149-203 Nom)
85-95 lb. ft. with lock nut and washer

(115-129 Nom)
Section 11
Q Series and Q Plus Brake Conversion Kits
Q Series Brake Conversion Kits are available to Kits are also available to upgrade standard
change P Series Cam-Master brakes (except 16.5 inch Q Series brakes to Q Plus brakes. These
models with cast shoes) into Q Series brakes with kits include all the necessary hardware.
“Quick Change” brake shoes. Figure 45. Q Series and Q Plus brake conversion kits are
These kits contain all the parts needed to change available from:
one P Series brake to Q Series brake. Each kit Rockwell International
contains two shoe and lining assemblies, two Florence Distribution Center
anchor pins, two anchor pin bushings, two shoe 7975 Dixie Highway
retainer springs, two brake shoe rollers, two brake Florence, Kentucky 41042
shoe roller retaining clips and one brake shoe
return spring. Instructions are included in each
kit.
Figure 45
BRAKE SHOE
AND LINING
ASSEMBLY
REANERa!!
CLIPS
I
Page30 Intended for CLARK dealers only
Section 12
Cam Brake Tips
Return Springs - Replace cam brake return you lubricate the bushings at least four times
springs at every cam brake reline. The return during the life of your brake lining.
spring is critical to alignment, accurate return of
the brake away from the drum and proper Brake Kits - Rockwell brake shoes, rollers,
automatic slack adjustment. camshafts and shoe return springs are designed to
perform as a system. Always install OEM spec-
Linings - Insist on the same brand of quality level components during maintenance or when
OEM friction lining material to help ensure fewer you upgrade from standard to long-life brakes to
relines and greater compatibility with your help ensure proper brake performance and
present system. maximum lining life.
Hardware - When you service cam brakes, Cam Heads - Cam heads can look the same, but
replace all the springs, anchor pins, bushings and that doesn’t mean they will perform the same in
rollers - not just the shoe return springs - to your brake system. Two cam head profiles can
help ensure maximum braking performance. appear to be identical, but very small differences
in cams from different manufacturers can be
Drums - To help ensure balanced braking, even significant enough to affect the performance of
lining and drum wear, and proper function of the your brakes. To ensure a balanced brake system
automatic slack adjuster, do not install a cast and optimum lining and drum life, always install
drum and a centrifuse drum on the same axle. the proper replacement cam.
A cast drum and a centrifuse drum each absorbs Cam Rollers - To avoid flat spots, lubricate a
and dissipates heat differently. When drum types cam roller directly in the web roller pocket and
and weights are mixed, different rates of heat not at the cam-to-roller contact area. Plat spots
absorption and dissipation occur that can affect can affect brake adjustment and result in
the brake system. premature brake wear or reduced braking
performance.
Air Chambers - To ensure proper brake
balance, all brake chambers on the same axle Automatic Slack Adjusters -
must be the same size and type to help ensure a
balanced brake system and maximum lining wear “Automatic” doesn’t mean maintenance-free.
and drum life. Properly installed and lubricated automatic
slacks help to ensure maximum brake system
Replacement Parts -Always use OEM quality performance.
standard parts. Rockwell brakes work as a system,
Never mix automatic slack adjusters on the
and when you replace original parts with “will-
same axle. When you replace automatic slack
fit” parts, you can compromise the performance of
adjusters, always use replacement parts that
the entire system.
were originally designed for the brake system
Trailer Cam Brakes - Long-life bushings to help ensure even brake wear, balanced
require proper lubrication for maximum braking and maximum brake performance.
performance and bushing life. Although you do
not have to replace spider cam bushings on trailer
axles as frequently, Rockwell recommends that
Page 3 1
GROUP 25
C500 Y 1809200-225S-225L-25OS-250L-3OOS-300L-350
GROUP 25-STEERING COLUMN AND STEERING GEAR
Removing Steering Handwheel ..................................... Section 2
Removing Column & Gear & Gear from Column.. .... Section 3
Steering Pump Removal and Overhaul ........................ Section 4
SM 575, July 97
‘ Copyrighted Material Steering Column and Steering Gear
C500 Y2235 Group 25
SECTION I
TROUBLESHOOTING
SM575 Copyrighted
SectionMaterial
Tile Page July 97
1. Hydraulic fluid level very low. 1. Check fluid level. Fill as

required.
1 No steering. I- 2. Hose broken. 2. Replace hose.
3. Power steering pump 3. Repair or replace power
defective. steering pump.
1. Hydraulic fluid level very low. 1. Check fluid level. Fill as

necessary.
2. Power steering pump - 2. Repair or replace power
defective. steering pump.
3. Steering gear box defective. 3. Repair or replace steering
gear box.
[ 1. Hydraulic fluid level low. I I 1. Check fluid level. Fill as

required.
2. System leaking. 2. Check for leaks. Repair as
IWheels turn but

requires effort.
3. Incorrect tire pressure.
4. Lack of lubrication.
necessary.
3. Correct tire pressure.
4. Lubricate.
C500 Y2235 Group 25
SECTION2
REMOVING STEERING HANDWHEEL

CLCIRK Group 25, Steering System
STEERING HANDWHEEL REMOVAL
_/-_\
I-
I’ ,‘
1’
/
I
I
I
I
I
I
I
I
I
/;
’ \ ,I
\
\ __’ /’
'\T.., \.‘ .,
i-i
,,,: ;
\‘ ./’
L./
‘
1. Disconnect battery cables at the battery. 6. Remove screws holding inner retainer and remove
inner retainer.
2. Lift flexible horn cover off steering handwheel hub.
7. Loosen and remove steering handwheel nut.
3. Put screwdriver in slot in horn button cover plate
and rotate cover in steering handwheel hub to unlock 8. Lii off steering handwheel.
from tabs in hub. Remove cover plate.
9. Reassemble in reverse order. Torque steering
4. Remove spring cover, spring and spring seat. handwheel nut to 147-54 Nom] 35-40 Ibf-ft.
5. Loosen screws holding outer retaining plate. Push

horn switch to side and out of slot allowing outer
retaining plate to be lifted off.
SM 575, July 9
‘7 Intended for CLARK dealers onlySteering Handwheel Removal . 25-2-l
C500 Y2235 Group 25
SECTION 3
REMOVING COLUMNAND GEAR
AND GEAR FROM COLUMN
Section
Material July 97
SM575
ClRRK Group 25, Steering System
REMOVING STEERING COLUMN AND COLUMN FROM STEERING GEAR
Column and Gear Removal Removing Column From Gear
! CABLE AND
A CONTACTOR
- INSULATOR
’ SPRING
\
WASHER
HORN WIRE CONNECTOR

1. Remove instrument panel and trim instrument panel.
I’
k
2. Position suitable container under truck to catch any
spilled hydraulic fluid. Disconnect power steering lines “\
from steering gear. Cap or plug all fittings and hoses. MACHINE SCREW
A
3
WARNING
- 12 POINT CAPSCREW
Hydraulic fluid is toxic to skin, eyes
and respiratory tract. Avoid skin and 1. Matchmark steering column to gear for reassem-
eye contact. Good general ventilation bly.
is normally adequate.
2. Remove 12 point capscrews holding column to
3. Remove bolts, lock washers, flat washers and nuts gear.
holding steering column bracket to cowl.
3. Remove machine screw and horn connector as-
4. Slide bracket with cushion off steering column. sembly.
5. Reassemble in reverse order. 4. Tie a length of string to electrical connector inside

column assembly for easy retrieval, the disconnect
wires.
5. Pull cable and contactor, insulator, spring and

washer from column.
6. Separate washer, spring and insulator from cable

and contactor.
7. Reassemble in reverse order using matchmarks to

line up column and gear.
SM 575, July 9
‘7 Intended for CLARK dealers only Steering Column Removal l 25-3-l
C500 Y2235 Group 25
SECTION 4
STEERING PUMP
REMOVAL AND OVERHAUL
SM575 Copyrighted
SectionMaterial
Tile Page July 97
Group 25, Steering System
STEERING PUMP REMOVAL AND OVERHAUL
Steering Pump Removal
SPLINE
1. Remove suction and pressure hydraulic lines from
steering pump. Cap or plug exposed fittings and ports. ADAPTER
2. Remove nuts and washersfrom mounting studs and STEERING PUMP

remove pump from transmission.
Steering Pump Overhaul
CAPSCREW
GASKET
GEAR
WEAR PLATE
\ STRAIGHT HEADLESS PIN
THRUST PLATE
Disassembly
A CAUTION
Cleanliness is of extreme importance in
overhaul of this unit. Before
disassembly, clean exterior thoroughly
to prevent dirt and foreign matter from
entering assembly. Disassemble unit
on clean work surface in dirt free area. BEARING
S,M575, July 9
‘7 Copyrighted MaterialSteering Pump Removal and Overhaul l 254-l
Disassembly (continued) b. Inspect internal surfaces for minor nicks or

scratches.
1. Matchmark cover and body to aid alignment
during reassembly. c. Inspect gasket area for burrs or sharp edges.
2. Remove capscrews and washers. 3. Inspect the gears as follows:
3. Separate cover fmm body. a. Inspect shafts for scores, grooves, nicks or
WGU.
4. Remove and discard gasket.
b. Inspect gear teeth for nicks and cracks.
5. Remove thrust plate.
4. Inspect thrust plate and wear plate for for scoring
6. Remove both gears.
or discoloration.
7. Remove wear plate and seal. Discard seal.
8. Remove bearing from body.
9. If damaged, remove straight headless pins from
A CAUTION
If thrust or wear plate defects are found,
body* it will be necessary to troubleshoot the
entire hydraulic system. Scoring
A CAUTION
indicates fluid contamination
discoloration indicates overheating.
and
If metal partivles are found on pump

components, the entire hydraulic Repair and Replace
system may be contaminated. This will
require cleaning the entire system and 1. Replace all worn or damaged parts. In addition,
refilling with clean hydraulic fluid. perform the following steps:
a. Remove minor scratches or scoring with cro-
Cleaning cus abrasive cloth.
1. Carefully wash all parts in approved cleaning b. Dress seal and gasket areas as necessary.
fluid. After cleaning, allow parts to air dry or use a
clean lint-free cloth.
Reassembly
1. If removed, install straight headless pins in body.
Inspection
2. Install bearing in body.
1. Inspect the body as follows:
3. Install seal and wear plate.
a. Inspect fear area for excessive wear.
4. Install gears.
b. Inspect internal surfaces for minor nicks or
scratches. 5. Install thrust plate.
c. Inspect seal grooves for burrs or sharp edges. 6. Install gasket.
2. Inspect the cover as follows: 7. Align cover with body and gear shafts. While
making sure gasket maintains proper position, push
a. Inspect gear shaft area for excessive wear.
cover over straight pins.
8. Installcapscrews and washers.
2!5-4-2 l Steering Pump Removal and OverhaulCopyrighted Material SM 575, July 9

‘7
Reinstall Steering Pump In Truck
1. If removed, install studs.
2. Install spline adapter on shaft of pump assembly.
3. Install gasket on studs.
4. Align steering pump assembly on studs and se-

cure using washers, lockwashers and nuts.
5. Remove caps or plugs and reinstall suction and

pressure hydraulic lines on steering pump.
6. Start engine and operate steering to left and right

direction to purge air from steering system.
7. Observe all hydraulic connections for any evi-

dence of leakage.
8. Check level of hydraulic fluid in sump tank and fill

as necessary.
SM 575, July 9
Steering Pump Removal and Overhaul l 25-4-3
GROUP26
C500 Y180-200-225S-225L-25OS=250L-3OOS-3OOL-350
GROUP264TEERAXLE
Steer Axle Removal ........................ ......................... ........ Section 2
Steer Axle Overhaul ... .. ............... .... ... .......................... ... Section 3
2-Piece Kingpin Design ............................... ................... 26-3-l
Single Piece Kingpin Design (Lot 8446 and above) ... 26-3-11
Steer Cylinder Removal and Overhaul . ........................ Section 4
Steer Cylinder Overhaul (Lot 7056 and Above) . ......... Section 5
Steering System Pressure Check ...................... .. ... ........ Section 6
SM 575, July 9
‘7 Copyrighted Material Steer Axle
C500 Y2235 Group 26
SECTION I
TROUBLESHOOTING
SM575 Copyrighted
SectionMaterial
Tile Page July 97
Constant noise from 1. Loose or worn hub bearing 1. Adjust or replace hub bearing
steering axle. cone(s). cone(s). Replace bearing
I set.
1. Worn bearing(s) in steering 1. Replace bearing(s).

arm.
2. Worn pin in steering knuckle. 2. Replace pin.
Noisy on turns only. 3. Worn bearings cones in 3. Replace bearing cones.
steering knuckle.
4. Capscrews securing cap(s) to 4. Tighten capscrews.
steering knuckle are loose.
1. Lack of lubricant in steering 1. Lubricate steering axle

axle mounting. mounting.
Noise when axle pivots. 2. Steering axle mounting 2. Replace bushing.
bushing worn.
3. Steering axle mounting cap(s) 3. Tighten mounting cap(s).
loose.

26-l-l July 97
C500 Y2235 Group 26
SECTION 2
STEERAXLE REMOVAL
Copyrighted
SectionMaterial
Tile Page
ElfIRK Group 26, Steer Axle
STEER AXLE REMOVAL
1. Parktruckon a level surface. Chockfront and back 5. Lii rear of truck with hoist and place suitable jack
of drive wheels. Lower forks to floor. Apply parking stankds under truck.
brake.
6. Remove steer tires.
7. Remove hydraulic hose as shown. Cap or plug all

exposed hose ends and fittings. Secure hoses out of
2. Remove counterweight grill the way of axle removal.
3. Add chain to eyebolts.
4. Use a suitable hoist and lift counterweight off and

pull away from truck.
A
Counterweights
WARNING
used on this model
series weigh as little as 4,680 Ibs [2123 8. Using a suitable lift truck as shown, place forks
ig] on the lightest short wheel base under axle to support it while clamp and mounting bolts
truck to as much as 15,240 Ibs [6913 are removed.
kg]on the long wheel base Marina truck.
Be sure your lifting equipment is of
sufficient capacity.
SM 575, July 9
‘7 Copyrighted Material Steer Axle Removal l 26-2-l
Group 26, Steer Axle ElfIRK
AXLE -1 L BOLT
LOCK WIRE /
9. Cut and remove lock wire from bolt heads. Re-
move bolts from axle clamps.
A ! CAUTION
Supportclamp as bolts are withdrawn.
Clamp is heavy and will come off with
bolts and could fall and damage
threads.
L ZERK
10. Lower axle and remove from undertruck. Remove
spacers, bushing and grease zerks.
11. When reinstalling axle, repeat steps 2 - 10 in

reverse order.
AXLE -I L BOLT
LOCK WIRE /
12. Add clamps and bolts. Torque to 475 - 525 Ibf-ft.

1644 - 711 Nom]. Add lock wires to bolts as shown.
26-2-2 . Steer Axle Removal Copyrighted Material SM 575, June 97

‘
C500 Y2235 Group 26
SECTION 3
STEER AXLE OVERHAUL
SM575 Copyrighted
SectionMaterial
Title Page July 97
ClfMW Group 26, Steer Axle
STEERAXLEOVERHAUL
SPINDLE NUT
1. Remove allen head screws. 4. Wipe grease from spindle and spindle nut and
remove nut.
PRY BAR
O-RING
HUB COVER
2. Remove hub cover and O-Ring.
5. Use pry bar to force hub away from, but not off of,
knuckle. Stopwhen the bearina reaches the end of the
BEARING
3. Add lifting tool and 5/8” hex nut to one of the studs
on the hub. Put web belt through the tool and attach to
hoist with a 1 ton min capacity. 6. Push hub back to knuckle. Pull bearing off of end
of spindle. Use hoist to remove hub from spindle.
SM 575, July 97
‘ Steer Axle Overhaul l 26-3-l
Group 26, Steer Axle ClflRK
SEAL
REAR OF HUB
RACE
7. Pry out bearing seal. 10. Knockoutthe rearbearing race. Knockthe raceout
from the front side of the hub.
REPLACEMENT / REASSEMBLY
NOTE: If bearing races were removed, they must be
machine pressed back into the hub before proceeding.
BEARING
-BEARING
8. Remove rear bearing.
11. Add bearing to rear of the hub.
NOTE: Do not grease the bearings at this time.
FRONT OF HUB <v- SEAL
9. Use hammer and punch to knock out front bearing 12. Add new bearing seal. Tap seal into place to be
race. Knock the race out from the rear of the hub. sure of a good, tight seal.
26-3-2 l Steei Axke Overhaul SM 575, July 97

‘
C5OOY2235 Group26
SECTION 4
STEER CYLINDER
REMOVAL AND OVERHAUL
Section
Material
CMRK Group 26, Steer Axle
STEER CYLINDER REMOVAL AND OVERHAUL

(Trucks prior to Serial Number Y2235I-7056)
DISASSEMBLY
LOCK WASHER
BOLT -
ALLEN HEAD
PIN
1. Remove bolts, lockwashers and locking pins from 4. Remove allen head screws.
both ends of the cylinder. Remove pins, swing drag link
out of the way.
BOLT
CYLINDER
5. Remove cover.
0@
@
2. Remove bolts.
0
7 CYLINDER 0
0 0
0
6. Pry out bearing seal.
NOTE: Seal will be damaged and must be replaced.
3. Pry cylinder off axle. Move cylinderto a flat, sturdy

work surface.
NOTE: A tray, pan or pail should be placed under the

cylinder or kept under the work surface.
SM 575, July 9
‘7 Copyrighted MaterialSteer Cylinder Removal and Overhaul l 26-4-l
Group 26, Steer Axle CUMU
\ HOUSING 1 REASSEMBLY
7. Pull off housing. Fluid will pour out from the hous- 10. Add new bearing seal. Tap seal into place to be
ing and from the cylinder. Be sure fluid pours into a sure of a good, tight seal.
container.
- O-RING
INNER O-RING
11. Add cover gasket (Seal) over O-ring.

WEAR RING 1 v
U-CUP SEALA
8. Remove gasket and spring gasket. Remove
O-ring, back-up ring and inner O-ring.
PISTON ROD ASS’Y
CYLINDER
12. Add cylinder over shaft.
INNER O-RING
- PISTON SEAL
9. Pull cylinder off of shaft. Remove cover gasket and

O-ring from shaft.
13. Add inner O-ring, spacer and O-ring to the end of
the housing.
26-4-2 Steer Cylinder Removal and Overhaul SM 575, July 97

‘
l
ElfIRK Group 26, Steer Axle
- CYLINDER
14. Add housing over shaft into end of cylinder.

18. Add seal to cover.
LOADING COVER
ALLEN HEAD
SCREWS
15. Add gasket loading cover
19. Add cover and allen head screws. Torque to 25 - 28
Ibf-ft.
PRING GASKET
16. Add spring loaded gasket and gasket
GASKET PUSH TOOL

20. Be sure mounting pins are in the cylinderfeet. Align
the pins with the holes in the axle. Tap cylinder into
place.
17. Force gasket into housing with gasket push tool.
SM 575, July 97
‘ Copyrighted MaterialSteer Cylinder Removal and Overhaul l 26-4-3
Group 26, Steer Axle CWIRK
21. Add bolts. Torque to 300 - 340 Ibf-ft.
SHAFT END
DRAG LINK
22. Swing drag link into shaft end. Align holes.
BOLT -
LOCK WASHER - PIN
PIN
23. Add grease zerk to pin. Add pin, lock pin, lock-
washer and bolt. Torque to 25 - 28 Ibf-ft.
26-4-4 l Steer Cylinder Removal and Overhaul

‘
Group 26, Steer Axle
Back-Up Ring-
v Blue
od Wiper (Excluder@
Typical lllustratlon

‘7
264-4 l Steering Cylinder Overhaul
Disassembly Inspection
l Remove both glands from housing and piston $ealing Surfaceq
rod.
l Sealing surfaces of the piston rod, cylinder
l Carefully pull piston rod from cylinder housing housing and glands must be smooth free of
bore. Do not scratch, nick or mar components. scratches, nicks or burrs.
l Remove and discard wiper rings, step seals, Lead In Surfacq
wear rings, back-up and O-rings from their
l Lead in surfaces of the piston rod, housing bore
grooves in both cylinder glands. Note location
and gland grooves must be smooth, free of sharp
of components upon removal.
edges, scratches or burrs.
Be car@ that you do not scratch or mar the ReuairintzMinor Dam=
inner surface of the glands. Scratches and nicks
on sealing w&aces can cause damage to new A Crocus Cloth may be used to remove minor
components resulting in leakage. scratches, burrs and sharp edges.
l Remove and discard the piston ring from the Never use sandpaper or emery cloth. Doing so, will
piston on the piston rod. cause further damage to parts.
Again, be car@ that you do not scratch , nick Polished surfaces may be smoothed up with a Crocus
or mar the cylinder piston or piston rod. Cloth, but be careful not to wear off the chrome
plating.
Cleaning l Discard and replace any part that cannot be
l Wash cylinder glands, rod and housing in a cleaned or buffed without changing tolerances
Stoddard type cleaning solvent. to the point of leakage.
l Wipepartsdrywithacleanlintfieecloth.Allow l Discard any chrome plated part that has plating

inner grooves and surfaces to air dry. worn off or is badly scratched, nicked or marred.
A WARNING
0
Remove All Jewelry WHEN USING AIR PRESSURE:
1 ---------mm-
Before Handling Parts. 1Wear eye protection and 1
1 protective clothing when 1
1 drying with air pressure. I
I Reduce air pressure to 30 PSI I
I (207 kPa). Debris removed with I
1 air pressure can cause injury. ,
0
Wash Metal Parts In
2
Stoddani Type Solvent.
0 4 Inspect All Parts For Damage.
03 Air Dry Metal Parts Lubricate All Parts With
0 5 Hydraulic Fluid Prior To 63

MS-68
Assembly.
SM 575, July 9
‘7 Copyrighted Material SteeringCylinderOverhaul l 26-5-5
Hydraulic System Reservoir
Steering C
1
to Aux Pump
(From Sump)
r
I
i I
I I /... -‘- ’
I I
1 I
I I
I I
I I PressureTesting Gauge
1 I \
1 I
1 I
I I
I I
c\ I
I
I
Install a 7
‘” Fitting between Elbow & Hydraulic
Hose
Connect Gauge to the T‘ ’ Fitting
c
-Auxiliary (Steer) Pump
- Steering Cylinder
26-6-2 l Steering System Pressure Check Copyrighted Material SM 575, July 97

‘
1 O-Ring
Seal
2 Spring Guide
3 spring
4 Ball and Ball Holder
5 Screen
SM 575, July 9
‘7
26-6-4* Steering System Pressure CheckCopyrighted Material
GROUP 29
C500 Y 180-200-225S-225L-250S-250L-300S-300L-350
GROUP 29-HYDRAULIC FILTERS
Hydraulic Filters (Lots prior to 8506) .......................... Section 1
Hydraulic Filters (Lots 8506 and above) ...................... Section 2
SM 575, July 9
‘7 Copyrighted Material Hydraulic Filters
Group 29, Hydraulics
Section 1
Hydraulic Filters
Contents
Filter Locations . .. ... .. ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . ... .. .. .. . .. . .. .. .. .. .. .. .. .. .. ..I... 29-l-2
Filter Service . . . .... .. .. .. .. .. .. .. ... .. ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. . ... . .. .. ....29-l-3
NOTE
This section covers the filtration s stem used
rior to lot 8506. For system used i6eginning lot
%506 and above, see Group 29, Section 2.
AWARNING
When using air pressure to blow off truck or parts: Wear eye
protection and protectiveclothing when drying with air pressure.
Reduce air pressure to 30 PSI (207 kPa). Debris removed with air
pressure can cause injury.
AWARNING A CAUTION
Hydraulic fluid is toxic to skin, Cleanliness is of extreme
eyes, and respiratory tract. importance. Before removing
Avoid skin and eye contact. filtersfrom truck,clean exterior
Good ventilation is normally around the filter canisters to
adequate. prevent dirtand foreign matter
from entering the reservoir.
Always wear Safety Glasses
SM 575, July 9
‘7 Copyrighted Material Hydraulic Filters l 29-l-l
A Remove all Jewelry before working on truck.
Hydraulic Sump Tank & Filters

Under normal operating conditions the hydraulic
filters should be replaced with new every 500 operat-
ing hours. The hydraulic fluid should be drained and
the pick up screens cleaned every 2,000 operating
hours or once a year which ever comes first.
Pretxiration
0 Move truck to a flat, clean work area.
l Fully lower upright and shut engine down.
l Apply parking brake.
l Open hood and remove side panels providing Park truck on flat, clean surface.
access to the hydraulic system filters.
l Have available a suitable container to hold ap-
proximately 50 gallons of hydraulic fluid.
0 Air clean area around sump filters.
AWARNING
WHEN USING AIR PRESSURE:
Wear eye protection and

protective clothing when
cleaning with air pressure.
Reduce air pressure to 30 PSI
(207 kPa). Debris removed with
air pressure can cause injury.
29-l-2 l Hydraulic Filters Copyrighted Material SM 575, July 9

‘7
Draining Hydraulic Reservoir

The Hydraulic System Fluid and Screens
should be serviced every 2000 operating hours or
once a year whichever comes first. Each hydraulic
filter has a pick up screen located at the bottom of
thecanistertube.Thesteeringcircuithasastrainer
screen located in the top side of the sump tank
beneath a rubber elbow. (See illustrationbelow.)
Tank should be drained when the hydraulic fluid is
near operating temperature.
l Position a suitable container (approx. 50 gal.
capacity) beneath the sump tank drain plug.
0 Remove dram plug and allow tank to dram Typical Illustration
completely.
NOTE
l Install drain plug and tighten securely.
g, WARNING Dispose of hydraulic fluid in

Hydraulic fluid is toxic to skin, accordance with local regulations.
eyes, and respiratory tract.
Avoid skin and eye contact.
Good general ventilation is
normally adequate.
Changing Filter Element(s)

The SystemFiltersshould be replaced with new
ones every 500 operating hours.
0 Loosen cover clamp at each hydraulic filter
assembly.
A CAUTION
Cleanliness is of extreme
importance. Before removing
filtersfrom truck,cleanexterior
around thecanistersto prevent
dirt and foreign matter from
entering the reservoir.
0 Remove cover and cover seals. Discard seals.

If the hydraulic system strainer screens are to be
serviced at this time, follow the next two steps other-
wise continue to next page.
l Loosen and remove clamps securing manifold
inlet Tube
hoses to the canisters.
Rubber Elbow
l Loosen clamp and rernove rubber elbow from Typical Illustration
inlet tube on top of sump.
SM 575, July 9
‘7 Copyrighted Material Hydraulic Filters l 29-l-3
ClflRK Group 29, Hydraulics
Hydrauli
Hydraulic Filter Assembly Filter Assem
Cover & Spring
Clamp
Nut-!
I
Lock Washer-----Q
I
Washer
Element +iz
Iv Gaskets
D
Elbow
Clamp
- Screen
,,‘.’
,i-’ Typical Illustration
Typical Illustration .T’

‘7
Group 29, Hydraulics ElfIRK
l Remove filter element from each canister. Dis-

card old elements.
l Thoroughly clean inside of each cansister with
a clean cloth.
Strainer Screens
Remove Steer Circuit Strainer Screen:
l Lift screen off sump tube and out of reservoir.
Remove Canister & Screens:
Remove clamps securing each manifold return
line to the filter canisters.
Cover
Remove stud nuts, lo&washers and washers
securing each of the filter canisters to the top of
t the reservoir.
Pull each canister straight upward allowing the
pick up screens to clear the reservoir cover.
Remove clamps securing each pick up screen to
the canister tubes.
Flange
T- 17 the canister is
Pull screens free of their canister tubes.
Wash Canisters & Screens:
removed for any
reason, (prior to Wash the screens and canisters in a Stoddard
installation) the type cleaning solvent. Wipe them dry and with
flange should be
coated with 3M #77 a clean cloth.
Spray Adheasive or
equivalent. Place the screens on a clean surface allowing
them to air dry. They must be completely dry
before installing them back into the sump tank.
Discard gaskets located between the reservoir
cover and each canister. Be certain all gasket
material is removed from the sealing surfaces.
Reservoir Breather & Fluid Level Din Stick
l Remove and checkthe sump tank breather/dip
stick for further serviceability. If the breather is
unfit for further service, replace it with a new
one.
- Canister
l A new breather should be installed every other
P.M.
SM 575, July 9
‘7 Copyrighted Material Hydraulic Filters l 29-l-5
EmK Group 29, Hydraulics
Installation
Installing Canister Pick UD Screens
l Place a clamp over each canister tube.
l Install a strainer screen on each tube.
l Secure strainer screens with the clamps.
Installinp Canisters
l Spray the underside of each canister flange and
the bottom of each new gasket with 3M #77
adheasive or equivalent.
l Position a gasket between each canister flange
and the reservoir cover.
A CAUTION
Be certain the mounting holes
in the flange and gasket
properly line up with the
mounting studs located on the
top of the reservoir and Manifold & Hoses 1
reservoir cover. L Inlet Tube
Rubber Elbow
l Install each canister into the reservoir. Again,
make certain all mounting holes are in proper
alignment with the mounting studs. Fill Hydraulic Reservoir
l Install washers, lo&washers and nuts over the Remove breather cap and fill reservoir with
mounting studs. Alternately tighten thesenuts to hydraulic fluid per Clark specifications MS-68.
provide an air tight, leak proof seal.
Check fluid level periodically with dipstick.
InstallinE Filter Elements. Cover and Cover Seal Tank is full when level reaches full mark on the
dipstick.
l Install a new element into each canister.
Whenthetankisfilled,installsumpbreatherand
l Position a new seal over the lip of each canster.
purge system of air as follows:
l Carefully position each cover & spring over
* Start engine and operate all hydraulic control
gasket and canister aligning the spring cup with
levers several times ... puring air out of the lines
the hole in the center of the filter element.
back into the sump tank.
0 Correctly position each clamp over the lips of
l Shut engine down.
the each cover and canister to provide a positive
seal between these components. Tighten clamps. l Check fluid level with dipstick. Add fluid as
required. Install dipstick.
To assure the sealing areas are air tight and leak
proof,make certain these components are in proper l Start engine and operate hydraulic controls.
alignment before locking them in place with the
l Shut engine down and recheck fluid level. If
required bring level up to the full mark on the
dipstick.
Clark Part No. 885386 I-Case of 24 onequart cans
Clark Part No. 886382 l-Case of 6 one-gallon cans Reservoir Capacity: Approx. 46 gallons.
(Capacity varies with Truck & Mast Size)

‘7
Section 2
Hydraulic Filters
Contents
Filter Locations . .. .. .. ... .. ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. . .. .. 29-2-4
Filter Service . .. .. .. .. .. .. .. . ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. . .. .. .. .. .. .. .. . . .. 29-2-5
Refill Sump Tank . .. .. .. .. .. .. .. ... . ... . .. .. .. .. .. .. . .. .. .. .. . .. .. .. .. .. .. .. .. . .. . .. .. .. .. .. .. . 29-2-6
NOTE
This section covers the filtration system used
be inning lot 8506 and above.. For system used
be!ore lot 8506, see Group 29, Section 1.
AWARNING
When using air pressure to blow off truck or parts: Wear eye
protection and protectiveclothing when drying with air pressure.
Reduce air pressure to 30 PSI (207 kPa). Debris removed with air
pressure can cause injury.
AWARNING A CAUTION
Hydraulic fluid is toxic to skin, Cleanliness is of extreme
eyes, and respiratory tract. importance. Before removing
Avoid skin and eye contact. filtersfrom truck, cleanexterior
Good ventilation is normally around the filter canisters to
adequate. prevent dirt and foreign matter
from entering the reservoir.
Always wear Safety Glasses
SM 575, July 9
‘7 Copyrighted Material HydraulicFilters l 29-2-l
-
Drain Pan [50 Gal)
NOTE
Dispose of hydraulic fluid in

accordance with local regulations.
Draining Hydraulic Reservoir Changing Filter Element(s)

The Hydraulic System Fluid and Screens The System Filters should be replaced with new
should be serviced every 2000 operating hours or ones every 500 operating hours.
once a year whichever comes first. The main
A
hydraulic system has a strainer screen located
inside the sump tank. The steering circuit has a CAUTION
strainer screen located in the top side of the sump Cleanliness is of extreme
tank beneath a rubber elbow. importance. Before removing
filtersfrom truck,cleanexterior
Tank should be drained when the hydraulic fluid is around thecanistersto prevent
near operating temperature. dirt and foreign matter from
entering the reservoir.
* Position a suitable container (approx. 50 gal.
capacity) beneath the sump tank dmin plug.
l Remove dram plug and allow tank to drain
completely. Removing the main hydraulic strainer screen is very
difficult, requiring the removal of the entire filter
* Install dram plug and tighten securely. system For this reason, this will most often be done
A WARNING infrequently. Changing the filters elements at least
Hydraulic fluid is toxic to skin, every 500 operating hours or more often in adverse
eyes, and respiratory tract. operating conditions is important to keep the hydrau-
Avoid skin and eye contact. lic system fluid clean.
The steering system strainer screen can be removed
normally adequate.
easily and should be done frequently.
SM 575, July 9
‘7 Copyrighted Material Hydraulic Filters l 29-2-3
Hyd Sump Filler Cap Hyd Sump Filter Assembly
Hyd Sump Filter Screen
HYDRAULIC FILTER SYSTEM
29-2-4 ’ Hydraulic Filters Copyrighted Material SM 575, July 9

‘7
Filter Cap Bolt

Steer System Strainer Screen Filter Cap
Rubber Elbow
mp
een
\,, fq“ Filter Elemel

\ ,“-
\‘ Sonnector
Remove Steer Circuit Strainer Screen:

\‘
l Loosen clamp and pull off rubber elbow.
23
l Remove screen.
Wash Screen:
l Wash the screen in a Stoddard type cleaning
solvent. Wipe dry and with a clean cloth.
l Examine screen carefully for damage or clog-
ging that does not clean out. Replace if neces-
sary.
l Place the screen on aclean surface allowing it to
air dry. Screen must be completely dry before
installing back into the sump tank.
Renlace Filters:
l Remove filter cap bolts and remove spring
Reservoir Breather/Filler Cans loaded cap.
l Remove andcheckthe sump tank breather/tiller l Remove used filter elements and separate to
caps for further serviceability. If either breather extract connector.
is unfit for further service, replace it with a new l Join two new filter elements using connector.
one.
l Place new connected filter elements into filter
l New breather/filler caps should be installed housing and reinstall filter cap and bolts.
every other P.M.
SM 575, July 9
‘7 Copyrighted Material Hydraulic Filters l 29-2-5
GROUP 30
C500 Y 180-200-225S-225L-250S-250L-300S-300L-350
GROUP 30-HYDRAULIC COMPONENTS
Troubleshooting ................................... .. ......................... Section 1

.
Hydraulic Pump-General ............................................ .. . Section 2
Tyrone Hydraulic Pump Overhaul . .............................. Section 3
J. S. Barnes Hydraulic Pump Overhaul ......... .. ............ Section 4
Vickers Valve Overhaul .................................................. Section 5
Lift and Tilt Control Valve Overhaul . .. .. .... ....... ............ Section 6
Commercial Intertech Valve Overhaul ......... ................ Section 7
Hydraulic System Pressure Check ....... .. ....................... Section 8
Hydraulic Diagrams . .. .................................................... Section 9
SM 575, July 9
‘7 Hydraulic Components
C500 Y2235 Group 30
SECTION I
TROUBLESHOOTING

1. Hydraulic fluid very low. 1. Check fluid level. Fill as

required.
2. Hose broken. 2. Replace hose.
3. Hydraulic pump defective. 3. Repair or replace hydraulic
pump.
4. Defective main lift valve. 4. Replace main lift valve.
I pump. I
1. Worn or damaged lift piston 1. Replace seal.

Oil leak at top of lift seal.
cylinder(s). 2. Scored cylinder wall. 2. Repair or replace cylinder.
3. Plugged vent line. 3. Clean or replace vent line.
Oil leak at top or end of

1. Worn or damaged seal. _ 1. Replace seal.
tilt or auxiliary function
2. Scored piston rod. 2. Repair or replace cylinder(s).
cylinder.
1. Hydraulic fluid level low. 1. Check fluid level. Fill as

required.
2. Fluid intake pipe clogged. 2. Remove obstruction from
intake pipe.
I
Pump not delivering
hydraulic fluid. l-
3. Suction filters dirty.
4. Air leak in suction line.
- 3. Replace filter cartridges.
4. Tighten suction line or replace
if defective.
5. Fluid viscosity too high for 5. Replace hydraulic fluid with
pump to pick up prime. correct grade for given
temperature and service.
6. Defective hydraulic pump. 6. Repair or replace hydraulic
pump.
SM575 30-lMaterial
Copyrighted -1 July 97
1. Leak in hydraulic control 1. Find and repair leak.

system.
2. Partially clogged intake line. 2. Remove obstruction from
intake line.
3. Fluid intake pipe clogged. 3. Remove obstruction from
intake pipe.
4. Suction filters dirty. 4. Replace filter cartridges.
5. Defective hydraulic pump. 5. Repair or replace hydraulic
pump.
1. Air leak at pump intake. Check by pouring oil on joints

while listening for change in
noise level. Tighten joints.
2. Air leak at pump shaft packing. Repair or replace hydraulic
pump.
3. Hydraulic sump breather Replace breather.
clogged.
4. Fluid viscosity too high. Replace hydraulic fluid with
correct grade for given
temperature and service.
5. Sump filters dirty. Replace sump filter cartridges.
6. Defective hydraulic pump. Repair or replace hydraulic
pump.

Copyrighted SM575
C500 Y2235 Group 30
SECTION 2
MAIN HYDRAULIC PUMP
Section Tile
Copyrighted Page
Material
Group 30, Hydraulic Components ElfIRK
Section 2
Main Hydraulic Pump
Contents
Disassembly ...................................................................................... 30-2-l
Disassembly ..................................................................................... .30-2-2
Reassembly ....................................................................................... 30-2-6
WARNING
Hydraulic fluid is toxic to skin,
Good ventilation is normally
Rotation adequate.
Inlet Port Shaft End Outlet Port
SM 575, July 9
‘7 Copyrighted Material HydraulicPump-General l 30-2-l
ElfIRK Group 30, Hydraulic Components
L Bearings
Dowel Pin
Drive Gear
Isolation Plate (Bottom)
Back-Up Ring 1
Pressure Plate
O-Ring Type Seal
LO-Ring
Position Viewed
t-rom snan
L Adapter
Flange
L Snap Ring
Pump Capacity: 65.5 GPM 2500 RPM

Capscrew Torque: 80 - 90 lb. pt. (108 - 122 Nom)
Pump Shaft should ;$yt$ ;$eely with a maximum
rotating torque of: . .
Group 30, Hydraulic Components
DISASSEMBLY Inspec t Parts for sharp edges and

Thoroughly clean outside surface of the pump using burrs.
a Stoddard type cleaning solvent and wipe dry.
Separate Flange from Body

l Place pump in a machinist’s vise with shaft up.
If the vise is not equipped with soft jaws, use a
clean block of wood between jaws of the vise
andsidesofthepump.Thiswillpreventmaning
ordamagingthemachinedsurfacesofthepump.
l Remove adapter flange -to- pump body
cap screws and lock washers.
l Remove all sharp edges and burrs from drive
shaft with a crocus cloth. This will prevent
damaging to the rubber lips of a new seal upon
installation.
l Lift adapter flange off pump body. If flange is
stuck, use a plastic or rubber rnallet and tape
flange edge to loosen.
l Remove O-ring from bottom side of adapter
flange.
Remove Shaft Seal
l Place adapter flange on a smooth clean surface
and remove snap ring.
l Now place flange on open jaws of vise (pilot
down).
l Tap old seal out of bore using a punch and
mallet.
A CAUTION
Tap seal out evenly being
careful that you do not scar or
damage the seal bore.
Drive seal straight downward by moving punch

around seal as it is driven out.
SM 575, July 9
‘7 Copyrighted Material Hydraulic Pump-General l 30-2-3
\ Dowel Pin
Adapter Flange
Body (Cover)
-\ \ /
Pressure Piat !
(White
il
O-Ring, Acdapter Flange I Isolation Plate

(Top)(Bottom)
C’@
Ring Retainer
Back-Up Ring l
Is2
O-Ring Type
30-2-4 . Hydraulic Pump-General Copyrighted Material SM 575, July 9

‘7
Disassemble Pump Body l Body Bearings will need to be cut through the
beating opposite the oil grove. Then the bearing
Refer to Section “c” on opposite page.
may be removed with a twisting motion using a
l Remove isolation plate. pair of vise-grip pliers. Use extreme care to not
dkmage the bores upon removal.
l Remove ring retainer.
l Flange Bearings can be wedged out with a
l Remove back-up ring.
screwdriver. Note if the old bearings are as-
Remove Pump Gears & Pressure Plate sembledbeloworabovethesur&ce.Newbear-
l Grasp drive gear extension and lift gear slightly ings must be installed to the same position. Use
with a quick upward motion. This will dislodge extreme care to not damage the bores upon
pressure plate Corn inside pump body. removal.
l Now, hold plate with one hand and release hold Cleaning
on drive gear. Lift pressure plate from pump.
l Wash all parts with a soft fiber brush in a
l Lift drive gear and idler gear straight upward
S toddard type cleaning solvent.
from pump body.
Remove Bottom Pressure Plate
l To remove bottom pressure plate, insert expand-
able bearing puller in shaft bore of plate. Apply
a light back and forth motion on the puller to
dislodge plate.
l Now, lift pressure plate straight upward out of
the gear bores. Air Hose 1 Cleaning Brush
Ifa bearingpuller is rwt available, then use a 90 ’

offset screwdriver and carejiAly insert flat in l Dry with compressed air. This should remove
bore beneath plate ana! l@ slightly, moving any foreign material collect in pump. Lay out
screwdriver from one bore to the other until parts in disassembled order.
plate has been dislodged. Use extreme care in
removing the plate. Do notpry orforce out. Do AWARNING
not mar or scratch machined surf&es. Wear eye protection and
l Remove ring retainer. protective clothing when
cleaning or drying with air
l Remove O-ring. pressure. Reduce air pressure
to 30 PSI (207 kPa). Debris
l Remove back-up ring.
removed with air pressure can
l Remove isolation plate. cause injury.
Bearing Replacement Inspection
In the event of bearing failure, the bearings may be
replaced #Megears huve not cuta trackin the housing l Pump Body. There will be a gear track on the
deeper than 0.015 inches. inside of the pump body. Measure the depth of
thistrack.Thenominaldepthofthiscutis0.008”
l Place body in a vise equipped with protective (0,203mm). If the track is less than 0.015, the
jaws, or use clean wood blocks on each side of body is all right for assembly provided it is not
the pump before securing pump in vise. cracked or damaged otherwise.
SM 575, July 9
‘7 Copyrighted Material HydraulicPump-General l 30-2-5
l Pressure Plate. The pressure plates show not the point of scraper, go around outer edge of the
show excessive wear onthe bronze side. If deep bottom pressure plate. Blow out any loose de-
curved wear marks arevisible, the plates should bris. Do not adtempt to remove “track-in”
be replaced with new ones. grooves in bores.
l Examine Gear Bores in pump body. During Examine Gears. If excessive wear is visible on
initial break-in at the factory, the gears cut into the journals, sides or face of the gears, or at the
body. The nominal depth of this cut is 0.008” point where it rotates in the seal, reject them
(0,203mm) and should not exceed 0.015” If any of the internal parts show excessive
(0,381mm). As gears cut into body, metal is wear, replace all the parts.
rolled against edges of the pressureplates. Using
a knife or sharp scraper, carefully remove metal For further information on inspection and fail-
that has rolled against top pressure plate. Using ure of parts, refer to the trouble shooting guide in
the rear of this section.
REASSEMBLY
* Press new bearings into the body so that they
Isolation Plate
protrude above the surface 0.220 / 0.230”. 1
l Press new bearings into the flange 0.090:
below surface.
IMPORTANT
If the flange had protruding
bearings at disassembly, the
new bearings must be installed
0.220 - 0.230” above the
surface.
The split in the bearing(s) must be positioned in

the same location as was the oil groove in the
bronze bearings.
0 Isolation Plate has a radius edge on the outer

edge. With the radius edge down, install plate on
the suction side of pump body as shown here.
30-2-6 l Hydraulic Pump-General Copyrighted Material SM 575, July 97

‘
Group 30, Hydraulic Components Eu(Ru
Lubricate the following parts with hydraulic fluid

prior to installing them into the body.
l Install back-up ring on the discharge side. Refer
to illustration in opposite column.
l Next, install the O-ring.
0 Now, nstall the ring retainer.
O-Ring Type Seal
l Pressure Plate has round milled traps that must

be installed on the discharge side of the pump. .. Pressure Plates to be assembled
bronze face up. Refer to illustration in opposite
column.
Lubricate plate with hydraulic fluid and care-
fully slide it downward into the gear bore. Do
not force the plate. If it hangs up, work it back
and forth until it slides freely into position.
A CAUTION
Be careful that you do not
scratch cylinder bores upon
installing pressure plate.
SM 575, July 9
‘7 Copyrighted Material Hydraulic Pump-General l 30-2-7
Install Pump Gears Typical Illustration
l With pump discharge port facing you, install

drive gear in gear bore.
l Install idler gear in opposite bore.
l Install pressure plate with bronze side down and Pressure Plate
round traps toward the discharge side of body.
* Install isolation plate on the suction side.
Isolation Plate
Tvcka.l Illustration
l Install back-up ring on the discharge side.

Isolation Plate
l Install O-ring as shown.
l Install ring retainer as shown.
Back-Up Ring
(Whrte)
O-Ring Type Seal
Ring Retainer
-L..&
/ Ring Retainer
rypical Illustration Typical Illustration
30-2-8 l Hydraulic Pump-General Copyrighted Material SM 575, July 9

‘7
Adapter Flange
Adapter Flange
1
l GreaseO-ringandinstallittotheadapterflange.
The grease is to hold O-ring in place at time of
flange to body installation.
l Coat the splines of the pump shaft with grease.
If drive shaft has a keyway, use tape or thin smin
material to protect lips of seal as flange plate is
installed over shaft.
Q Carefully lower adapter flange over pump shaft
and onto body dowel pins.
l Place hands, one on each side of flange, and
press downward on flange. The flange should
slide into position with very little resistance. If it
does not, llsflange slightly and check sealing
strips to see if they have slipped out of position Liberally Grease O-Ring
causing interference between scalings and the and install in groove.
bearings.
* LubricatethreadsofcapscrewswithSAW-1OW
Oil.
* Install a lo&washer on each capscrew.

l Install capscrews finger tight.
l Alternately torque each capscrew to:
80 - 90 lb.ft, (108 - 122 Nom)
l Check to see ifpump shaftrotates. The shaft will
be tight but should turn freely with a maximum
of 25 lb.ft. rolling torque.
If it takes more than 25 lb.ft. to rotate the shaft,
disassemble pump and examine the parts for
burrs or foreign material causing buildup or
interference between the parts. Check for top
isolation plate (with all square corners) being
installed in bottom of gear bore, instead of tip.
When shaft rotates freely, pump is ready for
installation.
30-2-10 l Hydraulic Pump-General Copyrighted Material SM 575, July ‘97

C500 Y2235 Group 30
SECTION 3
TYRONE HYDRAULIC PUMP OVERHAUL

TYRONE”
SERIES 20
TANDEM
ServiceInstructions
Mobile Fluid Products Division l Dana Corporation
Copyrighted l P.O. Box 511 l Corinth, MS 38834
Material
Mobile Fluid Products Division Intended for CLARK dealers only
l Dana Corporation l P.O. Box 25000 l Greenville, SC 29616
TS20.05
Disassembly
1. Clean outside of pump thoroughly. 4. Remove nuts (23) and washers from
studs.
2. Mark the pump sections on the side
nearest to the drive shaft exten-
sion so that they can be reassembled
back to the original relationship.
(Figure 1)
5. Remove pump from vise and set pump

on bench with shaft end up. Coat
the shaft extension with clean
grease. This will help to keep
from damaging the rubber sealing
surface of shaft seal when seal is
removed.
FIG. I
3. Place pump in machinist vise 6. Lift the flange (4) off the pump,
securely, shaft up, using a clean keeping the flange as straight as
block of wood between the flats on possible during removal. If the
each side and the jaws of the vise. flange is stuck , use a wood mallet
This keeps from marring the machined or plastic hammer and tap around
surface of the pump and causing the edge to loosen it. (Figure 3)
leakage at the port connectors.
(Figure 2)
Copyrighted Material FIG. 3

FIG. 2
Do not 2sell or distribute
7. Using vise grip pliers, remove stud 10. Grasp the drive shaft extension and
bolts (22) from pump. (Figure 4) lift upward to dislodge the pressure
plate. Grasp the pressure plate
between thumb and forefinger and
lift straight up off the shafts.
(Figure 6)
FIG, 6
8. When disassembling the tandem pump,

all parts removed with bodies
(1 and 2) should be laid out in
separate groups.
9. Remove ring retainer (13), o-ring 11. Remove both gears (7 and 5) by lift-
(12), back-up ring (14), and iso- ing them straight up out of the
lation plate (10). (Figure 5) body. (Figure 7)
FIG. 5 Copyrighted Material

3
12. It will be necessary to remove any 16. Bearing plate (3) can be removed
burrs from the gear "track-in" in by using method described in
the body (1) before attempting to Step 14.
remove pressure plate (9). After
burrs have been removed, the plate 17. Disassetile the next section by
can be lifted out. Using thumb repeating Steps 8 through 13.
and forefinger, lift the pressure
plate straight out of the body. Use 18. Wash all parts of the pump thor-
extreme care in removing this plate oughly with clean solvent and dry
as it will bind in the bores of the with shop air.
body if not kept straight during
removal. (Figure 8). 19. Inspect all parts to determine
which, if any, should be replaced.
See Parts Inspection section.
FIG. 8
13. Remove ring retainer (13), o-ring

(12), back-up ring (14), and
isolation plate (10).
14. Remove body (1). Using wood mallet

or plastic hammer, tap the sides of
the body. With the other hand, lift
body off dowel pins.
15. Remove spline coupling (16) from

drive shaft. (Figure 9)
FIG 9 Copyrighted Material

Intended for CLARK
4 dealers only
Assembly
20. If Parts 1, 2, 3, and 4 are re- 24. Install back-up ring (14), o-ring
placed, examine the new parts and (12), and retainer ring (13).
remove any nicks or burrs. Wash in (Figure 11)
clean solvent. Make sure that an
identifying mark is put on each new
part and on the same side as it was
on the old part. Refer to Step 2.
This should be done before any parts
are assembled.
21. Place the body (2) with its solid

flat end down and the mark made in
Step 2 facing you.
22. Coat the inside of the body and

bearings with clean hydraulic oil.
This will insure easier assembly.
FIG. II
25. Pick up a pressure plate, part 9.

Use the thumb and forefinger in the
23. Out of the group of parts from this
holes. Keep the bronze side of the
pumping section, examine the two
plate facing up and the rounded
isolation plates 10 and 11. You
trap slots facing the discharge
will find that plate 11 has rounded
side of the pump. Holding the
edges. Install this plate on the
plate as level as possible, slide
suction side of the body with the
it into place in the bottom of the
rounded edges down. (Figure 10)
body. Do not force the plate into
place. If it binds on the way down,
work it back and forth carefully
until it slides into position.
(Figure 12)
FIG. IO Copyrighted Material FIG. I2

5
26, Install the drive gear and idler 30. Install the isolation plate (10)
gear. The drive gear should be in with its square edges on the suction
the bore nearest the identifying port side. Install back-up ring
mark made in Step 2, with the (14), o-ring (12), and retainer (13)
splined end up. (Figure 13) on the discharge side. (Figure 15)
FIG. 13 FIG. 15
27. Install body dowels (20), one near 31. Install o-ring (25) in the bearing
the drive gear and the other near plate (3) on the side which has the
the idler gear. bearings extending beyond the plate
surface. Use heavy grease to hold
the o-ring in position. (Figure 16)
28. For proper timing of the gears

6 and 8 with gears 5 and 7, see
sketch.
29. Install pressure plate (9), bronze

side down against the gear faces
and with the trap slots facing the
discharge side of the body.
(Figure 14)
FIG. 16
32. With the o-ring down, and the

identifying mark made in Step 2
facing you, slide the bearing plate
(3) down on the shafts until the
plate makes contact with the dowels.
Use caution and keep the plate
level. If the surfaces are not
parallel when the bearing enters the
back-up ring (14), the bearing will
FIG. 14 Copyrighted Materialpinch and damage the back-up ring.
6 or distribute
Do not sell
r VALLEY OF TEEM
REAR DRIVE
TOP OF TOOTH
u PUMP TO BE TIMED
ASSHWN L-J
FRONT DRIVE GEAR To BE TIMED WITH REAR

DRIVE GEAR BY LINING UP A lWTH ON REAR
DRIVE WITH VALLEY OF TWD TEETH ON FRONT
DRIVE
TIMING SKETCH
33. Install the spline coupling (16) and 38. Install and tighten stud bolts.
o-ring .(25). (Figure 17) (Figure 19)
FIG. 17 FIG. IS
39. If a new flange plate (4) is used,

plug (27) will have to be pressed
34. Install duels (20). into seal drain hole on the dis-
charge side of the flange plate.
35. Install body (1) with identifying (Figure 20)
mark made in Step 2 facing you, and
with gear bore up.
36. To assemble this pumping section,

repeat Steps 23 through 31.,using
gears 7 and 5.
37. Install dowels (20) in body (1).

(Figure 18)
FIG.20
40. For seal replacement, refer to seal

assembly section in this manual.
FIG. 18 Copyrighted Material

41. Install o-ring (24) in the flange 44. Correct the cause of interference
plate. Use heavy grease to hold and reassemble the pump.
the o-ring in the groove while the
plate slides down over the shafts.
Refer to Step 32 and use the same
precautions in the final assembly
of the flange plate. (Figure 21)
45. When the shaft turns properly,

lubricate the stud threads with
SAE 10 oil and torque all of the
nuts 80 to 90 lbs/ft. each.
(Figure 23)
FIG. 21
42. Install washers (26) and nuts (23).

Tighten two opposite nuts. Use a
10" wrench to check the shaft for
binding. It should turn with 5 to
7 pounds-feet of torque applied. FIG.23
(Figure 22)
FIG.22
43. If the shaft will not turn properly,

disassemble the pump and examine it
for burrs or foreign material caus-
ing build-up or interference with
the parts. Also check for the
isolation plate with the radius
edge not being in the bottom of the
gear bore. Copyrighted Material
Intended for CLARK
9 dealers only
Seal Replacement
1. Stand pump on end and loosen all 4. The rubber lip of the seal should
fasteners holding flange to body. point toward the rear of the pump
Remove flange. so that the garter spring is inside.
(Fig. 3)
2. Lay the flange on a smooth clean
surface and remove snap ring.
(Fig. 1)
FIG. 3
FIG. I
3. Lay flange on open jaws of vise 5. Place a clean block of wood between
(pilot down), using punch and mal- the rear jaw of the vise and the back
let tap old seal out of the bore. of the flange. Next, place the seal
Caution must be taken not to scar in position in the bore of the flange.
the seal bore in the flange. Drive
the seal out straight by moving the 6. Place the seal press ring in position
punch around the seal as it is driven against the seal, taking care that it
out. (Fig. 2) is centered over the seal. (Fig. 4)
Copyrighted Material FIG. 4

7. By tightening the vise firmly, but
gently, press the seal into the bore.
Stop the pressure when the seal
touches the shoulder inside the bore.
8. Replace snap ring, making sure that

it snaps into the groove properly.
9. Wash the flange thoroughly in sol-

vent. Coat the lips of the seal
with heavy grease.
Bearing Replacement Inspection of Parts
Mobil-Master Series 20 and 25 pumps are 1. Visually inspect all parts. There
built with the highest capacity bearings will be a gear track on the inside
available. However, if the pump is run of the pump body. Measure the
on a system with contaminant present in depth of this gear track. The nomi-
the oil, or under certain other con- nal depth of this cut is .008"
ditions, bearing failure may be exper- [i,X)!;l and should not exceed .015"
ienced. In the event of bearing failure If the track 1s less
the bearings may be replaced if the thin .015; the body is all right for
gears have not cut a track in the assembly provided it is not cracked
housing deeper than .015 inches. or damaged otherwise.
To remove the old bearings, disassemble 2. Examine the pressure plates. They
the pump and place the body in a vise. should not show excessive wear on
Clamp on the side of the body using the bronze side. If deep curved
cardboard to prevent marring by the wear marks are visible, reject them.
vise jaws.
3. Examine the gears. If excessive
Using the small keyhole type hack saw, wear is visible on the journals,
cut through the bearing opposite the sides or face of the gears, or at
oil groove. Be sure the saw cuts com- the point where it rotates in the
pletely through the bearing shell, seal, reject them.
but cuts as little as possible into
the aluminum bore. 4. If any of the internal parts show
excessive wear, replace all the parts.
After the cut is made, grip the bearing
with vise-grip pliers and remove it with 5. For further information on inspec-
a twisting motion. Flange bearings can tion of parts, see PUMP TROUBLE-
be removed in the same manner. Take SHOOTING GUIDE, or DIAGNOSING TYRONE
care not to damage the bores. After the GEAR PUMP FAILURES.
old bearinqs have been removed, wash all
of the parts thoroughly in solvent.
Press in the new body bearings. They
should protrude above the surface
.220/.230 inch. Locate the s lit in the
flanae bearina at the same Df-ace the oil
roove in the-bronze bearings was -
hd. The flanae bearings, when
replaced, must protrude .226/:230 inch
above the surface.
Install the remaining parts of the

repair kit and replace on the machine.
No break-in is necessary and the unit
is ready to operate at full capacity.
Intended for CLARK I I dealers only
TROUBlESHOOTlilG GUIDE FOR GERR TVPE HVDRRUlIt PUlllPS
lDENTlFlCAllON CAUSE CORRECTIVE CHECKS
1. Sandblasted band around I. Abrasive wear caused by 1. Was clean oil used?
pressure plate bores fine particles. 2. Was filter element
2. Angle groove on face of 1. Dirt (fine contami- change period correct?
pressure plate nants, not visible 3. Were correct filter
3. Lube groove enlarged and to the eye) elements used?
edges rounded 4. Cylinder rod wiper
4. Dull area on shaft at seals in good
root of tooth condition?
5. Dull finish on shaft in 5. Cylinder rods dented
bearing area or scored?
6. Sandblasted gear bore in 6. Was system flushed
housing properly after
previous failure?
1. Scored pressure plates II. Abrasive wear caused by 1. Was system flushed
2. Scored shafts metal particles properly after
3. Scored gear bore 1. Metal (coarse) previous failure?
contaminants, 2. Contaminants generated
visible to the eye elsewhere in hydraulic
system?
3. Contaminants generated
by wearing pump com-
ponents?
1. Any external damage to Ill. Incorrect Installation 1. Did shaft bottom

pump in mating part?
2. Damage on rear of drive 2. Any interference
gear and rear pressure between pump and
plate only machine?
1. Eroded pump housing IV. Aeration - Cavitation 1. Tank oil level correct?
1. Restricted oil 2. Oil viscosity as
2. Eroded pressure plates flow to pump inlet recommended?
2. Aerated oil 3. Restriction in pump
inlet line?
4. Air leak in pump inlet
line?
5. Loose hose or tube
connection near or
above oil level in tank?
6. Excessive operation
of relief valve?
1. Heavy wear on pressure V. Lack of Oil 1,. Was oil level correct?
plate 2. Any leaks in piping
2. Heavy wear on end of inside tank?
gear 3. Any oil returning
above oil level?
1. Housing scored heavily VI. Damage caused by 1. Metal object left in

2. Inlet peened and metal object system during initial
battered assembly or previous
3, Foreign object caught repair?
in gear teeth 2. Metal object generated
by another failure in
system?
1. Pressure plate black VII. Excessive Heat 1. Was a valve stuck?

2. O-rings and seals brittle 2. Was relief valve
3. Gear and journals black too low?
3. Was oil viscosity
correct?
4. Was oil level correct?
1. Broken shaft VI I I. Over Pressure 1. Relief valve setting

2. Broken housing or flange correct?
2. Did relief valve
function?
C500 Y2235 Group 30
SECTION 4
J. SnBARNES HYDRAULIC
PUMP OVERHAUL
Copyrighted
SectionMaterial
Title Page
Overhaul
w...
m.
-.---
.-m
-- --
Manual SEmEs-61 DESIGN
..-. - -_-v_j, A;-;_-’ I. . z__
Single
Gear iii! :.=:g;=ig
Pumps 03oc SERIES- 51 DESIGN
GT3oc . SERI5-3ZDESIGN
Double
Gear w SERB-51 DESIGN
Pumps
~-7_~~-~---
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.
Section I -lNTRODUCllON
A. PURPOSEOFYANUAL
IIlistuanuaIistoauisturcnofhigh@ormanccsingleand
double gear pumps in properly installing. maimhing and
repaihng their units. The sit@ and double gear prmps arc
dchbaiinduaiiittsaxiotlII.
8. GENERAL INFORMATION mow-51 1 M-2303-S

GT3OC32 1 M-23~S
1. Relu&Publitrdnrr-SuviccpBrcsiDfDDaBLiGnszKibncBilB-
G3OC-32 1 &%23g5-S
G202ow-5 1 hwatks
G302OW-50 M-2387-S
G303OC-32 rbf-2388~s
2 Moddcaks-VaTiationswittiincadl~cmodeltics
artcavaedinthemodelcodc.I~lc2itacomplae~~
ofthcaxiescovtigthcscunits.Serviceinquiricsshaddahvays Table 1. Available Parts and Instakticm Drawings
includethccompiacunitmodeicodcnumbcrstampaiottthcrcar
COVQ.
MODELCODE BREAKDOWN
SINGLE aEAR PUMPS & THRWRIVE
(EI)_C(.) 0, •_~_*,~,.,.,~,.-“-“,(.)
Intended for CLARK
Table 2. hdo&l dealers only
Code Breakdown
Se&n II - DESCRIPTDN
A. GENERAL 8. ASSEMBLY AND CONSTRUCTION
The single and double gear pumps in this seties are used to pr& Basic Pump - The pumps ilhtstratcd in Figures I. la. ad 2 are
vi& fluid flow for the operation of hydraulic driven machinery. rttpresentaxive of all double and single pumps in thisscria. The
The double pump (Figure 1) consists of two single pumps. each P=qpumpamsim of a port section. fiunt and rear cover. daptor
having its own outlet port. sharing a common inlet port and input section (double pump). center section. drive gears. driven gears.
shaft. It is a compact power source capable ofeither serving two wear p&s. seal packs. shat? seals. and shaft coupiings fdouole
mparate hydraulic circuhs. or suppiying greatervoiume to a single pump). Thru-drive models have different port housing
circuit through the combined delivery of bmi~pumps. Since the subassemblies and drive gear shafts along with SAE drt\e
entire unit requires only one inlet connection and one moumittn couplings_
and drive point. the cost of the total hydnuiic installation 3
gcneraily lower than using two singie ptmlps. The pumps are cast The one pkce sbaiVgear consmmion provides m&mum stren_ti
iron construction for reliability. strength atui improved sound and shows the use of large bushings for mr load carrying
reduction. All gear pumps are assembled for either clockwise or capacity. The gears M carbumtd. hardened and ground to a
counterclockwise rotations. .- super finish. A ten-tooth gear design reduces pressure rippie and
provides quiet operation. The bushing provides a iead and PTFE
These latest design single gear pumps fFigure 1) have been imprqmcd overiay on a bronze backed steei bushing to assure
developed for increased pressme ratings.impmvcd low speed superior iubrication under alI conditions and gives optimum shaft
capability, better overail efftcicncy. enhaxed flexibility and ah_- The bushings adjust to shafts that are deflected by high
improved reiiability. The all cast iron constmction adds to pump hydraulic foads. This greatly increases the iife.of Ihe pump. The
durability and noise reduction. Tht high prasurc capacity and dcfltrxabk bronae-faced wear plates are axially pressure loaded
h,igh speed. allows for efficient power tmnnission in a smaI1 andbaiaxcdtominimize running ciearances and leakage across
sd package. gear faces, thus increasing operating efficiency.
-A”
DIMENSION /DRIVEN GEAR
iHAFI- I -/ 1 REAR COVER
LLIR \ ” -
-I I
I w \sw- --‘JPLlsc
GUI
- RIVE
D PACK
t5i-IAFr \ __-__\
FRO?CT CENTER
COVER SECI-ION
Figure 1. Single Gear Pump Seaion View Figure la. Thru-Drive Singie Gear Pump Section View
DRIVEN GEAR
SECI-ION SHAIT
Figure 2. Basic Double Pump Ccmstruction

Section III - PRlNClPLES OF OPERATION
Operationof the single and double gear pumps is cssanidy tk

samc.RowionoftbedtiveaaddtivengarscBtKestheinlcr
pressuretodazasc.Fhid.pushaiimotheialetbyatmosphcric
Dlcssurr.is~~to~outlaiackambazformaikrw&ntht
Thedoublcgearpumpisewniallytwosiqlegearpttqstmited
withaportsectionandshaftcoupling.Theinletportislocated
intheportsectionandiscommontobothpumps.
Refer to Figllm 3.
Section IV - INSTALLATIONAND OPEF?ATlNG1NSTf?UCTlONS

A. lNSTALLAllON DRAWINGS
‘ILOT
8. MOUNTING, AND DRIVE CONNECTlONS
High petfotmancc single and double gearpumps arc designed

for S.A.E. standad wa flange tnoumingsandareavailablcwith
Sitlgle~&UbleSbliS&.MoWXittgpPdrmtnS~AS~
andareawilableittscvdsizerattdtypes.
1. DirasDtive-Apilotonthe~fiattgc(Fi~4~
*urcs cotrcct mountingand&aft alignmatbprovidedthe pilot
isfirmlyscaudintheauxsorypadofthep0wersottrcc.Care
should be excrcisai in tightening ail flange mounting screws to
prevent misalignment. sh?ft keys and couplingsmust be properly
seated to avoid slipping and possible shearing.Propercoupling
alignment is essential to prolong pump lift.
CAUTION
shafIsaredesigncdtobeinstalledin
antplingswithaslipfitorvaylightpress.
P6undingthecoupiingontheshaftcanmin
the bushings and wear plates. Shaft
tokances are shown on the pumpinstalla-
tion drawilqs. (See Table 1.) Figure 4. Front cover Mounting Pilot
2. IndireaDrive-Anindktdtivenknmtingiss4tbjaxto D. PIPING AND TUBING

mgineaing approval.
. 1. Allpipcsaadtnb@t=tktltoRntgblyclautedbeforr
ttKtawkRcanmneadtdmalKJdsofdaning~sandblasting,
C. SHAFT ROTATION wircbdhg andpickkg.
NOTE NOTE. -- .
Forinsuuuionsottpickling,refatoshut
l221-s.
2. To minim& flow tzsanceand the possiiity of

tifiuibyan”L”inthcmodelcodc.Gee leahge.useonlyastlmnyfiaingsaltdamneaionsasneccstary
Table 2.) forproperitlstdMott. .
.
CAUTION 3.Thetnmtberofbadsintubingshouldbekepttoa
NCVerdrive~pUlltpitttkwmqg~on. exccSi=mrbtda=aodfktionofoilflow.
Damagemayrdttotheshah~~sad Tubing mEtEE bent too Sharpiy. The recomtnendedtaditls
4 packs. for bends is three tinxs the inside diameter of the tube.
E. HYDRAULIC FLUID RECOMMENDATIONS G. SOUND LEVEL
GENERAL DATA No& is indidy affect& by the fluid selection. but tht con
tkJIlofthcfluidisofpa=mountimponana in obtaining optima
Oilinahydrrpiicsystanpafonntthtdualfunnionoflubrica- xuiuaion of m sound levels.
tionandtmnm&sionofpower.Itconnmnet avitalfactorina
hydtaulicsystaa.and~stlecrionofitshouldkmadctith Some of the mjor fgctors affecting fluid conditions that cat
the assistance of a reputable supplier. Proper selection of oil the loudest n&es in a hydraulic system are:
assurcs&&aorylifeandopcrationofsysumcomponems.
1. vuyhlgh viscosities at stanup tanpcraalrcs can au
For Mobile appiications. otdcr data sheet M-2950-S. For the loudest n&es clue to cavitation.
Industeal applications. otda data sheet 1-286-S:’
2. Rtmniagwith a moderatelyhigh vi&&y fluid will sic
Tbeoilrecommendationsnotedinthedatashcesarcbasalon the release of amainal air. The fluid will not be complete
our experience in industry as a hydraulic component purgcdofsucbairiathctimcit remains in the reservoir and u
manufacmrcr. he recycled tllmugb the system.
:
Where spcciaI considerations indicate a need to depart from the 3. Ad flllid a be causedby ingestion of air throu
recommended oils or opaxting conditions, contact your nearest the pipe joints ofinlet l&s. hlgh vdoclty dixharge lines. cvlinr
sales or engineuing representative. nxi packings. Q by fluid dischaqing above the fluid lcvci in I
reservoir. Air in tht fhdd cpuses a noitc slmilr to cavitaric
F. CLEANLINESS 4. Cc ’ 1fluldScZtcauseeXcessivtwearofinten
pumppatts.whicbmay=mltininacasedsoundlcvels.
H. OVERLOAD PROTECTION
1. aa (flush) entire new system to remove paint. metal
chips, welding shot, etc. Rtkf vtivts nmstbt iastakd in the system as close to the pun
aorlnt s parsblt. l%e relief valves limit prcsmrc in each syst~
2. Filter each change of fluid to prevent introduction of toaprcsaii IlhlIMtdpfottUScoatpontIlKflUllltXCtSS
contaminantsinto the systan. prt~~wt.&bditfvtivtprtsurtsmingdtptndsonthcwc
rtquirautts tftbt circuit being fed and should not exceed I
3. k+rovidccontinuousfluid fdtration to remove sludge and Fnsslm~ofthepump.
pducts of war and cotmslon gcnczed during the life of the
sy-. I. $nmuP
4. Provide cominuousprotcalonofsystan fromamyof Whenever it is possible to do SO. fill thC Pump pOrU with SyStf
airborne comamimuimby=ling*syst=dorbypropcr fhridThitwin~itariaforthepumpwhmitisfirststan~
filtration of the air.
SelfRiming-Wltb~minimumdtivtspeaiof6OORPM.a&
5. Proper savifzing of filtaz, breather& Rservoirs. CC. should prime iwmcdbatdy. Failure to prime within a shon lenl
cannot be ovaemphasized. of time may ti in damage dut_to lack of lubrication. Inlet ii1
must be ttght and free from atr leaks. However. it may
6. Good system and reservoir design will insure aeration of rwrrssary to lowm a flaing on rht outlet side of the pump
fluids is kept to a minimum. alioWUltEiplZdairtoacape.
‘.
No LOad Starting - These pumps are designed to start up w
noloadonthtprrssmtponr.Thcyshouldnevubesrancda_eu
aload or a d&al ctnta valve.
Section V - SERVICE, INSPECTlON a MAINTENANCE

A. SERVICE TOOLS 3. Plas& hammer (Computhant, Model X-l HD.
&vd=t)
4. TorquE wrench box end adapter (StlWvant co. ”
No spud toolsart rapid for the dlmsscmbly or assembly BX-I 1116)
ofthcgtarprmpswiththc~~onofashaftseaidrivafor 5. Tm?acwrench box end adapter (Sturtcvant Co. l’
theG20”’ andCi30+*.Stt F&m 5 through 8. The following
sandardtoolsuclEqui& To& wrench (O-200 lb. R)
4 Torque wrench (0-200 lb. in.)
1. Scmvdrlvcr (6 inch) 8: Intcmal retain@ ring pliers (Truarc #23)
2. socka set with ratchet (H inch drive)
.-. :
.12 x 45’
it-
t S
{DLL
T
wmlre5. ImmseaIDriver
1
(r41so TOOL’
~S~~~
-It- .06 x 4s”
Figure 6. her Seal Driver Figure 7. Guide
-PLAmc - PRESS m
IF REO’
.LJE __
(GL__ __~ D)
_
&me 8. Outer Seal Driver
8. INSPECIION C. ADDlNG. FUJID To THE SYSTEM
Periodic inspection of the fluid condition and tube or piping When hydra& fluid is add& to repimish the ~ystaa. it should
connections can save time-consuming breakdowns and always be poured through a fine wire screen QOOmesh or fincrt
-$=$Vp=-P1 acement. The following shouid be checked or prefcrahiy pmnped through a 10 micron kbsoiutc) filter.
.
It is impottant that the fluid be dean and fm of any substance
which could w improper operation or wear of the pump or
1. All hydrauiic connaztions must be kept tight. A loose other hydraulic components. Therefore. the USCOfClothto Strain
comeaion in a pressure iinc wiU pamit the fluid to leak out. the fftnd shdd be avoided to pm-cm lint fmm getting into the
Ifthcfluidicvelbccomessolowasmuncoverthtiniapipeopca- system.
ing in the reservoir. extensive damagf to the pump may result.
Insuaionorraurnlincs.Ioosc anmanonspumitairtobedrawn 0. ADJUSTMENTS
into the system. rcsulthtg in noisy and/or erratic operation.
NO periodic +tstmem~ arc required. other than to maintain
2. Clean ffuid is the hut immamx for lcnta service life. *- proper shaft a@tmcnt with the driving medium.
Therefore. the reservoir should be checked perio&caRy for dirt
or other contaminants. If the fluid becomes contaminated. the E. LUBRICATION
system shouid be thomu_@y drained and the reservoir ckanai
before new fluid is added. banal lubricahm is provided by the fluid in the system. Lubrica-
tion of the input drive shaft coupiing should be specified by its
manufacmrer.
3. Filter ckmats also should be checked and replaced
pcriodicahy. A clogged filter cIcmau msuits inahigherpressmc F. REPLAcQllENTPA#Ts
drop. This can force pattides through the fiter or can cause the
by-passto open. resulting in a partiai or complctc loss of f%ration. R&able operation throughout the specified range is assured only
if genuine manufacturer’s parts are used. Sophisticated design
4. Air bubbles in the reservoir can ruin the pump and other proccses and materials are used in the mqnufacturc of our pans.
components. If bubbles arc scat. locate the source of the air aad Substitutions may result in uriy faiiure. Pans suvicc drawings
seal the icak. are shown in trbie 1.
‘..
G. TFIOUBLEWOOTING
5. A pump which is ntnning excessively hot or noisy is a
potential failure. Should a pump become noisy or overheated. Table3 Iiitkcommon difficuitics cxperi==d with gearpumps
the machine should be shut down immcdiatciy and the cause of and hydraulic systems. It also indicates tfse probable causes and
improper operation corrected. remedies for each of the troubles listed.
1 RVUYLL -VU& *UI..am- L
I. Excessive noise 1. Low oil level in reservoir Fill reservoir to pmper ievcl.
1. Air in system Bleed hydraulic lines at highest point
downstream of pump.
3. Oil t& thick Warm up pump in cold weather.
4. Damaged or missing seals inside Locate and replace scnls.
II. Pump overheating 1. Heat exchanger not functioning Locate and repair.
ProPCrfY
2. Bushings partiaBv seized inside unit Locate and repiacc nsccsw pans.
3. Pump assembly ilncompiete Check pump assembly
III. System not deveioping pressure 1. Relief valve stuck opm Repair or rcphcc.
2. Gear pump assembled for opposite Rcasscmbic pump for Proper mtation.
3. ~ztlct/oudc connections Reverse inkt/outkt comtections.

reversed
4. Diiccted or broken drive Repair or replace.
IV. Pump d&cry (flow) too low 1. Butrsonmatingsurfaccs * Disassanbic unit and remove burrs.
2. DamagedOtt&sing seals inside unit Replace damaged or missing seais.
3. Center section/gear clearance not to Return to shop for cvahtaaon and repair.
spaifkatilm
V. Loss of fluid 1. Ruptured hydrauiic fine Repface mpt=d line.
2. Leaking or missing seals Repiace seals.
3. Bolts or mm not t0rcptd to Torque to spcciiicaticms.
spcciiications
4. Seized bushings Rcpiacc nec+ssary Parrs.
‘Tabie 3. Troubleshooting Chart

-on VI - OVERHAUL OF SlNGLE GEAR PlJyP
.
A. GENERAL DlszKs&ietb&glcgwr~arfoliows:(RdatoEgarei0)
During ditzam&iy. piy particular altdon coidanification of l.SmoowrSIAQ)inavist.

thepam for amux assaab$.Figm X0is an explodedview
wbicbsbowstbcpropardano&ipofpm5fordimsanb~yaad a- Ranovetheti&sacws(1)alldd~~crso.
subqualt assembly. Remove bolts.
w&xrsand suds ifappkabk
WARNING b. GcntlyiiftcovasIA(4)fkomceatascaion(9).
a cimit anmctionmakc
Beforebreaking .
cmainthapnvuisofiandsFprm~ c: Ranove wcdrplatt (IO) framcova S/A(4).
d. Rcaxwedriveg=r (12) anddriva~& (6) time
culta scuion(9).
.
e. RtmovaiOf-~6’)fmmcovcrs/A(3)
mayrequiretkuscofaplasticbaamna.
B. DISASSEMBLY f. Ranovewcarpke(8)fromcovasIA(3).
g- Ranoveseairaainas 0 aadsealglands(6) from

cova S/A (4) andcova S/A (3).
i. Removeanddiscard'o'lings(5andI5)fromunu
S/A(4) andcova S/A(3).
NO~~BNCLATURE QTY
i EL
CovaSfA
i .
4 CovaSfA
. _ :
s
2zzd f
76 ScalRetaina
WUrrplate f
I: ccntuS&On&PiIlsIA
DrivenGear :
;: DriveGear 1
ShaftSeal(Inna) 1
:f RaainingRing - ifappkablc 1
14 ShaftSeal(Qqr) - if appkible 1
Figure9. SinglePumpI’art Noxnc&aturc
‘0’ Ring 5 isusedon GZD’61.

Not usedon theGT30.
Usedon theG30andGI30 only-

.
Figme 10. Singe Gear Pump Expioded View
8
j. Remove shati seal (14) from cover S/A (4) if
1. Assanble seals (6) into seal retainers 0). Note seal
appiicable.
rrraintrmustkarztmbledwiththcflatsidcf~gthtvnarplatc.
k. Remove mmining ring (13) if applicable.
1. Remove shaft seal (It) from cover s/A (4). NOTE
This completes the disasm&ly of a single gear pump. Stcpsl.a.mtdl.b.pataintoinso&tionof
coverS/A(4)shaftscals.LtMcatctheshaft
O. INSPECTJON AND REPAIR - Slngie Gear Pumps se&withMarfakR1grasctopfovidcitk
* itiaJ lubridon.
ahttg - All pans must bc th~rougbly cleaned and keptclean a. Install itma shah seal (12) into cover S/A (4). Make
during inspection and assembly. Close tolerance of patts makes
this rquircmat vcty inqxmant. Paint found on the cdg,esof all suttthcspringloadcdmanbcrofshaftsealfacuthcinsideof
parts must be ranovcd. aa all removed pans. using a pump.Usconcoftheshaft~drivcrsshownonpage6.Place
comma&lsolvattthatismmpatablewiththcsystanfluid.Com- thCshaftseai0ttdrivCcattdprruittphtlX.
.
pressed air may be used ia cleaning. but it must he filtered to a
remove water and contamination. b. Doublcsbafiscal~anatt-paformstep 1.a.
and install retain@ riDg (13) that install outer shaft seal (14)
I. Cover S/A - To tcmov; the shah seak perform the into cover S/A (4). install outer shaft seal (14) as foBows: Place
following steps: aguidcoverrbepilotdinmacrofarversIA(4).Nart.install
onewoutcrshaftseal(14).Makcsttmthesptittgloaduimanbcr
a. place cover S!A (4) in a vise (mounting fIange up). ofsh&satlfacestheimidtofthcputttp.F~y,insazzhcdtiver
Using a scmvdriver. pop att the outer shall seal (if applicable) attdshafrscaithroughthcguideandprcssinplacc.
bcingcamfulnottoraiseabutrontheshaftscaiborc.
c. Instau”O”ting(s),salraainas attdseaisagainst
b. Remove the retainingring (if appliifc) with internal cover S/A (3) and cover S/A (4).
retaining ring pliers.
d. Lubricate bronze face of wear plates (8). install
c. Removecover YA (4) from vise and place on work center section (9) on wear plates 0. Bt&t& surfaces of wear
bench with mountittg flaugc down. Using a bronze drift and plates must face gcats. hIakc sure wear plates and center section
hammer. drive the inner shaft seal out through the mountintt setflushagaiustcovaSJA(3).
flange. being careful not to damage the bear&g surface. - e. TapcthcspBncamaofdrivegatr(11)toprcvent
cuttingshaftsitaisduringassanbly. .
d. INpectthcdrivc(lO)Mddrivcn~(Ij)~hinp
of cover SIA (4) and cover YA (3) for pickup. scoring. discolora-
tion or excessive wear. Any of the prcccding conditions shall f. Lubritatedrivegear(11)anddlivellgear~10). hall .
drive gear (10) and driven gear (11) into cover S/A (3).
warrant replacematt of theawer S/A-s. hpccs mountingflange
for nicks &ui bum. RMme with it& s&c. - - NOTE
On pumps tbat use studs install taper-lock
2. Wear plates (8) - Inspect for erosion. pitting. stud in port section. Torque studs in cover
scratches and/or scoring. Replace if necessary. section to 33.9-47.S N.m (25-35 lb. ft.) The
length from face of port section to the end
3. Center section (9) - Inspect for porosity, cm&s. and of stud trust be a required length. Pigurcs
scratches (.OlOor deeper). Replace if neccstary. DO KOT debutr 1 and 2 show the location of the “A”
the figure eight edges of the cutter section. dimension. B&r to the appropriate Service
Literature for the dimens& size.
4. Drive gear (12) - Iaspect splints for nicks or excessive
wear. Inspect gear journals for scratches and discoloration. Any
g. Carefully position cover S/A (4) over &is (1).
diicoloration warrants rcplammat. Inspect gear teeth for spalling.
gears and center section guide pins. Gently slide over the gears
scratches and/or excessive wear. Replace if necessary. Stoning
until it is flush against wear plate (IO). Align notches on covers
teeth to remove burrs is pamissable. The face of the gear teeth
should also be inspected fa scratches and cracks. to center section.
It. Lubticau sacw threads(1) with hydradic fluid.
5. Driven gear (6) - Sante procedure as step 4.
Instail~(2).Torqucallsaertornuuu,70fiIbz.(f
D. ASSEMBLY 5 ft. lbs.) on Ci2O’sand 150 ft. lbs. (is ft. lbs.) on G30 models.
i. Tumthcdtive~(l2)apcrrvolutianwithasuitable
NOTE sockctwtutch.Nobindittgcanbccvidcntduringthisqmtion.
Coat aI1parts wih clean hydra&c fluid to
aid in assembly’& provide initial lubrica- The breaiurway torque nu==sy !o nun the drive gear must not
exceed 35 lb-in. after assembly.
tion. Use small mts of petroleum jelly
toholdscalraa&randscalinplaceduting
assembly.
+. .
9
’ Section VII - OVERHAUL DP DOUBLE GEAR PUMPS
A. DlSASSEMSLY j. Rctttmc “C* ring (14) from pott SCUiotI(15) and

discard.
Refer to single gearpumpdisassanbly (Section Vl) GENERAL k. Remove gear couplii (13) hota port scrtion (15).
proedures beforeproeaihg. (Refer to Egurc 12.)
Thiscompictcsthedicaccmnhly~fthccovermdgcarptmtps.
1. Coverauiputttp~bly-ThcGZO2O.G3at0attd
G3030 cover endpumpsarc dimsanblui in the same mautter.
ClamptheportKaion(l6))aavise~protcaiwjawsu,avoid 2. shafIendpump~-Gz020.G3020atldG3030
damageto theportseaion’s mad&cd surkcs. Diiblc the shaftendpumpsdhssanbluiindusamctnanner. Withthcport
cover end pump as follows: sccti~ciat@aliaaviscaspEvioUSiydcscribcd.disssmbie
thcshaft.endplttnpasfolltnvs
a. RanovcthcfourshorKscmvs(l)~four~
(2). a. Ratxwe ci@t nuts (16) and eight wash& (17).
b. Ranove the four long screws (3) and four washers . b. Remove from sbah end cover (18). Remove wear
(2). PlatcO.
c. Ranovcthercarcover.(4).Ranovcwearpiatt0. c. Remove seal giand (6) and “0” tiag (5) fhtn
Remove “0” ring (5). if applicable, and seai @ad (6) and seal shaft atd cover (18) and dhcarde
rctaincrfmmmarcovcranddiscard.
d. Remove weai plate (7) from caltcr section (IO). d. Rcmovcdrivegear(2o)aaddtivcng&r~l9)from

tatter scctiotlQ1).
c. Rcaxwedxivcgear(8)anddriv=gearQ)fmmcema
section (10). c. RanovaiofthccaltcrscctionQl)maynccessitate
tkuseofaphichmma.
f. Ranoval of the centersection (IO) from wear plate
(7)maynccmhauthewofaplastichammcr. f. Remove wear plate 0 from po” sccdorl(l5).
g. liftwarplate(7)fmtadapterscaiott. g. Rak seaI gland f6). scai rctaixr (12). alld “0”
ring (5) from pott section (15) aDddkcatd.
h. Ranoveseaigiand(li)fromadapterscaionand
discar+
Thiscompictcsditaycmblyofthcshaftmdpump. .
i. Remove adapter section and. “0” ring (5) and discard
from pOrr seaion (15). CAUTION
Iftksk&mdpumpordtecovcratdpump
issltqucdoffaiiurr,bothpttmpsmustk
.
dasasablcdaIldimpccttd.
NOMEXLATU~ Qm ..
Sami (short) 4
Lock Washer 8
Screw (long) 4
Rear Cover S/A 1
“0” Rinn
ScaiRe&a t
wear Plate 4
DliWGC2U
Drivm Gear :
Center Section 1
AdapterSection
SealGland ,.. :
couprmg 1 .
Pigurc 11. Pan Nomenciawc

. .
10
Used on the G30. GT30
0 C202OONLY and G3020 only. -.
n G302BONLY
&we 12. Double GCZXRunp. Exphkd Vi&
6. %~sPECTIO~~
AND R~AIR C. ASSEMBLY
To assemble double &mupumps: ht. assanble the cover d

Qcaning-Aupansnmstbethorouglllydeanedandm~~ pmp.s=md.assanbletlteshaftendpump.third.assanblethe
d&llgimpazionalldassatlbly.clt?se~aanccofpammatses covermdpunptotksitaftuadpump.
~rqt&multvayimponam.Paintfcmtldonthecdg6ofall
pam~krrmwed.Chttallratuwedpam,tiga NOTE
corrnncrciaisoivaxthatis~lewithdtesysmnfloidcom- Coatallpartswidtcleaahydraukfluidto
lXCSSCdairlINlYkUSCdiUciUUlhg,bPttitP3MkfitPrtd~ fkilitatc assunbly and provide initial
-kmovewaterilldeIImaddnn- l~on.usesmauamolmts
jelly to hold seal packs &lii$E?Z
AnewsaGtisquircdforassembiy.Refertopans~ng maina) in place during assaably.
notedinT~1forseaikit~.Washthemcraippablow
thandtywithairandpiaceonacleansurfacc(%aftpqer)for 1. Assanblcsaitpacksbyhrtingtbcseaipizndrintotbe
inspeaion. sealraaincK.Installsadpacksontilefoliowingpartspriorto
assanblywithtbescalraakswearplatcs.
1. FmntcovcrSIA-Totemovcthcdmblesinftsd. a.
perfotm
the following steps: a. ~“0”tiq(5)andsdrc*aina(6)~~
gland (12) into cavity located on f&a of rear cover (5).
a. PlaccfnmtcoverSIA~avise@ountiagfhgeup).
Usingasacwdrivcr,popouttkoutershaftscal(t2)bhgcarrfirl b. Install “0” ting Q aad seal tincr (6) and seal
nottorakcabutronthesh&scalbore. gland (12) into cavity located on face of adapter(10).
a Rculovethercsai@gring(23)widtimanal~
ring plias. c. Install seal tUainer (a) and seal gland (12) into
&itylocatcdoafaceofponscction(1s).
c RanovefrontawerS/A(l8)frumviseaud@accon
work~withtnountingflangedown.Usiagabromcdriftand 2. Skhdp1xnpassanbly-Pkcp0nsectionf16)invise ’
hammer.dliveinncrsilaftseal(24)outthrwghtrIout&flange with studs facingup. Assaable the shah end of pumpas follows:
bcingcanEfuInottodamagebcaring.
d. Inspazttlledriveanddrivalgexbnsllingsafshaft ~f&wiag~!i~and3.b.)pehn
endcowr(lg)forpi~.sroring,discof~~ormPessive toiasmuionoffluatcovcrsbaftscals.
wcar.AnyoftllcpEccdingconditionssball~anallt~ hlbricate the sbaft seal(s) with Marfak
oftbchntcovcrS/A.Iqectmountiqfhgefornickaud ~u,p+dCiIlithllUbriCatian,
burrs.Renlovewithhldiastotle.
a. Install i&r shah seal 04) into frost c&r (18).
zwearplates(7).-Itqxciforerosioapining, ~~titesp@1oaduimanber0fsMtseatfaccsthe~&
scmcks and/or scoting. Replace ifneccssq. ofpump.usc~af~sttpftseaidrivas~iaTabie4.placc
&eshaftscalottdriverandprcssinplace.Installraainingring
3. calter sections (10) and (21) - ilq=t for paosity. (23)intofrontcoveroni0pofshafrscai.
cracks.andscratch (.OlOor dcqer). Rcpiaccifnaxssq. DO
NOTdeburrthefiguzc&lttcdgeoftbecattersecth
4. Drive _ecars(8) and (19) - Inspectsplints for &ks or
excessive wear.Inspectgearjournalsfor saahcs auddbcolora-
tion. Anvdisw~omtion nwmns rep&cemau.lnspectgarteeth
for spailii, scratch at&r cxcessk wear. Rqhce if:
naxssary.Stoningteethtoratxnv btmGspamissable.Tkface
~1
ofthcgesrtecttlshouldalsok~forsratchttaudaacks. Tablc4. InntrSbaftSealDrivas
5. D&ngcars(9)alld0-Sameproccdmcasstep4.
b. Doubletiseai~ganent-Perfonnstep3.a.
andtlletliEUaIltkoutatdmfkseaiG2)imofTOtltCOVCr.Ipaail
outerslta&scalasfollows:Placeaguideowrthepilotdiamaer
ofhntawer.Next,insmlla~~~satlC22)onthe
driver.Makesltrethes@Bgloadedmcmbaofsilaftsealfaccs
theinsideofpump.Fiaauy,insatthedriverardshaftseal~
thcgaideandprcssinplace.RcfertoTable5forpropcrgnxic
and driver.
. .
MODELCODE m&A. -E DRIVER
0amtillg)
w-2 4.00
G20**-6 I 4.00
&Rearalver(4)-In!qectthtdrivcanddrkngcar
bushings for pickup. scoring. discoi~radonand/orwear..4ny of G20**-7 5.00 see
the preceding conditions shail lamant rqdacement of dJl?rear G30+*4 I 5.00 Figure8
1
cover. 5.00
I
G30**-7 I
5.00 I
12
Intended for CLARK dealersTableonly 5. outer sfiaft Seaf Guide and Driver
c. Place wear plate 0 on potI saxion (is) with f. Makcsnrctbcassanblytbusfarisfhtsbandsoiid.
bronze face up and notch facing in&t patt. Lubticatctbcdtivegcar(8)anddtivengear(9).ittstdibotbgcars
inpiacc.lbcqlitredcndof dtivegcar(8)tmtstatgagcittto
d. Lubricatebmnzefaccofwcarpiate(7).Instailcmtcr coup@ (13).
scctionO1)ontopofwearpiatccI)pdimoi~holesof
ponscaion(Is)wirhmajordiatnaufGagportscaiottandnatcb
facinginiapott.Makesummrpiatcandcaxcrscctionsetflusb g. LubricatcbrottzcfaccofwearpiatccI)atuipiacc
againstpottsaztioa. overkatittgpittsofcatterscaiott(10)witbbronzetacc&wtl
aItdllotcbfacittgitlWporL
c. Tape the spiii area (long spainc, of drive gear (19)
to ment cmrine shaft seai during assattbiy. h Lubticatescai raaincr(6)amandfaccofrcaicover
(4) witb pamiam jelly. CardW place rear cover (4) over
ioc&tgpiasofcattcrscaioll(1O)witboutlctponoppwitcinia
f. Lubrktedrivcgcar(I9)aaddrivcngcar(2O).&staIi
dtivegcar(l9)intoportsection(ls)widtsbotzspiiactowa&’
poR scctiotL InstaIl dtivea gear (20). i Lttbricate &reads of fouf long screws (3). Place lock
wasbas(2)onsae-.Ittstau- tbrottgbrear cover (4) and
g. LubricatcbmtKkfaceofwcqiatc(7).Iastaii itltopottsaxiotl(ls).ctusstotquesctewstovaiucssbownia
wcarplatc(7)ovcrkatingpiMofceBtcrsection(G3Osaies) Table 6.
(2l)witbbromfacctowardscattcrscctionatldtto&~g
inlet port. j. LtMcate threads of f0nr sitort scmm (I). Place
lockwasbaS(4)onsctm.ItKtaRscmws~ralrcovcr
h xastdi seal raainer (16) d seal gland (12) into. (4)attdintoadapterscctiott(ll).cmsstorquc- to vaiua
cavitylocatuiottfaaofsbaftcadanrcr(l8).&staiI*o”tittg sbowaittTabie6.
(~.Appiypamleamjellyaropndscalprckarraonfaocoffrom
COWL
i. Car&iypositiottsbafkaadawer(18)ovcrsmds.
gearsaudcatterseuiongttidcpitts.Gattlysiidesbaftaxicover
overtbegearsuntilitisfbtsbqaittstwearpiatc(7).
j. Lubricatesmd(2S)tbtca&witbbydranlicfiuid.
Install wasbcrs(17)andmtts(l6)onatdsofstttds. Crosstorque
mts to 150fS 1b.k on UO- sqiesami70 f5 lb.& on G20- Tabie6. RcarCoverScrewToquc
skies.
3. cIatttpportsation(i3)btto*wirhstudsfadngdowtL 4. T~tbe&vegcar(i9)ottenvoiutioawitbisuitab~e
MakeslKcportscctiotlisdatnpcdscfaxdy.Asscmblerc?lrcovcr ~~cb_Nobittdingsbaiibccvidaatdutingtbisopera-
portion of pump as foiiowsz t&.~~totquc~tottmttkdrivegcarmust
aotexc#dtbcvalucsttotcdittTable7.
a. Instdi”O”ring(l4)itttogtooveiocatedonfaceof
pan section (is). xnstau “0” ring (5).
b. Install btbricatcd coupling (13) on spiine of drive

..
gear (19). Install covq end pump.
c Lttbricatciocatittgpinsaadfaccofportscaion(15).
~adapwseai~(ll)wcriocatingpinsofporrsedionwith
1
notch facing inlet port.
Table 7. Breakaway Torque
d. placcwcarpIate(7)onadaptcrsaxiott(l1)witb
brolKefaccltpaudnotcbfaf5nginiapott.
c. Lubticatc~6iceofwarpiate~whhdam
bydraulicfiuid.Itntaiiccntuseuiott(lO)otttopofwcarpiate
(7)witbtnajordiatnmrfac&gtbcwcarpiatcaudtbenotcbfac-
ittgittlctpotLLucatingpimofcaltcrsaziottsbou&imatcwitb
adaptcrsection(1l)bolcs. ”
Secdon WI1 - TEST
Figure 14. Double Pump Test Ckuit .
A. BREAK-IN JEST CONDITION NOTE

During the following 9 DO NOT hold
Test F?uid - Hyduuiic fluid in acEordanccwithdatashcct zv dunq each qde more
M-1950-S or 1-186s and having a viscosity between 50 and 80 .
sus at 180°F.’
5. Slouiy krcase rdief valve sating to 500 PSIG.
Fluid Tempcramrc - Auid at pump inlet to bc maintained at Itmncdiiciy,back off rdief valve to minimum setting (approx.
180°F +10/-40, 100 PSIG). Repeat this step five times.
FiItration - A bieh~. fuilflow. IO-15micron fiiter q&n 6. Set r&f \Ave to 500 PSIG. Warm ttp systa fluid to
mustbefmcdi;;mrriiatciraftcrpumpoudettocatchpatticlcs 18O’F +10/-40.
_pncraudduringhcakiliperiod.nlcmtcrsystanshaunot
develop back 7 in esccss of 50 PSIG at maximum flow. 7. When system fSuidtanpaam= is obtain& cycle gear
pumpf~timesfrom1WPSlGtolOOOPSIGattenRPM
IniaCondition-AfinktbatxximaimcL15PSIGatpump (see Tables).
itliet pon.
8. AttestRI’hf.cyck~pompfiw~atimcnnisof
B. BREAK-IN TEST PROCEDURE 5CtOFSXGlJtltil~ pt=tl=~is~scCTabl~
Sand9for nraximmnP====tW
1. In!JtangcarptmlpintocircuitksshowninFigures13
and 14. Make sur&u flow, lo-15 micron &hlJ=su=mt= 9. Repeatstep8.andcydcp471Otimesperpressuk
iWCianalIedat~dCtS.BCS~~comrcaiOllS~li~ m. __
andthemotorisaforpperpmpmtation. ’
10.Maintainratcdprrssmtsutitqanddteckminimum
flowofpumpasshowninTablcs8and9.
NOTE
3. Tumonqemudng~s*atup~. Du+gtheprrcedingtestthcrrshouidk
no evidence of- l&W
- 4. slowlyislneatmotorspcedtothcrestRpMasshownin
Tables 8 and 9. (NOTEzInlet pressure gauges should read 0-15
PSIG. Outlet pmmc gauges shouidaad 100-150 PSIG.)
.
14
MIN. PLm
NOM. DEL
--.
@1200 RPM TEST PE CO!DE,
MODEL @lOOPSIG RPM PSI USGPM
G20**7*‘_*’ 1 1800 3600 5.0
G20.9 I 9 Iso0 3600 8.0
ci20**11
_ __ 11 11800 3fxxl 11
. n
..”
14.0
L
G21F13 13 1 1800 1 Moo I
-
G21VI5 IS I 1800 I 3600 I 16.7
G2P_+‘I7 17 I 100
IL__ I, 3300
---- 1
, 7n.n
-
G2LD-19
-- I 19 I 1800 I 3Ow I Gd -
G20*121
--- -- 21 1 1800 1 2750 1 26.3
a**7A 1 24 1 1800 I 22!!0 1 31.0
G2w-rr 1 &I 1dOO 2wO 35.0
G20**30 I 30~ .I 1800 1 low I- - 41.4
~**m_n- I IS I llm I3m I aa 7
G3O __ 1
.___
G30**35 I *a ‘WI0 3wO 44.8
G30=*40 I 40 1 1800 l 2500 l 53.0
, ._ I
45 1 1800 1 2250 i 60.7
1-50 5i I1800 Izooo I 68.5
Table 9.. Double Gau Pump Test Ratings

Table 8: Single Gear Pump ‘ftst Ratings
..
Copyrighted Material -I!

C5OOY2235 Group30
SECTION 5
VICKERS VALVE OVERHAUL
Copyrighted
SectionMaterial
Tile Page
Section 5
Vickers Valve Overhaul
OVERHAUL OF VICKERS
MULTIPLE UNIT VALVES
CM11 SERIES - 21 DESIGN
(COURTESY OF : VICKERS INCORP.)
Description ........................................................................................ 30-5-2

Principles of Operation ...................................................................... 30-5-3
Installation and Operating Instructions ............................................... 30-5-8
Service, Inspection and Maintenance ............................................... 30-5-10
Overhaul ........................................................................................ .30-5-11
Exploded View .............................................................................. 30--5- 12
Testing ........................................................................................... .30-5- 14
A WARNING
adequate.
SM 575, July 9
‘7 Copyrighted Material Vickers Valve Overhaul l 30-5-l
DESCRIPTION
A. GENERAL C. OPTIONAL FEATURES
Vickers CM11 - 21 Series Valves are made up of 1. Micro-switch attachment - CM 1l*S models are
directional control valve sections mounted in banks and equipped with a switch mounting bracket and a cam
connected internally to common pressure and tank re- extension on the spool to actuate a micro-switch In
turn passages. A valve bank usually consists of an inlet when the spool is shifted. Center
and operating (R*, K* or F*), a number of operating Out
Spool detents - A spool detent assembly consists
sections(*) andanoperatingandoutletsection (‘Lor*E). 2.
of a special end cap with a spring loaded plunger and
Each operating section contains a sliding spool (for
a spool extension. The plunger engages in grooves
example A, B, C, T, D or W spool). In valve banks where
in the spool extension to hold the spool in the desired
only one operating section is required, an R* section is
position.
used with an L or E tank plate section.
D. MOUNTING
B. ASSEMBLY AND CONSTRUCTION
CM1 1 Series -21 design valves are mounted with lugs
Figure 1 is a cross-sectional view showing the construc-
casr into the inlet and outlet sections.
tion and assembly of a three-section valve. Each section
contains a sliding spool with centering springs and a E. APPLICATION
checkvalve. The inlet section also contains a relief valve
Vickers Mobile Hydraulic Division application engineers
assembly.
should be consulted for valve ratings and applications.
Passages between the bodies connect each section to
the common inlet and tank ports. Seal rings between the
sections seal the connecting passages. Sections are
held together by studs and nuts.
Centering Body
n0
Valve
Switch Bracket I
t-
Cam
Figure 1
30-5-2 l Vickers Valve Overhaul Copyrighted Material SM 575, July 9

‘7
PRINCIPLES OF OPERATION
A. GENERAL Con!rol Va&e
By-pass Flow
S\ensrng Ordlce
Control Orifice
Figure 2 is a schematic illustration of a three section
valve, showing the inlet and outlet ports and the by-pass,
pressure and tank passages. The pressure passage is
used to carry fluid to the cylinder ports when the spools
are shifted. The by-pass passage permits flow directly to
the outlet when the spools are not being operated. The
tank passage also carries fluid to the outlet; either return
flow from the cylinder ports or fluid diverted past the flow
control and relief valve.
The spools are shown in the centered or neutral position.

Under these conditions, fluid in the pressure passage is
block from the cylinder ports by the spool lands. Flow Tank Passage C linder
through the valve is through the by-pass and tank pas- 6 orts
sages to the outlet. Figure 2
(c) K* Section - The K’ section is essentially the

B. OPERATING SECTIONS same as the R’ section except it has a full by-pass
feature.
1. Inlet Sections - The CM1 l-21 Series valve bank
may be obtained with operating, R*, F* or K* inlet 2. Outlet Sections
sections. These sections are individually described (a) *L Section - When two or more spools are
below. required in avalve bank, the last section will be an *L
(a) R* Section - The R* section is equipped with an section. The “*“denotes the spool type. This section
integral relief valve for overload protection. It is built contains the exhaust oil port and also is built to
toaccept acheckvalvetoprevent returnflowthrough accept a check valve to prevent backflow when this
the valve. feature is required.
The integral relief valve, with an orifice plug, also acts as (b) *E Section - This section is used for tandem
a partial flow control valve. This feature lowers the operation by providing an outlet connection though
pressure drop between the inlet and out ports. (See which the by-pass feature for pump unloading is
paragraph 4 for relief valve and flow control operation). extended on to a subsequent valve bank. It is used
in conjunction with an “F*” type inlet section in the
The relief valve cracking pressure is pre-set at the
next valve bank. Like the *L section it contains an
factory. The pre-set cracking pressure range up to 2500
operating spool and is built to accept a check valve
psi maximum.
to prevent back flow when this feature is required.
(b) F* Section - The F* section has two pressure
3. Spool Operation
connections. One connection is made to the pump
source and the second connection is made with a Six standard spool designs are available (A, B, C, D, T
preceding valve assembly to accept the by-pass and W). Any combination of spools may be used with a
flow for tandem operation. valve bank to perform a variety of operations. All operat-
ing spools are equipped with centering springs which
The F* section like the R* section is built to accept acheck
return the spools to neutral.
valve to prevent return flow when this feature is required.
However, F* sections do not employ relief valve or partial For convenience A. S. A. symbols (Y32. 10-1958) are
flow by-pass. also shown with the following descriptions of each spool.
SM 575, July 9
‘7 Copyrighted Material Vickers Valve Overhaul . 30-5-3
CIRRK Group 30, Hydraulic Components
(a) “D” Double Acting Spool - “D” spoolsare

used for applications where pump flow must
be directed to either end of acylinder, depend-
Tank Return
b-4 ing on the direction of movement required.
The end of the cylinder not under pressure
has its return flow directed to reservoir via
internal coring of the valve sections. See
Figure 3 for spool position versus flow.
Pressure to “B”
“A” To Tank By-pass Open “A” To Tank
By-pass Blocked By-pass Blocked (b) “A” Double-Acti&j !3po& - The “A” spool is
a double-acting spool with variable orifices.
Figure 3 “D” DOUBLE ACTING SPOOL
An internal spool is used to provide this vari-
able restriction. So long is there is a positive
inlet pressure, the orifice is large, permitting
unrestricted return flow. Decreased inlet pres-
Tank Return sure permits the spool to shift, decreasing the
E-j
orifice size.
(4 “A3” and “A4” Spools - These are double-

acting spools with fixed orifices to restrict flow
to the reservoir from either cylinder port (see
Figure 4). This prevents losing control of the
load. Operation is otherwise the same as the
“D” spool. See sub;paragraph (a) above.
Pressure to “B” Pressure to “B”

“A” To Tank “A” & “B” Blocked
By-pass Open “A” To Tank
By-pass Blocked By-pass Blocked
1 MAN MAN
Figure 4 “A” DOUBLE ACTING SPOOL
(4 “B” - Motor Spool - “B” spools are used

when flow is directed to the operation of a
hydraulic motor instead of a cylinder. These
spools are double acting in character so that
Tank Return
the motor may be rotated in either direction.
The cylinder ports are left partially open in the
neutral position to allow free flow of oil be-
tween the motor and reservoir. Check valves
are not used in 73”
‘ spools. See Figure 5 for
spool position vs.. flow characteristics.
Pressure to “B” Pressure to “B”

“A” To Tank “A” & “B” Blocked “A” To Tank 1MAN MAN
By-pass Blocked By-pass Open By-pass Blocked
Figure B 73” MOTOR SPOOL

‘7
(e) “c” Float Spool - “C” spools are double

acting with an additional float position. The
spool is retained in the float position by a
detent, and it is spring centered to neutral
fromthe”in”and”out”positions. Bothcylinder
ports are open to the reservoir in the float
position to permit free flow of oil in eigher
direction. See Figure 6 for spool position
versus flow.
1 p
,la
MAN
A ’ B
Figure 6 “c” FLOAT SPOOL

(f) 7”
‘ Single Acting Spool - “T” spools direct
flow to one end of an operating cylinder only
as in the example of the lift mechanism on a
fork-type truck. Return flow is from the same
end of operating cylinder and relies on gravity
or mechanical means. See Figure 7for spool
position versus flow.
Tt5
[ MAN NMAN
AI B
Pressure to “B” “A” & “B” Blocked “B” To Tank

“A” Blocked By-pass Open “A” Blocked
By-pass Blocked By-pass Blocked
Figure 7 “T” SINGLE ACTING SPOOL

(g) Y
‘ /V” Single Acting Spool - The “w” spool
Pressure
is a single-acting spool which operates the
Cent1
reverse of the T’‘ spool explained above. -B Out=4 Tank Return
Flow is controlled to and from portA, and port
B is plugged. T P
I tx
A’B
“A” To Tank “A” & “B” Blocked !$E;gi$ “A

“B” Blocked By-pass Open
Bypass Blocked By-pass Blocked
Figure 8 W”
‘ SINGLE ACTING SPOOL
SM 575, July 9
‘7 Copyrighted Material Vickers Valve Overhaul l 30-5-5
4. Flow Control and Relief Valve By-pass Flow

Control Oriiice
Earlier design valves were equipped with simple relief
valves in the inlet sections. The partial flow by-pass
system in the CM1 l-21 valve makes use of a compound
type flow control and relief valve arrangement.
By sensing the pressure drop across an orifice at the

entrance to the by-pass, the valve acts as a flow control
to limit flow through the by-pass to approximately seven
gallons per minute. The balance of the pump delivery is
diverted through the reservoir passage. This arrange-
ment greatly reduces pressure drop through the valve in
the neutral position.
When a spool is shifted to operate a portion of a machine,

- .
the flow control is inoperative and full pump volume is Flo/w Control
ggs I
~a~vWef Control Valve
available to the system. The control valve then functions \ Sensing Orifice
Spring
as an overload relief valve. System pressure is limited to
a prescribed maximum by the action of this valve. Inlet
pressure c-3
body type “F” is not equipped with a relief valve. Full
Tank Return E-J
pump volume is available to the system at all times. Pressure Drop m
(a) Flow Control - Figure 2 shows a valve opera-

tion in neutral with flow in excess of seven gpm. Flow Figure 3
across the by-pass orifice results in a pressure drop. spring, the poppet is forced off its seat. (See Figure 9B).
The decreased pressure is sensed at the spring end Fluid immediately flows past the poppet to the reservoir
of the valve subassembly through a sensing orifice. passage. This flow creates a pressure drop across the
The slightly higher pressure at the other end of the sensing orifice and the control valve is no longer hydrau-
valve permits it to shift down, diverting excess flow to lically balanced. When this pressure differential is great
the reservoir passage. With flow less than seven enough to overcome the large spring, the valve shifts,
gpm, there would be negligible pressure drop across permitting flow to the reservoir passage.
the by-pass oriiice. Then the control valve would be
5. Check Valves - Timing of the valve spools is such
held closed by the large spring and all flow would be
that one cylinder port opens to pressure and the other
through the by-pass passage.
port opens to reservoir before the by-pass passage is
(b) Relief Valve - Operation of the relief valve completely blocked. To prevent return flow from a cylin-
feature is shown in Figures. Here anoperating spool der port from passing into the pressure passage and
would be shifted, porting fluid to the system and escaping through the partially closed by -pass, check
blocking the by-pass. valves are provided in each operating section except
Figure 9A show operation at less then the relief valve sections with “B” spool. The load is thus prevented from
setting. There is no flow over the by-pass oriiice, so full dropping.
system pressure is sensed at the spring end of the 6. Detent - The spool detent consists of a special end
control valve, as well as the opposite end. The valve is cap with a spring loaded plunger. The plunger engages
thus hydraulically balanced and the large spring holds it in a groove in the spool extension and holds the spool in
closed. the desired position.
Maximum pressure is determined by the setting of the 7. Tandem Operation - Tandem operation permits
small spring inside the control valve assembly. When operation of two banks of valves from the same pumping
system pressure is high enough to overcome this heavy source. An internal plug in the outlet section of the first

‘
Figure 10
- -
An le Between D, B, A3, A4 Spools

Single Actin D, A3, A4
Mifed Groove In Spools Simu9 ates “w” Port
Cam and Flats On B is Plugged
Spool End
Switch Is Actuated When Spool Is Shifted In Direction Indicated By Arrows
Figure 11
bank (Figure 10) separates the by-pass passage from If neither bank is operating, part of the fluid flows through
the reservoir passage. Cylinder exhaust oil is returned to both by-pass passages directly to reservoir. The balance
tank via the alternate discharge port and by-pass oil is is diverted through the reservoir passage of the first
directed out the primary discharge port to the by-pass section as shown in Figure 2.
port of the bank.
In some cases, it is desirable to have tandem valves
In Figure 10, either bank can be operated separately or connected in series where the second bank is dependent
both simultaneously. This is possible because of the upon the operation of the first bank. The first bank has
tandem by-pass connection from the inlet connection of control priority because the tandem by-pass connection
the first bankto the F inlet connection of the second bank. is not used. The cylinder by-pass oil of the first bank is
SM 575, July 97
‘ Copyrighted Material Vickers Valve Overhaul l 30-5-7
directed out of primary discharge port to the inlet port of 1. “E” Outlet Section - The “E” type section provides
the second bank.‘Use a “K” inlet section in the first bank an outlet section by which the by-pass feature for pump
if full flow is desired to the second bank. Otherwise unloading is extended to a subsequent valve bank (tan-
reduced flow will be encountered. dem operation). It is generally used in conjunction with
the “F” type inlet section on the subsequent valve bank
8. Electric Switch Section - Provision is made to
assembly. This “E” type section is only used with one-
actuate a switch to start the hydraulic power source on
spool banks.
electric powered machines only when it is needed. For
7”
‘ spool operation, the “A” port must be plugged. “w” 2. “L”Outlet Section - The “LYype section is basically
spool operation requires that port “B” be plugged. the same section as the “E” section except it provides
onlyoneconnectionforexhaustoiland isusedasthe last
All D, Tor W electric limit switch models are supplied with
section on a single-spool bank where tandem operation
“D” spools only. T’
‘ or “W ” spool operation is accom-
is not required.
plished by mounting the switch or rotating the spool
extension as shown in Figure 11. NOTICE
It should be noted that the
9. Narrow By-pass Sections - Narrow by-pass
pressure drop across the
sections have narrower by-pass grooves in the spools.
valve, when used in series
These provide better metering for low volume applica- operation, will be the sum of
tions. the pressure drops for each
section.
C. NON- OPERATING SECTIONS
The CM1 l-21 valve non-operating sections are the “E”
and I”‘ outlet sections. These sections do not have
operating spools. The functions of these sections are as
follow:
INSTALLATION AND OPERATING INSRUCTIONS
A. INSTALLATION DRAWINGS C. PORT CONNECTIONS
Installation drawing M=248821 should be consulted for Except for the alternate discharge port, all connections
installation dimensions. are compatible with standard SAE fittings and “0” ring
seals. It is only necessary to tighten fittings so that there
B. MOUNTING
is a firm metal-to-metal contact.
These valves can be mounted in any position. Enough
D. RELIEF VALVE
clearance must be left to provide access to the port
connections and to permit actuating the control mecha- Relief valve sub-assemblies in the inlet section are
nism. The valves should be securely bolted to the preset and tested by Vickers for given pressure settings.
mounting surface. Selection of the relief valve setting is based on the work
requirements of the system. If a different relief valve
setting is required, the valve sub-assembly should be
NOTICE replaced.
Valves should be mounted on
a relatively flat surface to E. TANDEM INSTALLATION
prevent possible distortion of 1. Port connections for tandem series operation are
the valve bodies.
shown in Figure 10.

‘7
2. The outlet section of the first bank must be an “E” NOTICE

section which is equipped with a plug (see Figure 10) For instructions on pickling,
to block the primary discharge port from the reser- refer to Vickers Instruction
voir. The alternate discharge port must be con- Sheet M-9600.
nected to the reservoir.
NOTICE
H. HYDRAULIC FLUID RECOMMENDA-
Slight leakage past the internal
plug is permissible. The plug TIONS
should not be tightened 1. General
excessively, as there is the
danger of distorting the body The oil in a hydraulic system serves as the power
and causing the spool to bind. transmission medium. It is also the system’s lubricant
and coolant. Selection of the proper oil is a requirement
for satisfactory system performance and life. Oil must be
F. MICRO-SWITCH & CAM INSTALLATION selected with care and with the assistance of a reputable
supplier. Two important factors in selecting a fluid are:
1. Figure 11 illustrates the correct mounting positions
for the micro-switch, bracket and cam. (a) Antiwear Additives - The oil selected must
contain the necessary additives to insure high
2. To convert a standard section to an electric switch
antiwear characteristics.
section, the end cap screws must be removed to
attach the bracket. The cam must be pressed into (b) Viscosity - The oil selected must have proper
the spool at the correct angle with the flats on the viscosity to maintain adequate lubricating film at
spool end as shown in Figure 11. Secure cam in system operating temperature.
spool with a good grade of epoxy adhesive.
A CAUTION
Usecautionwhileinsertingcan
Specifications
Use only high quality hydraulic fluid with zinc or equiva-
lent Anti-Wear additive which meets the requirements of
into spool to avoid damaging
nylon cam. ASTM D-2882 pump wear test with 50 mg. total weight
loss maximum per CLARK Specification MS-68.
G. HYDRAULIC TUBING
1. The number of bends in tubing must be kept to a
minimum to prevent excessive turbulence and fric-
tion of oil flow.
2. Tubing must not be bent too sharply. The minimum

radius for bends is three times the inside diameterof
the tube.
3. To minimize flow resistance and the possibility of

leakage, only as many fittings and connections as
are necessaryforproper installation should be used.
4. All tubing must be thoroughly cleaned before instal-

lation to remove dirt, rust and scale. Recommended
methods of cleaning are sand blasting, wire brush-
ing and pickling.
SM 575, July 97
‘ Copyrighted Material Vickers Valve Overhaul l 30-5-g
SERVICE, INSPECTION AND MAINTENANCE

A. SERVICE TOOLS B. INSPECTION
No special tools are required to service Vickers CM1 l- Periodic inspection of spool operation, oil condition and
21 series, multiple unit valves. pressure connection saves time-consuming breakdowns
and unnecessary parts replacement.
TROUBLE, CAUSE AND REMEDY CHART

T
TROUBLE PROBABLE CAUSE 1 REMEDY

Defective “0” rings in valve body. 1 ReplaCe “0” rings. I
Broken springs. Replace springs.
Oil leaks at either end of spool. Replace with new section of same
Bent spool.
size and type.
Spring-centered spools do not
return to neutral. Foreigh panicles. Clean system and valve.
Misalignment of operating linkage. Check linkage for binding condition.
Valve bank improperly torqued. I Retorque nuts to specified ratings. I
Detent type spools will not stay in Worn detent barrel. I Replace detent barrel. I
detent position. Weak or broken detent spring. I Replace detent spring. I
Relief valve not properly set, or
Repair, clean and adjust.
stuck in base and/or worn.
No motion, slow or jerky, action of Dirt or foreign particles lodged Disassemble, clean and
between relief valve control reassemble.
hydraulic system.
poppet and seat.
Valve body cracked inside. Replace valve section.
Spool not moved to full stroke. Check travel.
Small particle of dirt plugging orifice Remove relief valve and check
in relief valve sub-assembly. hole. If blocked, clear hole.
No relief valve action (high pres-
sure). Relief valve sub-assembly installed
Install properly.
backwards.
Oil bypassing between spool and Replace valve.
body.
Load will not hold. Oil bypassing piston in cylinder. Repair or replace cylinder.
Spool not centered. Refer to above spool remedies.
Dirt or foreign particles lodged Disassemble, clean and reas-

Load drops when spool is moved between check valve ball and seat. semble.
from neutral to a poser position.
Scored or sticking check valve. Replace poppet.
304-10 l Vickers Valve Overhaul Copyrighted Material SM 575, July 9

‘7
1. All hydraulic connections must be tight. Loose con- D. LUBRICATION

nections not only allow leakage, but also permit airto
Internal lubrication is provided by system oil.
be drawn into the system, resulting in noisy and
erratic operation.
2. Spools should return to neutral automatically when E. REPLACEMENT PARTS

thecontrol is released.The standard centering spring Only genuine parts manufactured or sold by Vickers
force is approximately 28 pounds with the spool in should be used as replacement parts for these valves.
the neutral position and approximately 56 pounds Only Vickers knows the true quality level required of each
with the spool in the shifted position. If more force is part. Consult your Clark dealer to obtain genuine re-
necessary, the spool may be binding or control placement parts.
linkage may be faulty.
3. System filters and reservoir should be checked

periodically for foreign particles. If excessive con- F. TROUBLESHOOTING
tamination if found, the system must be cleaned The table on the left lists the difficulties which may be
thoroughly before refilling. experienced with the unit and hydraulic system. It indi-
cates the cause and remedy for each of the troubles
listed. It should always be remembered that pressure
C. ADDING FLUID TO THE SYSTEM and delivery are factors which are usually dependent
When hydraulic fluid is added to the system, it should be upon each other. Adequate pressure gage equipment
pumped through a 25 micron filter. If such a filter is not and a thorough understanding of the operation of the
available, or practical to use in the field, a funnel with a complete hydraulic system are essential to diagnose
fine wire screen (200 mesh or better) can be used. improper operations.
It is important that oil be clean and free of all substance

which will cause improper operation and excessive wear
of the pump or other hydraulic units in the system. Be
sure to purge all air from the system.
OVERHAUL
A. GENERAL remove the “E”washers which retain the fulcrum rod
and remove the rod, levers and pivot pins.
During disassembly, particular attention should be given
to identification of parts for reassembly. Spools are 2. Attaching Parts - Remove the four tie studs and
selective fitted to valve bodies and must be returned to nuts and separate the valve sections. Be careful not
the same bodies from which they were removed. Valve to destroy or lose spacers.
sections must be reassembled in the same order.
3. End Caps - On CM1 l-21 models remove the micro-
Figure 12 is an exploded view showing the proper switch from the bracket. Remove the two screw
relationship for reassembly. Reference is made to these which secure the spool end cap and remove the cap
figures in the procedures which follow. (and switch bracket, if used). If the cap has a detent
assembly, screw out the detent plug and remove the
spring piston. Remove the “0” ring from the cap.
B. DISASSEMBLY
4. Operating Spool-Slide the spoolout of its bore and
1. Controls - Be sure the unit is not subjected to remove the “0” rings from the groove in the spool
pressure. Disconnect and cap all lines and discon- and from the valve body around the spool bore. Do
nect linkage to the spool. If hand levers are used, not remove the centering spring, retainers or the
SM 575, July 9
‘7 Copyrighted Material Vickers Valve Overhaul l 30-5-l 1
spool extension unless it is necessary to replace 1. Valve Body - On model with single-acting spool,
them. install the “0” ring on the port plug and plug the
5. CheckValve - Grip the stem of the check valve plug appropriate cylinder port. Tighten the plug securely,
with pliers and pull it out of the valve body. Remove but DO NOT over tighten. On F’ models, install the
the “0” ring and back-up ring. Remove the spring back-up ring and then the “0” rings on the fitting
and ball from the valve body. Tighten the fittingsecurely, but DO NOTovertighten.
6. Relief Valve Sub-Assembly- Screw out the plug 2. Relief Valve - Install the “0” ring on the relief valve
which retains the relief valve and remove the “0” ring plug. Place the relief valve assembly in its bore, hex
from the plug. Remove the spring and the relief valve nut end up. Install the spring and plug andtighten the
sub-assembly. In “F” sections, remove the solid plug securely be DO NOT over tighten.
Plug* 3. Check Valve - Install a new back-up ring and “0”

7. Valve Body - Remove the plug and”0” ring from the ring on the check valve plug with the “0” ring
blocked cylinder port on models with a single acting toward the spring and ball. Place the ball and
spool. If the alternate discharge port is plugged, it is spring in the body and install the plug. Be sure the
not necessary to remove the plug unless the body is hole inthe plug lines upwith the stud hole in the body.
to be replaced. On F* bodies, remove the fitting, “0” Check valves are not used in “B” spool sections.
rings and back-up ring. 4. Operating Spool - If the centering spring was re-
moved, install the spring and retainers on the spool.
Place the “0” ring in the groove around the spool
c
u. CLEANING, INSPECTION & REPAIR bore and install the “0” ring on the spool. Install the
1. Discard all old seals. Wash all parts in a clean spool in the bore. On electric switch models, be
mineral oil solvent and place them on a clean surface certain the cam extension is in the correct position.
for inspection. 5. End Cap - Install the “0” ring in the end cap groove
2. Carefully remove burrs by light stoning or lapping. and install the cap, switch bracket (if used) and
Be certain there is not paint or burring on mating attaching screws. Torque the screws securely. On
surfaces of valve bodies. models with detents, grease all the detent parts.
Install the end cap and check for proper spool
3. Inspect the valve spools and bores for burrs and
extension alignment. Install the piston, spring and
scoring. If scoring is not deep enough to cause
plug. Be sure to screw the plug in all the way.
objectionable leakage, the surfaces can be stoned
or polished with crocus cloth. If scoring is excessive, 6. Assembly of Unit
the valve body and spool must be replaced. Check
the valve spool for freedom of movement in the bore.
AsureCAUTION
Make all mating surfaces
4. Check the relief valve for smooth movement in its of valve bodiesarefreeof burrs
bore. The valve should move from its own weight. and paint.
Install seal rings and the seal ring retainer in the

grooves in the body of each inlet and center section.
D. ASSEMBLY (Figure 12)
Use petroleum jelly to hold the seals in place. Care-
NOTICE fully place the sections together in the same order in
Coat all parts with clean which they were removed. Coat the stud threads
hydraulic oil to facilitate with “Loctite” or similar sealant and install the studs.
assembly and provide initial Tighten the nuts to 15 foot pounds torque. If levers
lubrication. Petroleum jellycan are used, install pins in each spool and assemble the
be used to hold seal rings in
levers, fulcrum rod and “E” washers.
place on assembly.

‘7
Plug
6
-. /“O” Ring
Spring
“0” Ring ,Lw@
“0” Rim 2
Ext&sion
“c” Washer
er
Sleeve.
@I7Screw
Retainer
Ball
Dust Cover
“0” Ring
Figure 12
SM 575, July 9
‘7 Copyrighted Material Vickers Valve Overhaul l 30-5-l 3
C500 Y2235 Group 30
SECTION 6
LIFTAND TILT CONTROL VALVE
Copyrighted
SectionMaterial
Title Page
11. Remove the spool eye and O-ring seal. Use the 14. Remove the spools from the valve body. Put a
wrench flats on the spool end and a rod or tool in markon the spools for identification during assem-
the spool eye clevis hole. Remove the internal bly. Remove the fiber back-up rings and seals from
spring and poppet from each spool. Put a mark on both sides of the valve body.
each poppet for assembly to the spool and spool
end from which it was removed.
INSPECTION
12. Remove the spring with the tool shown in the 1. Wash the parts in solvent and dry with a lint-free
illustration below. Push the spool toward the spool cloth. Replace all rubber O-ring seals, spool seals,
cap and install the spring compressor tool. Put the fiber back-up rings and springs.
tool let between the inner spring guide and the seal
retainer plate. Remove the spool end cap and O-
ring seal using a socket wrench in the end cap
while holding the spool by the wrench flats.
2. Check the operation of the internal piston of the

relief cartridge by actuating it against the spring.
The piston should move freely without seizure. If
movement is limited, replace the cartridge.
13. Remove the poppet spring and poppet from the
spool. Put a mark on the poppet and the valve
spool as a reference for assembly. Remove the
seal retaining plate from the spool.
SM 575, July 97
‘ Llft and Tilt Control Valve 9 30-6-3
Group 30, HYdraulic Components
3. Check that the small wire around the cartridge 6. Carefully inspect spools for damage and wear.
moves freely in the hole. This wire controls correct Look for loose chrome plating, cracks or other
operation of the relief valve and keeps the orifice damage caused by foreign material in the system.
hole clean. .,
Wearof the spools increases fluid leakage. This loss of
fluid to the circuit causes a change in the way the
machine works.
Estimate the amount of damage and make a decision

to us or replace the spools.
4. Check the poppet seat in the cartridge. Replace

the cartridge if the hole is worn or shows damage. 7. Use a light to inspect the spool bores in the valve
Relief cartridges are factory assembled and tested, body for scratches, sharp edges and grooves.
and re replaced only as complete assemblies. Check for loose particles of dirt on the bore sur-
faces.
5. Inspect the pilot poppet to see if there is dirt in the

hydraulic system. In a clean system during normal
operation, the poppet will show only a very fine line 8. Put hydraulic oil on the spools and install the
at the point of contact with the cartridge hole. A spools in the valve body according to marks made
dirty system will cause wear of the poppet and at disassembly. Work the spools as in normal
other parts. Replace awom poppet and correct the operation and rotate them acomplete revolution to
cause of failure. check if they move freely. Remove spools for later
assembly.
.,
e
New Part
Seating
Erosion
Line
& Wear
Normal Operation Worn Part
30-6-4 l Lift and Tilt Control Valve SM 575, July 97
‘
9. Replace the poppet if: 2. Install the cartridge with a soft rod until it bottoms.
a. Valve operation is not correct. NOTICE

Do not damage the relief poppet hole in
b. There is a groovk in the face where it contacts the
the end of the cartridge.
spool seat.
IMPORTiNT
The spool and poppet are precision
fitted during assembly. If spool seat is
badly worn, replace the control valve.
3. Install a new O-ring seal on the relief cap and install

the cap. Tighten to [61 Nom] 45 lb. ft. of torque.
10. Replace the spool eye if the clevis pin hole is worn
oversize or is out of round.
iii3
4
-.
-
ASSEMBLY
Look at the parts views of a typicaLvalve assembly on 4. Put the relief poppet and the spring in the relief cap.
pages 20 and 21 as a reference. Check that the poppet enters the hole in the
cartridge.
1. Put the valve body in a vertical position with the
relief adjustment side up. Apply grease to the new
O-ring seal on the relief cartridge and install this
end into the valve body. Hit careful!y with a soft
hammer until the cartridge enters the valve.
SM 575, July 97
‘ Lift and Tilt Control Valve l 30-6-5
5. Turn the adjusting screw in by hand until you feel 8. Apply grease to a new spool seal and install it on
the spring tension. Install the jam nut with a seal the spool with the marked side out. Seals that do
washer on each side. Install acorn nut and leave not have marks are earlier types and must be
loose until the relief valve is set.. replaced with the newer seals.
6. Install the plain hex headed relief cap. Put grease 9. Using a seal installing tool, set the spool seal at the
on a new O-ring seal and tighten the cap to [61 Nom] bottom of the seal bore.
45 lb. ft. of torque.
IMPORTANT
Do not damage or cause distortion to
the seal.
7. Install each spool in the dame valve bore following

the marks made during disassembly. Install each
spool the same distance from each side of the
valve body. The spool wrench flats must be on the 10. Add a new wiper seal to the spool end and install
operating side of the valve. the retainer plate. Tighten bolts to a torque value of
[20-27 Nom] 15-20 lb. ft.
30-6-6 Lift and Tilt Control Valve Copyrighted Material

l SM 575, July 97
‘
11. Install the spool poppet and spring to the correct 14. Use a seal installing tool to prevent seal damage.
spool end according to marks made at disassem- Push the seal into position until it bottoms.
bly.
15. Add a new fiber back-up ring to each seal. If a seal

is in the correct location, the back-up ring will be
12. Put a new O-ring seal on the spool eye and install flush with the valve body surface.
the eye in the spool. The poppet spring must be in
the center of the recess in the eye.
Tighten by using the wrench flats on the spool and

a rod or tool in the spool eye. The spool eye will be
tightened laterwith the cap on the other end of the
spool.
16. Install the poppet and spring, if used, in the same

spool end according to marks made during disas-
sembly.
13. Apply grease to new seals and install with the

marked side out. Seals less mares are earlier
types and must be replaced.
SM 575, July 97
‘ Llft and Tilt Control Valve l 30-6-7
17. Install a seal retaining plate on each spool end. 20. Hold the valve spring cover in position and install
the bolts and lock washers. Tighten the bolts to a
torque value of [20-27 N-m] 15-20 lb. ft.
Installation of this cover puts the spool in the

neutral position and completes the assembly of the
valve.
18. Install a cupped shaped spring guide in each end

of the centering spring. Install the spring in the
spring tool. Install a new O-ring seal on the spool
end cap.
SPECIAL INSTRUCTIONS
This section gives a description of the changes made
in the “100” and “100-A” series control valves. A “100”
or “100-A” series is any valve model where the version
number is 100 or over. Example: V37DD102 and
V37DSll O-A.
MODEL NUMBERING SYSTEM

V38 SDD 12
19. Install the spool end cap into one end of the spring VALVE J 1 VERSION
assembly and engage the threads. Tighten to a SERIES NUMBER
torque value of [41 Nom] 30 lb. ft. T
OPERATING PLUNGERS
Use the hex socket in the spool cap and a round (Type and number of plungers and
tool in the clevis hole of the spool eye. This method their sequence - first letter denotes
will tighten the spool cap and the eye at the same plunger nearest the valve inlet).
time.
MAIN RELIEF VALVE

(V37, V38, V46 - “100” Series):
1. Follow the Disassembly Steps 3,4, and 5 on pages

1 and 2 of the general instructions.
‘
CMRK Group 30, Hydraulic Components
2. Remove the hex-cap and O-ring from the side 6. Inspect the pilot poppet as shown in Step 4, page
opposite the adjusting screw. 4 of the General Instructions.
7. Clean all parts carefully and assemble in reverse

order. Refer to the General Instructions, Steps3,4,
5 and 6 on pages 5 and 6 for correct assembly of
the relief pilot poppet.
-701 - (or
3. Using a 6.4 mm) 1.4 inch brass rod, put it through
the hole in main relief valve poppet-seat. Push the SEAL INSTALLATION
pilot poppet-seat and the relief main poppet out (V37, V36, V39, V46 - “100” and “100-A” Series
the adjustment side of the valve body.
1. Give protection to the seal while installing it by
putting a small piece of plastic around the spool
end.
IMPORTANT
Removetheplasticafterthesealmoves
over it.
Never remove the plastic by pulling it
through the seal.
4. To remove the main relief poppet-seat, install the
main relief poppet removed in Step 3.
With the l/4 inch brass rod carefully hit the rod
against the main poppet and seat, and push it out
the adjustment side of the valve body.
2. Put hydraulic oil on the spool and a thin layer of

grease on the seal and the plastic.
5. The illustration below shows the relief valve parts.
Inspect the main relief poppet and seat for any Install the seal with its flat side out on top of the
wear or defect and replace if necessary. plastic.
3. Select the correct seal installing tool for the valve

series.
Using a small mallet, carefully force the seal into

the valve body.
SM 575, July 97
‘ Llft and Tilt Control Valve l 30-6-9
4. Assemble the seal retainer plate and the wiper 5. Slide the wiper seal assembly into position by
seal, then install this assembly on the valve spool. pushing it with the wiper retainer plate.
a. Temporarily remove the spring from the wiper 6. Install and tighten the wiper retainer bolts to [20N=m]
seal. 15 lb. ft. torque.
b. Put grease on the seal and the seal retainer 7. Install seals on the opposite end of the spool
plate. following the same method.
c. Carefully install the seal retainer plate overthe

flexible lip of the seal and push it against the
back of the seal.
d. Install the spring.
_, Wiper Retainer Plate

- Spring
- Wiper Seal
Seal Retainer Plate
‘
SEAL INSTALLING TOOLS

Figures 22359, 22360 and 22361 give the dimensions needed to make seal installation tools in the shop. Make
the tools from cold rolled steel, carburize and harden. Tools are not available from Clarkorthe valve vendor. Refer
to the valve serial number plate to identify the valve series.
=7-f- f
MODEL NO. A B C D
V39 All Series 1.981 2.355 .060

(inches) 2.60
1,983 2.357 .064
V38 All Series 1.619 1.989 .060

(inches) 2.24 3.50 5.00
1.621 1.991 .064
V39 All Series 50.32 59.82 1.52

(millimeters) 66.0 101.6 152.4
50.37 59.87 1.63
V38 All Series 41.12 50.52 1.52

(millimeters) 56.9 88.9 127.0
41.17 50.57 1.63
FIGURE 22359
SM 575, July 97
‘ Llft and Tilt Control Valve l 30-6-l 1
--------
I“-tF IL.5
I
..A
I II\J& -
MODEL NO. A B C D E F G H J
V37 Ail Series 1.375 1.742 .060 5.00 50 .25 1.875
2.00 50
(inches) 1.746 .065
V37 All Series 34.93 45.25 50.8 1.52 127.0 12.7 6.4 47.63
44.35 1.65 12.7
(millimeters)
K. Knurl outside diameter Figure 22360

L. (-127 mm) .005 in. corner break
BICIDIEIFIGIHIJ
; :;;; 1 1.594 1 1;; 1 .625 1 500 / 3.00 / 25 1 1.375
V46 All Series 28.58 ;;:;; 1 40.49 / ; 1;; 115.88 1 127.0 / 76.2 / 6.4 1 34.93
(millimeters)
K. (3.18 mm) .125 in. dia. drill for vent Figure 22361
L. Knurl outside diameter
30-6-12 l Lift and Tilt Control Valve SM 575, July 9‘ 7
APPLYING SEALANT ON THE SPOOL ENDS

(U37, U38, U39, U46 - “100” AND “100-A” Series
The valve spool eyes and end caps must be installed 4. Put Loctite Sealant Grade CUU on the male threads
with Loctite to prevent leakage. only. Use nozzle on the bottle and put three (3)
drops on first three (3)) threads.
1. Check that the threaded surfaces are clean, dry
andfreefromgreaseoroil.Useaspraycanandput IMPORTANT
Locquick Primer Grade T on the parts. Do not put loctite on the parts other
than the threads.
5. Tighten spool eye and end cap to a torque value of

[54-l 08 Nom] 40-80 lb. ft.
6. Permit parts to dry for a minimum of 20 minutes at

a temperature of (21°C) 70°F or above. Do not
move parts during this time.
2. Remove all primer except for a thin layer using

compressed air (207 kPa) 30 PSI or less. Permit to
dry for a minimum of three (3) minutes.
3. Carefully put new O-rings on the spool eyes and

end cap.
SM 575, July 97
‘ Lift and Tilt Control Valve l 30-6-13
Group 30, HYdrauIic Components
Retainer Bolt
Wiper Retainer Plate
0 :I
- Seal Retainer Plate
- Spool Wiper
ay Oil Seal
Spool Eye - ’ - Spool Eye

Q
O-ring Seal -e e- O-ring Seal
Poppet Spring - 1 f- Poppet Spring
POPpeW 3 cl- Poppet
Tilt Spool -Y@ - Liit Spool
d
&!
Poppet -
9
Poppet Spring -
F
Oil Seal - @sJ
Spool Wiper -0
Seal Retainer Plate - 0 _
0
7 Centering Spring
O-ring Seal *a
Spool Cap 7
:!z
x 0 I SpringDetent
-
@G Guide
Spring
_
Spring Cover - ’ LZJ- -Guide Bolt
$2
I
a- &
I?
Cover Bolt ---&
-L-J 0
- Spring Cover
+V
- Plug _t;‘”
UJ- Cover Bolt
ti
TYPICAL HYDRAULIC VALVE
‘
@a---
@--
Acorn Nut
Washer
-Jam
Q%) Nut
Washer -a
Adjusting Screw - 8
:
Relief Valve Cap - ~9
B
& - O-ring Seal
- Poppet Spring
I
- Poppet Seat
0
& -O-ring Seal
Poppet Plunger -
L Mounting Bolt
Valve Body
- Plunger Seat
O-ring Seal -e
Relief Valve Plug
TYPICAL HYDRAULIC VALVE
SM 575, July 97
‘ Lift and Tilt Control Valve l 30-6-l 5
C5OOY2235 Group30
SECTION 7
COMMERCIAL INTERTECH
VALVE OVERHAUL
SM575 Copyrighted
SectionMaterial
Tile Page July 97
VA 20135
VG 20135
Directional Control Valves
SERVICE MANUAL
l7 Commercial
0 Intertech
Intended for CLARK dealers only Service Instructions HS - 27
Introduction General Information
This manual has been prepared to Commercial’s VA and VG model measured from the top of the port to
assist you in the proper maintenance valves are contemporary versions of the bottom of the housing. These are
of Commercial Intertech’s VA20/35 our well-proven A20/A35 units. The referred to as hi-boy sections. Those
and VG20/35 directional control VG models are cast from compacted without, are low profile or lo-boy
valves. To facilitate repairs, and graphite, a high strength iron alloy sections (see Figure 2).
before any work is done, we sug- which allows the valve to be rated at
gest that you read the assembly and 3500 psi. VA models are cast from Overhaul
disassembly instructions completely. grey iron and are rated at 2500 psi.
These directional control valves are Valves are often used in hazardous
Also remember that the first rule of open-center and designed in both enviroments therefore,care should be
good maintenance is cleanliness, parallel and series circuitry. They are taken to frequently inspect the prod-
including the work environment. of sectional or stack type construc- uct for damage due to improper use,
MAKE SURE YOU DISASSEMBLE tion which permits additional work corrosion or normal wear. Repairs
AND ASSEMBLE YOUR HYDRAULIC sections to be added to the valve should be made immediately if
EQUIPMENT IN A CLEAN AREA. Dirt bank. This design also makes needed.
is the natural enemy of any hydraulic possible the combination of sections Always refer to the machine’s
system. for parallel and series hydraulic. owner’s manual for the proper
circuits in a single bank. The internal
procedure to remove the valve
Genuine Parts coring of each valve section deter- from the machine.
mines its circuitry and the number of
The illustrations in this manual and
gasket seals it requires.
the instructions which refer to them, Remove the valve bank from the
All sections with optional features
apply only to Commercial Intertech equipment and disconnect all hoses,
such as port relief valves, crossover
assemblies, sub-assemblies and fittings, control handles and linkage
relief valves and anti-cavitation
components. All valve components connectors that might be attached to
checks are dimensionally larger as
except for spools and housings are the valve. Plug all ports and thor-
available as replacement parts or oughly clean the valve bank’s
sub-assemblies. Spools are hone- exterior, after which the port plugs
fitted to their individual housings. can be removed.
Therefore, damage to either of these
components means the entire ALL WORK MUST BE
section must be replaced.
PERFORMED IN A
We recommend that you use only CLEAN AREA.
original Commercial Intertech re-
placement parts in your service
program. Manufactured on the
same production lines to the same
exacting tolerances and quality
controls as the original equipment,
genuine Commercial Intertech
replacement parts are your best
hedge against premature compo-
nent failure and costly downtime.
Service parts and assemblies are
available through your original
equipment dealer or any authorized
Commercial Inter-tech distributor.
m Commercial
0 Intertech
0 1989 Commercial Intertech Corp. Copyrighted Material
Valve Bank
Figure 2
Disassembly C. Next mark the port boss closest
to the spool clevis on each work
Step I - section with a “C” (for clevis end).
Mark the Valve Bank
This step is the most critical step in D. Lastly, if relief valves must be
the disassembly procedure. It removed from the valve bank they
should be followed very closely to should be marked with the number
ensure that the valve bank is prop- of the casting and port to which they
erly reassembled after repairs have belong. Inlet and mid-inlet relief
been made. See figure 1. valves are marked with their casting
A. Take a waterproof, quick-drying

marker and mark each casting with a
sequential number. Start by marking
number only.
Step 2 - Tie Bolts

v 1 Milled Relief
Parallel Lo-Boy Section

Remove the four (4) tie bolts which
the inlet casting as #1 and finish by
hold the bank together and separate
marking the outlet with the highest
the sections.
number.
NOTE: VA valve fasteners thread into
the outlet casting. VG valve fasten-
B. Then mark the port boss closest
ers pass through the entire bank and
to the back cap on each work
have a hex nut and washer fastened
section with a “B” (for back cap
at both ends.
end).
Milled Relief
Figure 1
ud
4B Series Hi-Boy Section
Step 3 - Section
Seals
The inlet, mid-inlet and each parallel
work section have four (4) section
seals (Items 1 & 2, Figure 2) on the
downstream mating face. A series
work section has three (3) section
seals on its downstream mating face
(Items 1 & 3, Figure 2). These
section seals should be removed
and discarded.
Step 4 - Valve Back

Cap
Remove the two (2) cap screws
(Item 4) which fasten the back cap
to the work section and then remove
the back cap (Item 5)See Figure 4.
Step 5 - Control distort the spool. As the stripper CLEANlNG,INSPECTION
bolt threads disengage the spring
Spool and Seals (Item 15) and spring guides (Item AND REPAIR
Grasp the spring end of the spool with 16) will pop free of the spool. 1. Inspect the spool bores, check
a clean rag and pull the spool with a seats and spools for deep
twisting motion. Generally the rear re-
Step 8 - Detented scratches, gouges or excessive
tainer plate (Item 6) backup ring (Item wear. If any of these conditions exist,
7) and spool seal (Item 8) will come Spool replace the section. Minor surface
out with the spool. CAUTION: For damage on the control spool and
Again these parts should not be
detented spool models, be careful not check poppet may be carefully
removed from the spool unless they
to remove the detent poppet sleeve polished away with very fine crocus
need to be replaced. Wrap the -,-+cI
(Item 17, Figure 4) unless it is to be c;IlJLI I.
detent sleeve (Item 17) with a clean
serviced. Next remove the two retainer 2. Examine the machined surfaces of
rag. Grip the rag covered sleeve and
screws (Item 9) from the spool clevis the valve housing for nicks and burrs
pull firmly. As the sleeve moves
end of the work section. Then remove that could cause leakage between
backwards, the detent balls (Item
the two retainer plates (Item 6) the sections. Lightly stone these sur-
18) and the detent spring (Item 19)
backup ring (Item 7) and the spool faces to remove any rough spots.
will pop free. The rag should capture
seal (Item 8). The spool should now be CAUTION: A shallow milled relief
these parts and prevent their loss.
tagged or marked with its work sec- area (noted in Figure 2) extends
Next clamp the spool in a soft jawed
tion’s identification number (from Step across the 0 ring face of the valve
vise and remove the detent poppet
1). Spool seals (Item 8) and backup housing. It should not be stoned or
retainer (Item 20) use an undersized
rings (Item 7) should be discarded. ground off.
bar through the detent ball bore as a
3. Wash all parts thoroughly in a
wrench. Cautious application of heat
Step 6 - Transition may again be required because an
clean solvent and blow dry before
beginning reassembly. Pay special
Check anaerobic adhesive is also used in
attention to the number and letters
The transition check is located in the the retainer’s assembly.
marked on the parts in Step 1. If any
CAUTION;Too much heat may
bottom center of the work section marks are removed during cleaning,
distort the spool.
housing. Remove the check valve remark immediately.
cap (Item 10) and its 0 ring seal
(Item 11) then remove the check
spring (Item 12) and the check valve
poppet (Item 13). NOTE: Only
cylinder (ports blocked in neutral)
work sections have a transition
check.
Spool - Disassembly
Remember to use
Step 7 - Spring Only Genuine
Centered Spool
These parts should not be removed
from the spool unless they need to
Commercial
be replaced. Once the spool is free
of the work section housing, it must Service Parts.
be handled carefully to avoid
damage. Place the spool in a soft Call or write:
jawed vise and remove the stripper
bolt (Item 14) with a wrench. Cau- Commercial Intertech Corp.
tious application of heat may be 373 Meuse Argonne
required to free the stripper bolt
because an anaerobic thread
Hicksville OH 43526
adhesive is used in its assembly. Phone: (419) 542-6611
CAUTION; Too much heat may
FAX: (419) 542-887 1
Typical Valve Section
- Work Section
Figure 3
Figure 4
PARTS LIST
Item DescriMion Qtv. VAIVGPQ Part No. VANG35 Part No.
Parallel Section Seals* See figure 2
1. Square Seal 3 391-2881-206 391-2881-200
2. Square Seal 1 391-2881-200 391-2881-403
Series Section Seals See Figure 2
1. SquareSeal 2 391-2881-206 391-2881-200
3. Square Seal 1 391-2881-627 391-2881-628
Parallel and SeriesSectionComponent Parts. See Figure4

4. BackCapScrew 2 391-1433-020 391-1433-009
5. BackCap 1 341-6000-100 342-6000-100
6. RetainerPlate 3 391-2183-001 391-2183-005
7. Backup Ring 2 391-2681-378 391-2681-426
8. SpoolSeal 2 391-1985-014 391-2887-212
9. RetainerPlateScrew 2 391-1433-015 391-1433-002
10. CheckValveCap 1 391-0581-044 391-0581-044

Or Valve Cap (F.I.N.)1 391-2281-015 391-2281-015
11. **0 Ring Seal 1 391-2881-204 391-2881-204
12. **CheckSpring 1 391-3581-713 391-3581-713
13. **CheckValvePoppet 1 391-2481-069 391-2481-069
14. StripperBolt 1 391-1432-022 391-1432-021
15. CenteringSpring 1 391-3581-608 391-3581-633
16. SpringGuide 2 391-1642-045 391-1642-013
17. Detent Sleeve 1 391-3283-015 391-3283-008
18. DetentBall 2 391-0282-010 391-0282-009
19. Detent Spring 1 391-3581-130 391-3581-015
\ 20. Detent Poppet Retainer 1 391-2583-008 391-2583-006
*Parallel Sealing Face includes inlets and mid-inlets.

**Not required inFloat-in-neutral Sections. Copyrighted Material
Assembly Valve Bank Assembly
Reverse the procedures outlined in backup rings (Item 7) and new spool Return all relief valves to their proper
Steps 1 through 8. Also follow the seals (Item 8) in position as shown in positions (see Step 1). Coat the
additional instructions listed below: Figure 4. Carefully insert the spool section seals (Items 1 & 2 or Items 1
into the housing. Make sure that the & 3) with grease and place them in
Spool Assembly spool and housing are in the proper their grooves (Figure 2). Place the
orientation (see Step 1). Place valve sections on the tie bolts in their
Spring Centered LoctiteTM262or its equivalent on the proper sequence (see Step 1).
Clamp the control spool in a soft backcap screws (Item 4) and front Torque the tie bolts in a cross pattern
jawed vise. Apply a small amount of retainer screws (Item 9) threading to:
LoctiteTM262or equivalent anaerobic them into the valve housing. VA20 - 29 foot pounds
adhesive to the stripper bolt (Item VG20 - 42 foot pounds
14) before assembly. CAUTION: When installing the transition check VA35 - 34 foot pounds
Follow the adhesive manufac- refer to Step 6. Torque cap screws to VG35 - 75 foot pounds
turer’s instructions for proper 80 - 90 ft. Ibs.
cleaning and curing.Failure to
clean and prepare parts
properly may result in assem-
bly failure Assemble the spring
(Item 15) spring guides (Item 16)
and stripper bolt (Item 14) onto the
spool (Reverse of Step 7). Lightly
coat the spring assembly with high
temperature grease to prevent System Overload Relief Valve
rusting.
Detented
Clamp the control spool in a soft
jawed vise. Apply a small amount of
QQ
Loctitem262 or equivalent anaerobic 4 1
adhesive to the detent poppet
retainer (Item 20) and thread it into
the control spool. CAUTION:
Follow the adhesive manufac-
turer’s instruction for proper
cleaning and curing.Failure to
clean and prepare parts
properly may result in assem-
bly failure. Then lightly coat the Figure 5
detent balls (Item 18), detent spring
(Item 19) and detent sleeve (Item 17)
with high temperature grease. Next
place the detent balls and spring Item Description Qty VAlVG20 VA/VG35
into the detent poppet retainer as 1. 0 Ring 2 391-2881-332 391-2881-260
shown in Step 8 and partially com- 2. 0 Ring 1 391-2881-156 391-2881-137
press them with a small clamp. Now
3. Backup Ring 1 391-2681-163 391-2681-165
slide the detent sleeve into position,
4. Gasket Washer 1 391-1583-013 391-1583-012
pushing the clamp out of the way at
the same time.
Valve Section
The main relief valve protects the hydraulic system against overload pressures.
Assembly It is located in the inlet housing and it also can be found in mid-inlet sections
Apply a light coating of clean used in the valve bank. Figure 5 illustrates the arrangement of the parts and
hydraulic oil to the valve spool. Place serviceable seals. This is a cartridge type relief valve and is removed from the
the retaining plates (Item 6) new control valve as an assembly for replacement or service.
Service instructions
for VA / VG remote
Control Operators
Read these instructions

carefully. Failure to follow
these procedures can result
in poor performance and / or
Item 10 4-Pieces 391-2881-242 391-2881-242
product failure. Make sure all
work is done in a clean area.
Figure 8
Section Disassembly Preparation of Parts
1. Remove cap screws ( 8 ) from 4. Remove spool and spring pack- 1. Clean adhesive from threads of
both ends of the valve section. age assembly from valve section. spool, stripper bolt, housing, cap
Remove seal retainer ( 2 ) and seals screw holes and hex nut with Loc-
2. Remove end caps ( 6 ) , seal (10 ) ( 1 & 10 ) to replace seals. titem Chisel Gasket Remover.
and end cap tube ( 11 ) from each
end of casting. 5. If stripper bolt ( 3 ) must be 2. Wash all parts in solvent to
removed from the spool for replace- remove grease and oil. Blow dry.
3. Remove seal retainer ( 2 ) and ment of parts, it may be necessary to
seals ( 1 & 10 ) from the clevis end apply heat to the hex nut andstripper
of the spool assembly. bolt to loosen adhesive that was
applied to the threads.
Use heat carefully to avoid
warping spool.
Section Assembly
CAUTION Failure to follow
these recommended
assembly instructions can
result in poor performance
and / or failure of the product.
Product should be thoroughly
tested to ensure proper
operation before the valve is
put into service.
NOTE: If stripper bolt ( 3 ) was not 5. Torque the hex nut ( 9 ) to 175 in. 10. Spray threads of the capscrews
removed from spool, proceed to Ibs. ( ?I 25 in. Ibs. ) and set the spool ( 8 ) and the cap screw holes in the
step 6. assembly aside to cure for a mini- housing with LOCQUIC Primer
mum of 8-hours. After curing, test Grade NFTM and let dry.
1. Place spool in a soft-jawed vise, the hex nut to be sure it withstands
threaded end up. 125 in. Ibs. of breakaway torque. 11, Apply Loctite 262 RedTM to
t.hreads of the two cap screws ( 8 ).
2. Spray the threads of the new 6. Apply light grease to seals. Insert them through valve cap ( 6 )
stripper bolt ( 3 ) and hex nut ( 9 ) Assemble “0” ring ( 10 ) on OD of and screw them into the valve
with LOCQUIC Primer Grade NFTM seal retainer ( 2 ) and “0” ring ( 1 ) in housing. Tighten cap screws evenly
and let dry. Apply Loctite 262 RedTM the end of the seal retainer. and torque to 175 in. Ibs. ( + 17 in.
to threads. CAUTION: Seals are similar in size. Ibs.)
Be sure to insert seals 1 & 10 in their
3. Slide one of the spring retainers proper position. They are not 12.lnstall seal retainer ( 2 ) with seals
( 7 ) on to the end of the stripper bolt interchangable. on clevis end of spool. Install end
( 3 ) with the longest threads. Screw cap tube ( 11 ) and valve cap (6 )
the stripper bolt into the valve spool 7. Install one seal retainer with “0” as in figure 8.
as far as it will go. BE SURE THE rings on spool. Then slide the spool
SPRING GUIDE SLIDES FREELY. into the housing. 13. Install two cap screws ( 8 ),
tighten evenly and torque to 175 in.
4. Slide the springs ( 4 & 5 ) over 8. Lightly grease “0” ring ( 10 ) and Ibs. (+ 17 in. Ibs.) to complete
the stripper bolt. Install the other install it on the valve cap ( 6 ). assembly.
spring retainer and compress the
springs so that the hex nut ( 9 ) can 9. Install end cap tube ( 11 ) on seal
be screwed onto the stripper bolt. retainer ( 2 ) Then slip end cap ( 6 )
BE SURE THE SPRING RETAINER on the end cap tube ( 11 ).
SLIDES FREELY.
q CommercialIntertech
Hydraulic Valve Division
373 Meuse Argonne
Hicksville, OH 43526
Phone: (419) 542-6611
Copyrighted Material Fax: (419) 542-8871
TROUBLESHOOTING
TROUBLE PROBABLE CAUSE REMEDY
Pinched or blown section seal Replace seal
Oil leaks between sections Stud fasteners not correctly Replace seals and
torqued re-torque
Mounting plate not level Loosen mounting bolts

and shim as required
Over pressurized tank core Correct high back-pressure condition

Oil leaks at either end
of spool Worn or damaged spool seals Replace seals
Broken centering spring Replace
Spring - centered spools Misalignment of operating Check linkage for

do not return to neutral linkage mechanical binding
Foreign particles in system Clean valve & system
Cylinder leaking or worn Check cylinder - repair
Load will not hold Port relief valve not holding Remove & clean or replace
Spool or housing scored or

worn excessively Replace section
Dirt or foreign particles Disassemble, clean

lodged between check valve & reassemble
Load drops when spool poppet and seat
_
moved from neutral
Scored or sticking check Replace poppet
valve poppet
Worn pump Check flow & pressure
Defective cylinder or motor Repair or replace
Low reservoir oil level Add oil to specs
No motion, slow or Clogged suction strainer Clean or replace

erratic system
operation Suction line restricted Check lines
Relief valve not properly set Check pressure setting
Relief valve poppet or Replace relief

seat scored & sticking valve
Valve spool not shifted Check spool linkage

to full stroke travel
Service Instructions HS-27

5MCPI 1 l/92 Copyrighted Material
Printed in USA Intended for CLARK dealers only
C500 Y2235 Grow 30
SECTION 8
HYDRAULIC SYSTEM
PRESSURE CHECK

CUIRK Group 30, Hydraulic Components
Section 8
Hydraulic System Pressure Check
(Lift Circuit)
Contents
Piping Diagram and Tester Connection ........................................... 30-8-2
Checking pressure with Hydraulic Tester ....................................... 30-S-3
Checking pressure with Schroeder Hydraulic Tester ..................... .30-8-4
A WARNING
adequate.
SM 575, July 9
‘7 Copyrighted Material Hydraulic System Pressure Check l 30-8-l
Group 30, Hydraulic Components EIRRK
Lift Circuit Pressure Relief Setting
2750 psi [18,961 kPa]-Standard Trucks

3000 psi [20,685 kPa]-Marina Trucks
3150 psi [21,720 kPa]-Y350 Model
\ Notice
Main Hydraulic Pump connects to rear of transmis-
sion. Accessible beneath floor plate.
\ Pressure Gauge
HY draulic Reservoir 1
I
,/=
/
/7
/ Main
i Pump
/ Relief Valve Adjustor
/ (FactoryPreset) \
Lift Valve is located

beneath seat deck accessible
thmugh the
enginecompartment.
30-9-2 l Hydraulic System Pressure Check SM 575, June 9

‘7
C1RRK Group 30, Hydraulic Components
Typical lllustrtion
Checking Pressure l Read pressure gague as system operates over

relief.
The hydraulic relief valve setting may be checked
with a Mica Quadrigage (Clark Part No. 1800106) l Gauge should register between 2900 & 3000
or by installing a conventional pressure gauge PSI (20,000 & 20,700 kPa). If it does not,
having a scale of 0 to 4000 PSI (0 to 27576 kPa). report condition to designated authority.
l Remove plug from test port on the pressure The relief valve adjustor is an internal part of the
line at the lift pump. hydraulic valve and is accesssible by removing the
l Connect pressure gauge to this port. cap located opposite valve spool. Refer to illustra-
tion on opposite page. Do not exceed specified
l Start and operate engine at governed RPM. pressure setting. Changing pressure setting will not
l Fully extend mast. increase lifting capacity or speed beyond designed
limits of the hydraulic system.
SM 575, July 9
‘7 Copyrighted Material Hydraulic System Pressure Check l 30-8-3
Group 30, Hydraulic Components CMRK
1
Pressure Indicator
Inlet Port
Temperature Indicator
Operating Instructions
Load Valve
Orifice Selector
Outlet Port
Flow Indicator
System Pressure Check
using
Schroeder Hydraulic Tester #I 800060

Connect pressure line of the tester into the l Close the tester load valve until pressure no
hydraulic circuit as previously described on longer increases on the tester pressure indi-
page 3. cator. CLOSE LOAD VALVE ONLY
Insert tester return line into the hydraulic ENOUGH TO REACH PEAK RATE OF
reservoir. FLOW AND PRESSURE.
Move hydraulic control lever to maximum lift l The flow reading should compare with flow
and hold lever in this position. register at 1500 PSI.
Gradually close the tester load valve. If the pump or valve is worn, flow will drop
off appreciably as pressure is increased.
Read tester pressure indicator as the hydrau-
lic system operates over relief. The tester Severely vibrating gauges are often an indica-
should register specified relief setting listed tor of entrained air. Check for suction line
on the previous page. leaks.
Hold the hydraulic control lever in position l If readings taken are not reasonable close.
until the temperature indicator registers 120 appropriate repairs should be made. Report
degrees. condition to designated authority.
When the hydraulic fluid reaches 120 de-

grees, note and record reading on tester. Com-
pare this reading with the one you will obtain
in the next step.
30-8-4 l Hydraulic System Pressure Check Copyrighted Material SM 575, July 97

‘
C5OOY2235 Group 30
SECTION 9
HYDRAULIC DIAGRAMS
Copyrighted
SectionMaterial
Title Page July 97
GROUP 32
C500 Y 18092009225S-225L-2505-25OL-3OOS-3OOL-350
GROUP 32-TILT CYLINDERS
Tilt Cylinders-Remove and Replace ............................. Section 1
Tilt Cylinder Service Procedures (thru Lot 7045) ....... Section 2
Tilt Cylinder Service Procedures (Lot 7055 and above)Section 3
Tilt Cylinder Drift Test ................................................... Section 4
Tilt Cylinder Adjustment ............................................... Section 5
SM 575, July 9
‘7 Copyrighted Material Tilt Cylinders
C500 Y2235 Group 32
SECTION I
TILT CYLINDERS
REMOVEAND REPLACE
SM575 Copyrighted
SectionMaterial
Title Page July 97
Group 32, Tilt Cylinders
Section 1
TiltCylinderRemove& Replace
Contents
lLaD-mnu Modans
Preparation (TAt Cylinder Lines) ....................................................... 32-l-2
Removal & Installation ...................................................................... 32-l-5
Hi-lr%lluModells
Preparation (Tilt Cylinder Lines) ....................................................... 32-l-6
Removal & Installation ...................................................................... 32-l-8
SM 575, July 9
‘7 Copyrighted Material Tilt Cylinder-Remove and Replace l 32-l-i
Lo,-uiot k&Ml@!o~
Tilt Cylinder Removal Preparation
Step 1
* Move truck to a flat level surface.
l Using the lift/lower lever, move upright to the
vertical position and completely lower carriage
allowing the lift cylinders to retract.
l Using forward tilt, position forks flat on ground
to remove as much load as possible from the tilt
cylinder mounting pins..
l Apply parking brake, shut engine down and Hoist Capacity [Min.
remove ingnition key from switch. IO Ton (9074 kg)
l Move both lift and tilt levers into each position
for a few moments. This is to releave trapped
pressure in the hydraulic lines without the en-
gine running.
AWARNING
Never remove both cylinders
at one time. One tilt cylinder
should be attached to the
upright at all times.
l If available, use a catch truck of the same capac-

ity or a suitable hoist of at least 10 ton (9074kg)
capacity to support the upright.
l Attach a chain hoist around the upper rail, see Step 3
opposite illustration. Apply tension to hoist. l Loosen and remove hose connections from the
elbows located at the anchor end of the cylinder
Disconnect Tilt Lines to be removed. Refer to items (1 & 2) on
opposite page. Cap the elbow fittings and plug
Step2
the hydraulic lines.
A WARNING l Loosen and remove connections securing hy-
Hydraulicfluid Is toxic to skin,
draulic tube to tilt cylinder. Refer to item 3.
Avoid skin and eye contact. Remove tube from cylinder. Cap the tube fit-
Good ventilation is normally tings and both elbows.
adequate. l Remove the tilt lock (counter balance) valve
l Tag all hydraulic lines as to theirproperlocation. from the cylinder. Plug the ports.
l Have available, clean rags and a suitable con- Installation

tainer to catch any spilled hydraulic fluid.
Installation is the opposite of removal. Be
l Have available protective caps and plugs that certain parts are clean and fittings tightened securely.
may be installed in the lines and components
when disconnected.
32-l-2 * Tilt Cylinder-Remove and Replace Copyrighted Material SM 575, July 9

‘7
CUIRK
cylinder.
@It-----_
A~ARNING
should beattached to the mast
at all times.
L.H. Tilt Cylinder
Cylinde
Typical illustration
SM 575, July 9
‘7 Copyrighted Material Tilt Cylinder-Remove and Replace l 32-l-3
CLINDER
TUBE -
R.H.
TILT
: CYLINDER
; ASSEMBLY
TO
LEFT HAND
FROM
SIDE PORT
L. .-. .., _ ,... , CYLINDER
.
PLUG
TILT CYLINDER
LO-TILT MODELS ONLY

32-i-4 9 Tilt Cylinder-Remove and Replace Copyrighted Material SM 575, July 9

‘7
Tilt Cylinder Removal Typical Illustration
Rod End
l Remove snap rings mounting pin.
l Tap pin f&e of cylinder yoke and mast with a
bronze drift and mallet.
Anchor End
l Remove capscrews and lockwashers releasing
keeper plate from cylinder flange and mounting
pin.
l Tap pin free of truck anchor and cylinder
mounting flanges.
r Bushing
Torque to: 86 to 97 Ib.ft. (117 to 131 N:m)
- Torque to: 35 to 40 Ib.ft. (47 to 64 N:m)
Rer to Section 5 for Rod Adjustment
Cleaning and Inspection Tilt Cylinder Installation

Clean parts with a Stoddard type cleaning fluid and l Install wrench on rod flats and screw rod end
allow to air dry. onto piston rod (1). The rod should be threaded
into the rod end (minimum requirement) and
Examine all mating parts for smooth surfaces. Check-
amount equal to the diameter of the piston rod
ing keeper plates, yoke keys and grease fittings for
(ref. see arrows item A). Install bolt (2), key (3),
damage. Discard parts having nicks, burrs, scoring or
nut & washer (4).
unserviceable rough spots. Replace damaged plates,
keys and fittings. l Install bushings into mast and truck flanges.
Align cylinder anchor and rod ends and install
Examine bushings for further serviceability. Discard
mounting pins, snap rings and keeper plates.
any that are questionable.
Lubricate grease fittings.
SM 575, July 97
‘ Copyrighted Material Tilt Cylinder-Remove and Replace l 32-l-5
EmK Group 32, Tilt Cylinders
32-l-6 . Tilt Cylinder-Remove and Replace Copyrighted Material SM 575, July 9

‘7
Hi-Tilt Models Typical Illustration
Tilt Cylinder Removal Preparation

Step 1
l Move truck to a flat level surface.
l Using the lift/lower lever, move upright to the Always use
vertical position and completely lower carriage. Safety Hooks
l Using forward tilt, position forks flat on ground
to remove as much load as possible from the tilt
cylinder mounting pins..
l Apply parking brake, shut engine down and
remove ingnition key from switch. Hoist Capacity [Min.] -‘m
l Move both lift and tilt levers into each position 10 Ton (9074 kg)
for a few moments. This is to releave trapped
pressure in the hydraulic lines without the en-
gine running.
AWARNING
l If available, use a catch truck of the same

capacity or a suitable hoist of at least 10 ton
(9074 kg) capacity to support the upright.
l Attach a chain hoist around the upper rail, see Step 3
opposite illustration. Apply tension to hoist.
l Loosen and remove hose connections from the
Disconnect Tilt Lines tee located at the anchor end of the cylinder to
Step 2 be removed. Refer to items 4, 6 & 7 (L.H.
Cylinder, or items 21,22 & 23 (R.H. Cylinder).
AWARNING Cap the tee fitting and plug the hydraulic hose.
eyes, and respiratory tract. l Loosen and remove connections securing hose
Avoid skin and eye contact. to tilt lock valve (mounted at rod end of cylin-
Good ventilation is normally der). Refer to item 7 (L.H. Cylinder) or item 23
adequate. (R.H. Cylinder). Remove hose from truck. Cap
the tee fitting and plug the tilt lock valve ports.
l Tag all hydraulic lines as to their proper loca-
tion. l Remove the tilt lock (counter balance) valve
from the cylinder. Plug the ports.
l Have available, clean rags and a suitable con-
tainer to catch any spilled hydraulic fluid. Installation
l Have available protective caps and plugs that Installation is the opposite of removal. Re-
may be installed in the lines and components placealldamagedparts. Becertainpartsareclean and
when disconnected. fittings tightened securely.
SM 575, July 9
‘7 Copyrighted Material Tilt Cylinder-Remove and Replace l 32-l-7
a WARNING
175 to 190 IbIt.
O.H.G. Mounting Flange 7
“JWIvrl, I ..I I.
Torque to: 3:
Refer to Section 5 for Cylinder Rod Adjustment
TvDid Illustration
Tilt Cylinder Removal Cleaning and Inspection

CleanpartswithaStoddardtypecleaningsolventand
AWARNING allow to air dry.
Hydraulic fluid is toxic to skin, Examine all mating parts for smooth surfaces. Check
eyes, and respiratory tract. keeper plates, yoke keys and grease fittings for dam.
Avoid skin and eye contact. Replace any that are damaged. Check bushings for
Good ventilation is normally further serviceability. Discard parts having nicks,
adequate. burrs, scoring or unserviceable rough spots. Replace
Anchor End damaged plates, keys and fittings.
l Remove capscrews and lo&washers releasing Tilt Cylinder Installation

keeper plate from cylinder flange and mounting
. Install a wrench on the flats of the piston rod and
pin.
screw rod end onto rod an amount equal to the
l Tap pin free of mounting flange and anchor end diameter of the piston rod. Refer to insert A
of cylinder. shown on page 4. Install bolt, nut and key to the
Rod End rod end.
l Remove cotterpins and tap mounting pin free l
Install bushings into mast and truck flanges.
Align cylinder anchor and rod ends with the
of the cylinder rod end and the mast mounting
flanges and install mounting pins.
flange. Remove cylinder from truck.
. Install cotter pins at the rod end, and install the
l Remove bushings from rod end and mounting
keeper plate, lo&washer and bolts at the anchor
flange on the overhead guard.
end. Lubricate grease fittings.
32-i-9 . Tilt Cylinder-Remove and Replace Copyrighted Material SM 575, July 9

‘7
C500 Y2235 Group 32
SECTION 2
TILT CYLINDER SERVICE PROCEDURES
SM575 Copyrighted
SectionMaterial
Tile Page July 97
Section 2
Tilt Cylinder Service Procedures
Contents
Disassembly ................................. ...................... .... ................ ........... 32-2-l
Inspection ..................................... ........................ .................. ........... 32-2-6
Reassembly .f..................................................................................... 32-2-7
Special Tool ... .............................. .......................................... .. ......... 32-2-8
Cut-A-Way
SM 575, July 9
‘7 Copyrighted Material Tilt Cylinder-Sewice Procedures l 32-2-l
rr
Wear Ring - -O-Ring Seal
Back-Up Ring
Retainer (Shear Ring)

r Spacer
#$-Snap Ring
L Piston Rod
b Gland Ass ;embly
L Housing Assembly
-Back-Up Ring
r
O-Ring Seal- Retainer (Shear Ring)
External Retainer Ring
Typical lllustrtion
32-2-2 l Tilt Cylinder-Service Procedures Copyrighted Material SM 575, July 9

‘7
Group 32, Tilt Cylinders ElfMu
TILT CYLINDER OVERHAUL

Thisprocedure covers truck serial numbers:
Y2235-l-7045 thru Y2235-9999-7045 only
Y2235HT-l-7045 thru Y2235ElT-9999-7045 only
Disassembly
l Thomghly wash outside of tilt cylinder with a
brush using a Stoddard type cleaning solvent.
Wipe cylinder dry with a clean rag.
~ >ng
l Fully retract cylinder. Push piston rod as far as it

will go into the cylinder housing. & f--- Spacer
l Remove external snap ring from housing.
l Remove tube end spacer from cylinder head.
I
Piston I
Rod
I
*
I
v I
=zCzzE I
I
I
I
% i
- Housing Typical Illustration
SM 575, July 9
‘7 Copyrighted Material Tilt Cylinder-Service Procedures l 32-2-3
l Carefully drive the cylinder head downward

Move Gand Assembly
until the front edge of the piston head is just Downward
below the retainer ring. below Shear Ring
Typical Illustration ~_
Gently Drive
* Drive retainerringapproximately 180”opposite Retainer Ring
Downward
the ring grove using a screwdriver and the heel
of your hand.
A CAUTION
Be very careful that you do not
scratch or damage the inside
diameter of the housing wail.

‘7
Hi-Tilt Models
Cylinder Housing
l Removeretainerbypryingitoutofthe housing
using a screwdriver.
Lo-Tilt Models
l Remove retainer with a pair of snap ring pliers.
A CAUTION
Upon removing shear ring, be
very careful that you do not
scratch or damage the inside
diameter of the housing wall.
Housing
” j
l Now, pull the piston rod with cylinder head and Pull ,Au.stfmbly
piston out of the cylinder housing.
CylinderHousing
l Wash all parts in a Stoddard type cleaning -Piston Rod
solvent and place on a clean work bench.
7’ t Gland Assembly I 5
Housing
SM 575, July 97 Copyrighted Material Tilt Cylinder-Service Procedures l 32-2-5

Group 32, TiltCylinders
Gland Assembly Back-Up Ring

seal
seal- 1 r r r Barrel (Housing) Assembly
(~~;r,~\++JJ.@..
Sack-Up Ring -,
Reference: 32-045 LowTiltModels Typical Illustration
Cleaning & Inspection l Clean all metal parts with Stoddard type solvent
and blow dry with shop air.
l With the piston and rod removed, check the
cylinder barrel for scratches, cuts or nicks.
l Check the piston for scratches, cuts or nicks.
NOTE
The piston and rod are separate
items. Make sure that the piston
nut is securely in place. If thenut is
removed, be sure to install a new Air Hose Typical Illustration
O-ring and a new nut.
l If you have to replace the piston, use extreme AWARNING

caution when removing the piston nut. Do not Wear eye protection and
damage the piston rod threads. protective clothing when
cleaning or drying with air
l Discard all O-rings, back-up rings, seals and pressure. Reduce air pressure
snap rings. Install new parts.
32-2-6 . Tilt Cylinder-Service Procedures Copyrighted Material SM 575, July 97

‘
Barrel (Housing) Assembly
Reference: 32-038 Hi-Tilt Models Twical Illustration
Reassembly
to 30 PSI (207 kPa). Debris
removed with air pressure can . If the piston rod and piston are okay, install the
cause injury. rod assembly, using new seals, into the cylinder
barrel.
l Examine all mating and nested parts for smooth
surfaces. Discard and replace ah parts having l
Assembly is generally theopposite of disassem-
nicks, burrs, scoring or unserviceable rough bly. Be sure to install new seals, back-up
spots. Use a crocus cloth to clean up polished rings,wear rings, retainer rings, snap rings and
surfaces of piston rod.Becareful you do not wear the rod wiper.
off chrome plating when polishing. . Lubricate all parts with hydraulic fluid prior to
installing them.
A CAUTION . After assembly is complete, f!illthe cylinder with
Do not use emery cloth or clean hydraulic fluid and plug the barrel ports to
sandpaper to polish surfaces. prevent contamination. Install the tilt cylinders
To do so will damage into the truck.
components.
SM 575, July 97 Copyrighted Material Tilt Cylinder-Senrice Procedures l 32-2-7

ClflRK Group 32, Tilt Cylinders
Seal Installation Tool

Clark Part Numbers 1801783 and 1801784
Figure 1:
l Open tool as shown.
l Place seal between pins. Figure 2:
l Rotate handles together, keeping
Figure 3:
l Placesealintocylindergroov
and release handles.
l Pull tool free fi-om seal.
l Press seal into groove usin;
your fingers. Do not use 1
rypical Illustration
32-2-9 l Tilt Cylinder-Service PrOCedureS Copyrighted Material SM 575, July 9

‘7
C500 Y2235 Group 32
SECTION 3
TILT CYLINDER SERVICE PROCEDURES
SM575 Copyrighted
SectionMaterial
Title Page July 97
. Do not sell or distribute
Section 3
Tilt Cylinder Service Procedures
Contents
Disassembly ................................. .. ...... ........ .. ........................ .. ......... 32-3-3
Inspection ..................................... ........ .......... ........................ .. ......... 32-3-5
Reassembly ................................... ............ .......... .............................. 32-3-6
Special Tool ............................. .................................... ..................... 32-3-8
JLo-TiJlu amid Hi-mu Modens

Effective Serial Numbers
Y2235-l-7055 and above
Y2235HT-l-7055 and above
Cut-A-Way
SM 575, July 97 Copyrighted Material Tilt Cylinder-Service Procedures l 32-3-l

ElIIRK Group 32, Tilt Cylinders
Install Energizer and Glyd Ring@

Piston Rod
Piston
7 I
Install Piston Glyd Ring@

. Inspectsurfacesofthepistonandpistonrodtobe
r- Piston Glyd Ring@Seal Used
‘ some models
sure they are clean, smooth and free of damage.

. Lubricate the piston with hydraulic fluid.
. If removed, install piston onto rod.
. Install new O-Ring over rod and into piston.
. Install nut and tighten finger tight.
. Place piston rod into a vise equipped with soft
jaws that will not damage the chrome surface of
the rod.
. Tighten piston rod nut.
. Lubricate and install the square energizer ring
If used, lubricate spacer O-rings with hydraulic
into the grove in the piston. Refer to illustration
fhlid.
above.
. If used., install one O-ring into each groove
Lubricate and install the Glyd Ring@ into the
located on the inside diameter of the spacer.
groove over the energizer.
. Lubricate piston rod with hydraulic fluid
Remove piston rod from vice and lubricate with
hydraulic fluid Check to be surface of rod was Now, using a plastic parts bag or similar mate-
not damaged. A crocus cloth should be used to rial, over the threaded end of the piston rod and
clean up a marred surface. Wipe surface clean carefully slide the spacer (with o-rings) onto the
and lubricate with hydraulic fluid. rod.

‘7
Assemble Cylinder Gland

Seals and energizer rings must be bundled carefully.
Cutting, scratching or nicking these components im-
pairs their ejjkiency. Position Step Seal
l Lubricate gland assembly with hydraulic fluid. (within Energizer)
in Groove shown
l Prior to installation, insect seal to be swe the
sealing step is free of damage.
l Lubricate the squareenergizerringwith hydrau-
lic fluid.
Step 1 Locate energizer ring in gland glove.
Groove
Refer to opposite illustration.
Step 2 Fold Step Seal as shown in opposite column.
The use of tool shown (ref. A,B,C) in illustra-
tion is recommended for seal installation.
Step 3 Next, Lubricate and position the seal with-
in the energizer. The “Seal Step” nustface
towardthe ‘@ressureside” of the gland. Check Locate Energizer in Groove
to be certain the “step”is facing in the right
direction. You can do this by feeling the seal
with your finger. Refer to Cut-A-Way in
circle - opposite column.
NOTE lace
‘ Seal between pins. Rotate handles together
Ifthe sealwasinstall~inco~~~tly,
it may be removed and reinstalled
at this point.
Now, press the kidney shaped area into the

groove with your fingers. Do not use a sharp
tool.
A CAUTION
0 C
Locate seal in
If you press the seal into the lease handles.

groove and then discover the
seal is installed incorrectly,
remove and discard seal. Once
a seal has been pressed into
position and then removed it
must be discarded or leakage
Press seal in grove
will result.
Seal Installation Tool using your fingers.
Clark Part Numbers
1801783
1801784 Typical Illustration
SM !575,July ‘97 Copyrighted Material Tilt Cylinder-ServiceProcedures l 32-3-7

Assemble Housing
. Lubricate piston rod, piston and seal with hy- Retainer
- (Shear)
draulic fluid. Ring
. Lubricate cylinder housing wall with hydraulic
fluid
. Carefully slide piston and rod all the way into
cylinder housing.
A CAUTION
Be careful you do not cut or
damage seals upon assembl-
ing cylinder. Cylinder leakage
will occur if this happens.
. Wrap the threaded end of the piston rod with a
plastic parts bag or similar material.
. Now, carefully install gland assembly over pis-
ton rod and into housing.
. Push gland below the “retainer (shear) ring” 1 Install Gland Assembly
groove located in the wall of the housing.
2 Install Retainer (Shear) Ring
. Lubricate and locate the retainer (shear) ring in
housing groove. Remove the bag. 3 FQll piston Rod and gland
upwardseatingringingroove.
. Pull upward on the piston rod, brining the gland
asssembly in contact with the shear ring seating
it in the housing groove.
. Typical Illustration
Install retainer ring into gland groove securing 4 InstallRetainer
the gland assembly to the cylinder housing.
. After assembly is complete, fill the tilt cylinder
with clean hydraulic fluid and plug the barrel
(housing) ports to prevent contamination until
the cylinder is installed in the truck. i
T I
I

‘7
C500 Y2235 Group 32
SECTION 4 .
TILT CYLINDER DRIFT TEST
SM575 Copyrighted
SectionMaterial
Tile Page July 97
Group 32, Tilt Cylinders EmI6
Section 4
Tilt Cylinder Drift Test
Effective Serial Number%

SM 575, July 9
‘7 Copyrighted Material Tilt CylinderDrift Test l 32-4-l
Tilt Cylinder Drift Test

Test
0 Elevate Load
. . Make a capacity test load. Refer to the data
plate on you truck for maximum truck ca- 10 to 154uches
Check for Drift
pacity.
NOTE
Be certain the load is evenly
distributed on the forks. If the in Ful BackTilt.
load is a stacked load, it must
be stacked to provide
maximum stability.
Pick Uu Test Load

Adjust forks as wide as possible to provide
even distribution of weight.
Inch forward until the forks completely
engage the load.
Elevate carriage and load approximately 10
to 15 inches.
Tilt upright to the full back tilt position.
Shut engine down.
Apply parking brake.
Cvlinder Drift Smcificationq lElevate Load
The tilt cylinders should not drift more than l/2 10 to 15Inches
to 3/4 of an inch (12.7 to 19 mm) in a five (5)
minute period.
To Measure Cvlinder Drift_
. Measure the distance between the cylinder in Ful BackTilt.
gland and the back of the rod end. Record
Check for Drift
this measurement.
. After five minutes has elapsed, measure the
distance between the tilt cylinder and the
rod end If measurement exceeds the above
limits, report condition to designated au-
thOrity.
3242 l Tilt CylinderDrift Test Copyrighted Material SM 575, July 9

‘7
C500 Y2235 Group 32
SECTION 5
TILT CYLINDER ADJUSTMENT
Copyrighted
SectionMaterial
Tile Page
Group 32, Tilt Cylinders CMRK
Section 5
Tilt Cylinder Adjustment
J%fectiveSerial Numberq
SM 575, July 9
‘7 Copyrighted Material Tilt Cylinder Adjustment . 32-5-l
Tilt Cylinder Adjustment

1
Rod Admment
Park truck on a flat level surface.
Position upright in the vertical position.
Completely lower carriage placing forks
flat on the ground. A
Apply parking brake. Nut WARNING
Shut engine down. Do Not
Disconnect
Remove key from ignition switch.
Cylinder(s).
AWARNING
Do not disconnect cylinder
from upright or truck.
Remove Kev. Bolt & Nut
l Loosen lock nut.

l Remove bolt and nut. NOTE
l Remove key from rod end. Check for no tilt racking
(unequal adjustment) at full
Adiust Cvlinder forward and back tilt.
. Install a wrench on thepiston rodjkts.
. Turntherodafullturnatatimeintotherod rhread engagement same distance
end. The piston rod should be threaded into H rod diameter.
the rod end an amount eaual to the diameter
of the niston rod 6ninimum reouirement).
1Width
ie., Measure diameter of piston rod. If rod
diameteris2-inches (or50mm), threadrod
into the rod end the same distance as the
diameter.
After obtaining correct adjustment, install
the key, bolt and nut.
Torque the CLAMP BOLT to specifica-
tions.
Hi-Tilt Models: 175 to 190 lb.ft.
(237 - 258 N.m)
Lo-Tilt Models: 86 - 97 lb.ft.
(117 - 131 N.m.)
32-5-2 9 Tilt CylinderAdjustment Copyrighted Material SM 575, July 9

‘7
GROUP 33
C500 Y 1809200~225S-225L-250s~25OL-3OOS-3OOL-350
GROUP 33-HYDRAULIC VALVES
Hydraulic Relief Valve .................................................... Section 1
Hydraulic Tilt Lock Valve(s) .......................................... Section 2
SM 575, July 9
‘7 Copyrighted Material Hydraulic Valves
C5OOY2235 Group 33
SECTION 1
HYDRAULIC RELIEF VALVE

Material Handling
El!!lRH
_-__-_ Company Group 33, Hydraulic Valves
Section 1
Hydraulic Relief Valve
Contents
33-l-3
ExplodedView ................................................................................
Cleaning& Inspection...................................................................... 33-l-2
Disassembly& Reassembly............................................................33-l-3
Relief Valve (Marina)
Main Valve -to- Lift Cylinder

Hydraulic tines NOTE
The relief valve shown here was used Only
on a few early model Marinatrucks and a few
standard trucks with the “No Drift” optlon.
SM 575, June 9‘ 7 Hydraulic Relief Valve . 33-l-l

Group 33, Hydraulic Valves
CLEANING & INSPECTION
0 Remove all Jewelry before handling parts.
Cleaning
0 Thoroughly wash parts in a Stoddard type

cleaning solvent. Be certain parts are clean
and free of any debris. Wipe parts dry with
a clean lint free cloth.
0 Air dry parts;
A WARNING
WHENUSINGAIRPRESSURE
----------
r,,,, eye protection and1
1 protective clothing when 1
1 drying with air pressure. 1
1 Reduce air pressure to 30 PSI 1
I (207 kPa). Debris removed I
I with air pressure can cause I
I injury. -------- 1
Inspection
0 Checkallpartsfordamage.Inspectthreaded
areas for scratches or nicks which could
leak. Use proper light source to check in
side body cavity for scratches, nicks etc.
Check body for distortion or damage. Re-
place defective parts.
LZ.4
0 Lubricate all parts with clean hydraulic
MS-68
fluid prior to assembly.
33-l-2 l Hydraulic Relief Valve Copyrighted Material SM 575, July 97

‘
Group 33, HydraulicValves
AWARNING
Hydraulic fluid is toxictoskin,
normally adequate.
Sesing
Pipe Plug _
Relief Valve Disassembly Reassembly

l Remove and discard preformed packing. Lubricate all parts with clean hydraulic fluid prior
to assembly.
l Remove sensing valve.
l Install new valve kit(s).
* Remove Relief Valve.
l If removed, install new plugs.
0 Avoid disassembly of the body plugs unless
visible leakage or malfunction makes removal l Install lubricate new preformed packing and
necessary. If damaged, remove pipe plugs install packing in body.
from body.
l Install protective plugs into valve ports until
l Clean and inspect valve per instructions on such time as the valve is installed in the truck.
the previous page.
SM 575, July 97
‘
Copyrighted Material Hydraulic Relief Valve l 33-l-3
C5OOY2235 Group 33
SECTION 2
HYDRAULIC TILT LOCK VALVE(S)

GROUP 34
C500 Y 18092009225S-225L-25OS-25OL-3OOS-3OOL-350
GROUP 34=UPRIGHT, CARRIAGE AND FORKS
Fork Removal and Inspection ....................................... Section 2
SM 575, July 9
‘7 Copyrighted Material Upright, Carriage and Forks
C500 Y2235 Group 34
SECTION I
UPRIGHT TROUBLESHOOTING
SM575 Copyrighted
SectionMaterial
Title Page July 97

required.
No lift, tilt or auxiliary 2. Hose broken. _ 2. Replace hose.
function. I- 3. Hydraulic pump defective. 3. Repair or replace hydraulic
pump.
4. Defective main lift valve. 4. Replace main lift valve.

required.
Load cannot be lifted to
2. Hydraulic pump defective. 2. Repair or replace hydraulic
maximum height. t- pump.
3. Upright rails binding. 3. Make upright adjustments.
Oil leak at top of lift

cylinder.
SM575 Copyrighted
34-lMaterial
-1 July 97
C500 Y2235 Group 34
SECTION 2
FORK REMOVAL AND INSPECTION
Copyrighted Tiile Page July 97
ClRRK Group 34, Upright-Carriage-Forks
FORK REMOVAL AND INSPECTION
Fork Removal
1. Lower forks to floor and tilt upright forward to take

load off fork pins.
2. Place load on forks to prevent them from tipping

over during removal.
FS>RK
Carpenter Square
2. Inspect the forks for twists and bends. Put a 2”

thick metal block, at least 4” wide by 24” long on the
RETAINER PLATE’ blade of the fork as shown with the 4” surface against
the blade. Put a24”carpenterssquareon the topof the
3. Remove fork retainer pins.
block and against the shank. Check the fork 20” above
the blade to make sure it is not bent more that 1 inch
4. Remove bolts and washers and remove retainer
maximum. If the fork blade are obviously bent or
plate.
damaged, have them inspected by a person trained in
fork inspection before putting the truck in service.
5. Pull fork bar out of carriage. Use lifting device or
sufficient personnel to remove. Fork bar weighs ap-
proximately 130 Ibs [59 kg].
6. Use sling and hoist to move forks. A single

A WARNING
The serviceability of the forks is of
standard 46 inch fork weighs approximately 500 Ibs critical importance to the safe opera-
1227 kg]. tion of the truck. If any doubt exists as
to serviceability, consult your Clark
dealer.
Fork inspection
1. Inspect the forks for cracks, breaks, bending and

wear. The fork top surfaces should be level and even
with each other. The height difference between both
fork tips should be no more that 3% of the fork length.
A WARNING
If the fork blade at the heel is worn
down by more than 10 per cent, the
load capacity is reduced and the fork
must be replaced.
SM 575, July 97
‘ Copyrighted Material Fork Removal and Inspection l 34-2-l
GROUP 37
C500 Y 180-2009225s~225L-25OS-25OL-3OOS-3OOL-350
GROUP 37XOUNTERWEIGHT
Counterweight Removal and Installation . .. .. .. . . .. .. . .. .. .. . Section 1
SM 575, July 9
‘7 Copyrighted Material Counterweight
C500 Y2235 Group 37
SECTION 1
COUNTERWEIGHT REMOVAL
AND INSTALLATION
SM575 Copyrighted
Section Material
Title Page July 97
ClRRK Group 37, Counterweights
COUNTERWEIGHT REMOVAL AND INSTALLATION
1. Unbolt and remove counterweight grill plate.
2. Remove counterweight bolt, washers and nut and

install eye bolts as shown.
COUNTERWEIGHT BOLT
Counterweight Bolt
The counterweight bolt is made of special, high tensile
strength steel. It is not commercially available. If
necessary, replace only with a genuine Clark replace- A WARNING
Counterweights used on this model
menf’part. Never substitute with a bolt made of lower
strength steel. Torque bolt to 900 - 1000 lb-f-t11200 - series weigh as little as 4,680 Ibs [2123
1360 Nom]. kg]onthelightestshortwheebasetruck
A
to as much as 15,240 Ibs [6913 kg] on
WARNING the long wheelbase Marina truck. Be
Never allow a truck to be put in service sure your lifting equipment is of ad-
without thecounterweight bolt in place. equate capacity.
If in doubt, check. Check torque regu-
larly.
Counterweight Removal
SM 575, July 97
‘ Countenveight Removal and Installation
Copyrighted Material l 37-l -1
Group 37, Counterweights EUIRK
Auxiliary Countetweight
3. Rig chain as shown and lift counterweight from

truck. Lay counterweight on floor with the inside
surface towards the floor.
1. The auxiliary counterweight, when used, sets in a
A WARNING
Never leave an unsupported counter-
pocket in the truck frame. It has no fastening and is
held in place by the main counterweight. It can only be
removed after the main counterweight has been re-
weight standing vertical. Some will moved. Install an eye bolts as shown, to remove the
stand in this position but they are not auxiliary counterweight.
stable. The counterweight could tip
over, causing injury to personnel. 2. Reinstall counterweight in reverse order. Torque
counterweight bolt to 900 - 1000 ft-lb [ 1200 - 1360 Nom]
37-l-2 l Counterweight Removal and Installation

‘
GROUP 38
C500 Y 18092009225S-225L-25OS-25OL-3OOS-3OOL-350
GROUP 39-DECAL REPLACEMENT AND PLACEMENT
Decal Replacement and Placement ............................... Section 1
SM 575, July 9
‘7 Copyrighted Material Decal Replacement and Placement
C500 Y2235 Grow 39
SECTION 1
DECAL REPLACEMENT
AND PLACEMENT
SM575 Copyrighted
SectionMaterial
Title Page July 97
CUIRK Group 39, Decal Replacement and Placement
DECAL REPLACEMENT AND PLACEMENT
PINCH POINT DECAL
CAUTION FORKS
NOTE
The plate and decal location shown on this
page was effective with trucks built prior to
lot 8518. For decal location on trucks built
with lot 8518 and higher, see page 2.
i :
TRANSMISSION OIL i i,,
REQUIREMENTS /“i :
SIDE VIEW
. FUEL REQUIREMENTS
/
DIRECTIONAL CONTROL CONVERTOR OIL
\ SHIFT CONTROL PR?SSURE
AUX VALVE
ATE
PATENT
OSHA requires the nameplate and safety information plates and decals be maintained in legible condition.
Consult your CLARK dealer for replacement nameplates or decals, if required, and place as shown above.
SM 575, July 97
‘ Copyrighted Material Decal Replacement and Placement l 39-l-l
Group 39, Decal Replacement and Placement ClflRK
INSIDE RIGHT
GUARD LEG
Transmission Fluid Decal
k
‘ c?\ “Made in USA” Label
INSTRUMENT PANEL Manual Location De

Patent Decal
NOTE
The plate and decal location shown on this
page was effective with trucks built with lot
8518.
SEAT SUPPORT-TOP VIEW
Model, Lot & Item number
39-l-2 l Decal Replacement and Placement Copyrighted Material SM 575, July 97

‘
GROUP40
C500Y180-200-225S-225L-250S-250L-3OOS-3OOL-350
GROUP40-SPECIFICATIONS
General Specifications ... .. .. ..................................... ........ Section 1
PM Inspection and Drivers Daily Inspection Forms ... Section 2
SM 575, July 9
‘7 Copyrighted Material Specification
Group 40, Specifications
Section 1
Specifications
Contents
Specifications (General - All Models) ...................................... 00-1-l thru 3
Specifications (Ford Models) ................................................... oo-1-4thru7
Specifications (Cumins Engine) .................................................... 00-l-10
SM 575, July 9
‘7 General Specifications l 40-l-l
GENERAL SPECIFICATIONS Fuses: 15 Amp Indicator Lamps: No. 57
Truck Capacities & Weights Gross Vehicle Weights

(Approx. with cutoff height uprightt)
Mode Designation Rated Load Capacity
Models Truck Weight Empty Weight
@24” (61cm)LoadCenter
c500-Y 180 45,170 lbs 27,170 lbs
C500-Y180 18,000 lbs (8165 kg)
C500-Y2OOS 51,120 lbs 31,120 lbs
C500-Y2OOS 20,000 lbs (9072 kg)
C500-Y225S 54,990 lbs 32,490 lbs
C500-Y225S 22,500 lbs (10,206 kg)
C500-Y225L 58,120 lbs 33,120 lbs
C500-Y225L 22,500 lbs (10,206 kg)
C500-Y25OS 65,960 lbs 35,960 lbs
C500-Y25OS 25,ooO lbs (11,340 kg)
C500-Y25OL 53,070 lbs 30,570 lbs
C500-Y25OL 25,000 lbs (11,340 kg)
c500-Y3OOS 56,850 lbs 31,850 lbs
c500-Y3OOS 30,000 lbs (13,608 kg)
C500-Y3OOL 64,210 lbs 34,210 lbs
C500-Y3OOL 30,000 lbs (13,608 kg)
c500-Y350 72,060 lbs 37,060 lbs
C500-Y350 35,000 lbs (15,876 kg)
NOTE
Rated capacity applies when using uprights with Marina Models
maximumMFH up to and including: 216: (5468,4) C500-Y 165M 69,200 lbs 31,300 lbs
Powrshift Transmission C500-Y2OOM 74,100 lbs 32,500 lbs
Make & Model: Clark 28316
speeds: 3-Forward and 3-Reverse Models Loaded Empty
Converter: 13.5 Drive Axle Drive Axle
Ratios: lst4.01 2nd2.12 3rd1.04
C500-Y 180 40,247 lbs 13,660 lbs
Drive Axle (w/Air -Drum & Shoe Type).
Brakes
C500-Y2OOS 46,084 lbs 16,250 lbs
Spiral bevel ring and pinion planetary with “S” cam
actuated brake shoes w/non-asbestos linings. C500-Y225S 49,734 lbs 16,170 lbs
Wheels & Tires C500-Y225L 53,494 lbs 16,200 lbs
Tire @rive & Steer): 12.00 x 20 NHS 16 ply C500-Y25OS 60,122 lbs 15,370 lbs
Load Limit: 17,600 lbs at 100 PSI C500-Y25OL 49,216 lbs 17,440 lbs
Electrical System 12-Volt Negative Ground c500-Y3OOS 52,638 lbs 17,330 lbs
Cummins Models C500-Y3OOL 59,505 lbs 17,140 lbs
l Battery: Two (2) BCI Croup 31 c500-Y350 65,881 lbs 16,450 lbs
Cold Cranking Current: 12 V DC

1250 amps @ O”FTotal Marina Models
Ford Models C500-Y 165M 69,200 lbs 31,300 lbs
l Refer to page 4 C500-Y2OOM 74,100 lbs 32,500 lbs
40-I-2 l General Specifications Intended for CLARK dealers only SM 575, July 9
‘7
Group 40, Specifications ClflRU
System Filters l Cooling Sys Crossflow type radiator
27 qts (25.5 liters)
l Engine Air Replaceable Element
l Radiator Cap 7 PSI Nominal
l Hydraulic Replaceable Element(s)
l Coolant Use a mixture of 50% ethyl
-Two (2) canisters w/Screens
ene glycol permanent-type
lactated in top of sump tank
antifreezecontainingrustand
or suction screens w/single
corrosion inhibors only with
return line filter.
50% water.
l Transmission Replaceable Element
l Crankcase CumminsEngine Models
l Steering System Low Fill: 12.4(13qts)
“Strainer Screen” Cleanable type located in top Max. Fill: 14.2 (15 qts)
of sump tank. l Crankcase Ford 460 CIDEngine Models
l Breather Cap Replaceabletypelessdipstick with Filter: 8.0 qts (7.6L)
located in top of sump tank. w/out Filter: 9.0 qts (8.5L)
Fluid Recommendations
Fuel Recommendations l Transmission Specifications C2 or C3,
Cummins Diesel Amoco 1000, Texaco
1893TDH or equivilent
l D-2 with Cetanerating of 45 or higher.
l SumpTank Clark Specification MS-68
l D- 1 & Jet A- 1 also acceptable.
Hydraulic Fluid w/anti-wear
Ford Models additives, or equivalent only.
l Gasoline: 87Octaneminimum(MotorMethod) l Power Steering GM 1050017, Texaco TL
l L.P.Gas: HD-5 Propane 3644 or equivalent.
Reference Material
Fluid Capacities & Volumes Refer to Section 2 for PM and Drivers daily
l Fuel Tank Long Wheel Base Models inspection fi-oms available through your Clark
47.5 gal (179.8L) Dealer.
l FuelTank Short Wheel BaseModels Refer to the Lubrication Chart in Section 3
35.5 gal (134.4L) showing the location of all lubrication points.
l Transmission HR 28000 includes converter Refer to Section 4 for further recommended
30 qts (28.4 liters) fluids, lubricants and specifications. This listing
is intended as a guide in the selection of a
l Drive Axle Differential less Axle Ends
lubricant to meet the requirements of Clark.
(Clark & Rockwell) 14 pts (6.6 liters)
Refer to the Engine Manual covering your spe-
l AxleEnds Capacity Each End
cific engine for recommendations of the engine
(Clark & Rockwell) 8 pts (3.8 liters)
manufacture.
l SumpTank Long Wheel Base Models
Refer to the Index for specific instructions and
50.5gal(191.1 liters) illustrations covering items such as “hydraulic
l SumpTank Short Wheel Base Models system fdters” etc.
35.5 gal (134.4 liters) Refer to the following pages for specifications
covering Ford Gasoline, LPG and CNG.
SM 575, July ‘97 Intended for CLARK dealers only General Specifications l 40-l-3
FORD ENGINE SPECIFICATIONS 0 Ignition Timing

Gasoline Models: lo” BTCD
Gasoline / LPG / CNG
L.P.G. Models: 16” BTCD
* Ford LSG-8751 VS-Block
C.N.G. Models: 14” BTCD
. Weight (Dry): 73 1 lbs (323.4 kg)
l Spark Plugs
. Engine Type: 90” Valve-in-Head
Type: Motorcraft ASF 42
0
Bore: 4.36 in. (110.7 mm)
Size: 14mm
.
Stroke: 3.85 in (97.8 mm)
Description: Suppression Type
.
Displacement: 460CID (7.5 Litre)
Spark Plug Wiring: Resistance Type
.
Rotation (viewed from front): Clockwise
.
Engine Firing Order: l-5-4-2-6-3-7-8 Cooling System
.
Compression Ratio: 8.0 : 1 l Water Pump: Centrifugal Dual Outlet
*
Cylinder Block and Head Material: Cast Iron Pump Drive: 36” V-Belt
.
Engine Balance: Externally Balanced Pump Capacity: 50 GPM @ 1600 RPM
Q
Flywheel Bobweight: 24.0 oz.-in. Pump Flow: 3.1 Liter/Second
.
Vibration Darnper Bobweight: 24 oz.-in Pump Capacity: 67 GPM @ 2400 RPM
.
Crankshaft Pulley: 2-Sheaves Pump Flow: 3.1 Liter/Second
0
Governor Type: Velocity Pump Pulley: 3 Sheave
.
Air Filter: Dry Type (replaceable element) l Fan Drive Ratio: 1.15 x Eng. RP
Fan Spacer: l-inch thic
Performance l Radiator: Crossflow w/transmission
l Design Rated Power: cooler in side tank.
Continuous BKP: 120 @ 2600 RPM Capacity: 27 qts (25.5 L)
0 Design Rated Torque: Radiator Cap: 7 PSI Nominal
Continuous 263 lb&. (357 N*m) @ 1400~~~ l Thermostat: Fully Opens
0 Governor Speed Settings (+25, -25) - GasolineKNG: 180” F (83” C)
Gasoline Models: L.P.G.: 160” F (72°C)
Full Load: 2500 RPM

Fuel System
No Load: 2600 RPM (High Idle)
l Fuel Recommendations
L.P.G. & C.N.G. Models:
Gasoline: 87 Octane minimum (Motor
Full Load: 2500 RPM Mathod)
No Load: 2650 RPM LPG: HD-5 Propane
All Models: l ‘FuelPump
Idle: 600- 650RPM Type: Mechanical Diaphragm
40-l-4 l General Specifications SM 575, July 97
l Static Pressure @ Engine Idle Electrical

5.5 / 7.5 PSI (0.39 / 0.53 kg) l 1ZVolt Negative Ground System
l Capacity l 55-Amp Alternator with Regulator
4OGPH(151.4UHR)@ 3600RPM
l Wire Hames: Ignition Module &Patch. Refer to
l Pump Drive Camshaft Eccentric Wire Schematic on following pages.
Location: Lower Left Side of Front l Fuses: 15 Amp
Cover
l Fuel Filter Camshaft and Related Parts
Type: Pleated Paper Replaceable Element l Crankshaft
Location: Integral with Fuel Pump Type: 5 Bearing Shell Molded
l Intake Manifold Heat Control Material: Special Cast Iron Alloy,
Type: Exhaust Cross Over Induction Hardened

l Journal Diameter
Lubrication
2.1238 / 2.1248 in. (53.945/53.97OInI-n)
* Lubrication System
l Camlift
Type: Pressure to crankshaft main bearings,
Intake: 0.2526 in. (6.416 mm)
connecting rod bearings and cam
shaft bearings. Exhaust: 0.2780 in. (7.061 mm)
Reduced pressure to rocker arms. l Bearings
Gil mist to piston pins and cylinder
walls. Type: Replaceable Insert
Indexed pressure to timing gear. Material: S tee1 Backed Aluminum Lead
l OilPump Overplate
Type: Rotor Total Effective Length: 2.90 in. (73.66 mm)
Location: Inside Gil Pan Total Effective Area: 17.57 in. (113.36 cma)
Intake: Non-Floading Shrouded Screen in l Camshaft Drive

sump. Type: Silent Chain
Normal Oil Pressure Sprocket Material: Die Cast Alumninum with
40 / 65 PSI @ 2000 RPM (2.8 / 4.6 kg/cm2) Nylon Overlay
l Oil Filter:
Type: Full Flow Disposable (Spin-On)
l Crankshaft
Filter Attachment:
Base Mounted Left Side
0 Crankcase Capacity
l Crankpin Journals
Diameter: 2.4992 / 2.5000 in.
with Filter: 9.0 qts (8.5L)
(63.480 / 63.500 mm)
SM 575, July 9
‘7 General Specifications l 40-I-5
GlflRu Group 40, Specifications
Electrical Crankpin Journals -
1ZVolt Negative Ground System Lenrrth:
55-Amp Alternator with Regulator 2.013 / 2.017 in. (51.130/51.232mm)
Wire Harnes: Ignition Module &Patch. Refer to Main Journals -

Wire Schematic on following pages. Diameter:
Fuses: 15 Amp 2.9994 / 3.0002 in. (76.185/76.205 mm)
Length:
#l 1.132/ 1.172 in. (28.753/29.769mm)
0 Crankshaft
#2&4 1.120/ 1.130 in. (28.448/28.702mm)
#3 1.124 / 1.126 in. (28,550/28600mm)
Material: Special Cast Iton Alloy,
#5 1.263 / 1.321 in. (32.80/33.553 mm)
Induction Hardened
Journal Overlap: 0.824 in. (20.930 mm)
l Journal Diameter:
Crankshaft Snrocket:
2.1238 / 2.1248 in. (53.945/53.97Omm)
Material: Sintered Iron
0 Camlift -
Vibration Damner:
Intake: 0.2526 in. (6.416 mm)
Type: Rubber Floated
Exhaust: 0.2780 in. (7.061 mm)
Main Beariws
l Bearings
Type: Replaceable Insert Select Fit
Type: Replaceable Insert
Material: Steel Backed Overplated Copper
Material: Steel Backed Aluminum Lead
Overplate
Effective Length:
Total Effective Lewth: 2.90 in. (73.66 mm)
#l, 2,4 & 5 0.746 in. (18.948 mtn)
Total Effective Area: 17.57 in., (113.36 cm,)
#3 0.66 in. (16.764 mm)
0 Camshaft Drive:
Total Length: 3.644 in. (92.558 mm)
Type: Silent Chain
Total Effective Surface Area:
Sprocket Material: Die Cast Ahunninum with
Nylon Overlay 34.34 in.* (220.916 mm*)
Crankshaft and Related Parts Pistons, Rods and Bearings

l Crankshaft Connecting Rods
Type: 5 Bearing Cast Nodular Iron Type: I-Beam
Lenmh Overall: 29.146 in. (740.308 mm) Material: S tee1 Backed Overplated Copper
Lead
. anknin Journals -
Length (Center-to-Center):
Diameter:
6.6035 / 6.6065 in. (167.729 / 167.805 mm)
2.4992 / 2.5000 in. (63.480/63.500mm)
‘7
Pistons, Rods and Bearings - continued - l Length:

l Connecting Rod Bearings 3.29 / 3.31 in. (83.566 / 84.074 mm)
Type: Replaceable Insert Select Fit l Diameter:
Material: Steel Back4 Copper Lead 1.0398 / 1.0403 in. (26.411/26.42411@
l Effective Lenti Each Bearing Krank End): l Piston Fit:
0.841 in. (21.361 mm) 0.0003 / 0.0006 in. (0.076 / 0.015 mm)
* Total Effective Surface Area 0ank End):
Valves and Valve Operating
52.84 i%. (340.924mm )
Mechanisms
l pistons
. Intake Valve
Type: Autothermic
Type: Recessed Head
Material: Die Cast Aluminum Alloy
Material: Forged Silchrome #l
Finish: Tin Plate
. Head Diameter:
Length: 3.74 in. (95.00 mm)
2.075 / 2.090 in. (52.7 1/53.09 mm)
Piston Rings and Pins . Stem Diameter:
Piston Rings 0.3416 / 0.3423 in. (8.677 / 8.694 mm)
Number: 3 . Stem Oil Control:

Type: Nylon Umbrella
Top Compression Ring
. Seat Material (Cylinder Head):
Type: Inside Bevel Straight Face
Induction Hardened
Material: Cast Iron Alloy
. Seat Angle: 45”
Finish: Moly Filled Groove
. Totator Type: Ford Free Turn
Second Compression Ring
. Spring Pressure - Open:
Type: Tapered Face
229 lbs. @ 1.33 in. (103.9 kg @ 33.8 mm)
Material: Cast Iron . Spring Pressure - Closed:
Finish: Phosphate Coated
80 lbs. @ 1.81 in. (36.3 kg@ 46.00 mm)
Oil Control Ring . Exhaust Valve
Type: 3 Piece Segmented
Type: Recessed Head
Material: Steel
Material: Forged 21-4N Steel, Tungsten Co-
Finish: Chrome Faced Rails, Oxide Coated balt Faced (Hardened)
Expander Rustless S tee1
. Head Diameter:
Piston Pins
1.500/ 1.515 in. (38.KW38.481 mm)
Type: Press Fit in Rod, Tubular
. Stem Diameter:
Material: Heated Treated SAE-5015 Steel
0.3416 / 09.3423 in. (8.677 / 8.694 mm)
SM 575, July ‘97 General Specifications l 40-l-7
Valves and Valve Operating Mechanisms - continued -
Exhaust Valve - continued -
* Stem Oil Control: Nylon Umbrella Type

. Seat Insert Material:
Moly Tungsten Chrome Alloy
Seat Angle: 45”
Valve Lift: 0.481 in. (12.127 mm)
Rotator Type: Ford Free Turn
Spring Pressure - Open:
229 lbs. @ 1.33 in. (103.9 kg @ 33.8 mm)
* spring Press - Closed:
80lbs. @ 1.81 in. (36.3 kg @ 46.0 mm)
. Valve Operating Mechnism
Tappet Type: Hydraulic
Tappet Material: Hardened Alloy Cast Iron
Push Rod Material: Low Carbon Welded
Steel Tubing
Push Rod Length:
8.585 / 8.615 in (218.06/218.82mm)
RockerArmType: PedestalMountedCylindri-
Cal Pivot
Rocker Arm Material: stamped SAE 1010
Steel
40-l-8 l General Specifications SM 575, July ‘97
Alternator Ford 460 CIU

12 Volt Nregative Ground
10 Ga-wire limited to 60
Amp Alternator Maximum. Wire Harness
8 Ga-wire used for larger
alternators.
Schematic LSG8751-60
37-------
Alternator,
Starter and
Starter Relay
are grounded
by mounting
bolts to engine
block or to the
Switchgage
system frame. 21 - System
152 inserted here
(when used)
I
Voltmeter
i
2 Battery
z
T
i7A B
I I 1
?
Grokd
Hour Meter and other

Rccessories inserted @ ” -6
Distributor
qere (when used). \\. 7a
Circuit #16R shall

have a resistance of
1.05to 1.15Ohms at
75’ F as measured
from terminal to
Terminal.
Ground
Ground
Coil
i Tach Test ]
HighlTension
i_-.. 9
SM 575, July 9
‘7 Intended for CLARK dealers only General Specifications l 40-I-9
ENGINE SPECIFICATIONS Fuel System

l Fuel Recommendations -
DIESEL ENGINE
D-2 with Cetane rating of 45 or higher
0 cummins
6BT5.9
D-l & Jet A-l also acceptable
l Weight (Dry): 880 lbs (400 kg)
l Bore: 4.02 in. (110.7 mm) Lubrication
0 Stroke: 4.72 in (120 mm) Lubrication System
* Displacement: 359 CID (5.88 Litre) Type: Pressure to crankshaft main bear-
0 Rotation (viewed from front): Clockwise ings, connecting rod bearings and
camshaft bearings.
0 Engine Firing Order-z l-5-3-6-2-4
l Compression Ratio: 17.5 : 1 OilPump:
l Air Filter: Dry Type (replaceable element) Minimum Gil Pressure At:
Rated Speed: 30 PSI (207 kPa)
Performance At Idle: 10 PSI (69 kPa)
* Design Rated Power: Typical Oil Pressure At:
Continuous BHP: 152 @ 2500 RPM Rated Speed: 50 PSI (345 kPa)
* Design Rated Torque : At Idle: 30 PSI (207 kPa)
Continuous 414 lb.ft. (561 Nom) @ 1600 RPM Gil Filter:
l Governor Speed Settings (+25, -25) - Type: Full Flow Disposable (Spin-On)
Full Load: 2500 RPM
No Load: 2650 RPM (High Idle) Crankcase Capacity -
Idle: 800 RPM (No Accessories) w/o Filter: 15.0 qts (14.2 L)
with Filter: 17.3 qts (16.4 L)
Cooling System
l Water Pump
‘7
C5OOY2235
Group 40
SECTION 2
PM INSPECTION AND
DRIVERS DAILY INSPECTION FORMS


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SM-575

Read and understand this manual before operating

This manual covers machine

Serial No. Y2235-l-7056 & above

ALWAYS GIVE THE MACHINE SERIAL NUMBER

Book No. SM 575 2nd Revision

333 West Vine Street

Group 39 Decal Replacement and Placement

GROUP SECTION DESCRIPTION

0 Clark Material Handling Company 1997

GROUP SECTION DESCRIPTION

22 WHEELS AND TIRES

25 STEERING COLUMN AND STEERING

GROUP SECTION DESCRIPTION

29 1 Hydraulic Filters (Prior to lot 8506)

32 1 Tilt Cylinder Remove and Replace

33 1 Hydraulic Relief Valve

39 DECAL REPLACEMENT AND PLACEMENT

SAFETY SIGNS AND MESSAGES USER SAFE MAINTENANCE PRACTICES

The following instructions have been prepared from

3. A scheduled planned maintenance, lubrication and

4. Only trained and authorized personnel shall be

A WARNING 6. Avoid fire hazards and have fire protection equip-

7. Before Starting Work On Truck:

16. Batteries, motors, controllers, limit switches, pro-

17. To avoid injury to personnel or damage to the

18. Industrial trucks must be kept in a clean condition

19. Modifications and additions that affect capacity

As an aid in performing and documenting your PM

Remove all jewelry (watch, rings, bracelets, etc.) before

Inspect the forks for twists and bends. Put a 2” thick

Inspect the upright assembly: rails, carriage rollers, lift

Inspect all lift line hydraulic connections for leaks.

Wheels and Tires Function Tests

Press the horn button to check horn function. If the

loose or missing. Have missing bolts or lug nuts

Water Oil Hour Brake Air

Water Temperature Gauge Air Pressure Gauge

Oil Pressure Gauge Fuel Gauge

Checks with the engine running...

NOTE: The electrically operated gauges register cor-

Service Brake Pedal

l Check the function of the parking brake. Release,

9 To check parking brake holding capability, park

A CAUTION l Push forward on the lift control lever. Watch the

Steering System... When you have completed the operational tests,

Unlatch and open the hood to access the engine

Engine Cooling System l lnspectthecoolantforcondition. Lookforexcessive

Engine Oil and Filter Change Testing

operating temperature. This is important as transmis-

Air Cleaning Check Torque Of Critical Items, Including:

Lift Chain Inspection and Measurement Lift Chain Replacement

Lift Chain Inspection and Wear Criteria

2 -(WORN CHAIN LENGTH) E

3 - (SPAN) The number of

Troubleshooting .............................................................. Section 1

Engine Removal .............................................................. Section 2

Ford Engine Specifications ............................................ Section 3

Cummins Engine Specifications ......... .. .. ... .................... Section 4