Clark epx 16 20 s forklift service repair manual
- 1. EPX16-20s Part No. 8037870 Book No. SM-715 Jun. 2005 RATED CAPACITY : 1250~2270kg SERVICEMANUAL #40-1,Ungnam-Dong, changwon-city, Kyungnam, Korea TMX12-25
- 2. Truck Models Covered by this Manual This manual consists of “base” module that pertains to all TMX12-25, ECX16-18 models and other mod- ules that pertain only to specific models. Manuals shipped with the truck contain the base module and the modules specific to the purchased truck. You may, however, purchase specific modules and expand your manual to fully cover multiple models. To do so, order the desired modules as you would any other Clark part. Arrangement and Use of this Manual Clark arranges parts and service procedures by stan- dardized Groups. In this manual, Groups are similar to “chapters”. Groups are listed in the indexes on the next page. Each Group begins with a table of contents that shows the Sections contained within the Group. Lengthy Sections also begin with a table of contents. Each Group and Section has an identifying name and number, or “ID”. Each page also has a unique ID. The page ID con- sists of three numbers separated by hyphens. The three numbers represent the Group number, the Sec- tion number, and the page number. For example, “00-1-2” on the lower corner of the page indicates Group 00, Section 1, page 2. The Group number sometimes has a letter or letters added to it in parentheses if one or more variations of the Group exist. For example, if the truck has a stan- dard transaxle, Group 06 is expressed as “06(S)”; if the truck has a hydrostatic transmission, Group 06 is expressed as “06(H)”. You can quickly locate a specific point in the manual by using the headers and footers that appear on every Section page. The following illustration points out these areas. This manual is intended for the use of trained service personnel. Please read Group SA, “Safe Mainte- nance”, and the Operator’s Manual before working on or operating the truck.
- 3. Group SA, Safe Maintenance SM 715, Dec ’04 Safety • SA-1-1 Safety Signs and Messages Safety signs and messages in this manual and on the lift truck provide instructions and identify specific areas where potential hazards exist and special precautions should be taken. Be sure you know and understand the meaning of these instructions, signs, and messages. Dam- age to the truck, death, or serious injury to you or other persons may result if these messages are not followed. NOTE This message is used when special informa- tion, instructions or identification is required relating to procedures, equipment, tools, pressures, capacities, and other special data. IMPORTANT This message is used when special precau- tions should be taken to ensure a correct action or to avoid damage to, or malfunction of, the truck or a component. CAUTION! This message is used as a reminder of safety hazards that can result in personal injury if proper precautions are not taken. WARNING! This message is used when a hazard exists that can result in injury or death if proper precautions are not taken. DANGER! This message is used when an extreme haz- ard exists that can result in injury or death or serious injury if proper precautions are not taken. The above terms have been adopted by Clark Material Handling Company. The same terms may be used in dif- ferent context in service literature supplied directly or indirectly by vendors of truck components.. Safe Maintenance Practices The following instructions have been prepared from cur- rent industry and government safety standards applicable to industrial truck operation and maintenance. These rec- ommended procedures specify conditions, methods, and accepted practices that aid in the safe maintenance of industrial trucks. They are listed here for the reference and safety of all workers during maintenance operations. Carefully read and understand these instructions and the specific maintenance procedures before attempting to do any repair work. When in doubt of any maintenance procedure, please con- tact your local Clark dealer. 1. Powered industrial trucks can become hazardous if maintenance is neglected. Therefore, suitable mainte- nance facilities, trained personnel, and procedures must be provided. 2. Maintenance and inspection of all powered industrial trucks shall be done in conformance with the manu- facturer’s recommendations. 3. A scheduled planned maintenance, lubrication, and inspection program shall be followed. 4. Only trained and authorized personnel shall be per- mitted to maintain, repair, adjust, and inspect indus- trial trucks. Work should be performed in accordance with the manufacturer’s specifications. 5. Properly ventilate work area, vent exhaust fumes, and keep shop clean and floor dry. 6. Avoid fire hazards and have fire protection equipment present in the work area. Do not use an open flame to check for level or leakage of fuel, electrolyte, oil, or coolant. Do not use open pans of fuel or flammable cleaning fluids for cleaning parts. 7. Before starting work on truck: a. Raise drive wheels off of floor and use blocks or other positive truck positioning devices. b. Disconnect battery before working on the electri- cal system. 8. Before working on engine fuel system of gasoline- or diesel-powered trucks, be sure the fuel shut-off valve is closed. Section 1. Safety
- 4. Group SA, Safe Maintenance SA-1-2 • Safety SM 715, Dec ’04 9. Operation of the truck to check performance must be conducted in an authorized, safe, clear area. 10. Before starting to drive truck: a. Be in operating position with seat belt fastened. b. Be sure parking brake is engaged. c. Put direction control in neutral. d. Start engine. e. Check functioning of direction and speed controls, steering, brakes, warning devices, and any load handling attachments. 11. Before leaving truck a. Stop truck. b. Put directional control in neutral. c. Apply the parking brake. d. Stop the engine by turning off the key switch. e. Put upright in vertical position and fully lower the forks or attachment. f. Put blocks at the wheels if truck is on an incline. 12. Brakes, steering mechanisms, control mechanisms, warning devices, lights, governors, guards, safety devices, and frame members must be carefully and regularly inspected and maintained in a safe operat- ing condition. 13. Special trucks or devices designed and approved for hazardous area operation must receive special atten- tion to ensure that maintenance preserves the origi- nal, approved, safe-operating features. 14. Fuel systems must be checked for leaks and condi- tion of parts. Extra special consideration must be given in the case of a leak in the fuel system. Action must be taken to prevent the use of the truck until the leak has been corrected. 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, protec- tive 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 equip- ment, consult the manufacturer’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, opera- tion and maintenance instruction plates, tags, or decals must be changed accordingly. This is an OSHA requirement. 20. Care must be taken to assure that all replacement parts, including tires, are interchangeable with the original parts and of a quality at least equal to that provided in the original equipment. Parts, including tires, are to be installed per the manufacturer’s proce- dures. Always use genuine CLARK or CLARK- approved parts. 21. Use special care when removing heavy components from the truck, such as counterweight, seat deck, upright, etc. Be sure that lifting and handling equip- ment is of the correct capacity and in good condition. Also, this removal may upset the stability of the truck. The frame must always be safely blocked for major component removal. NOTE You should also be familiar with additional operating and maintenance safety instruc- tions contained in the following publications: ASME B56.1 - 1988: Operator Control-Industrial Tow Tractors (Safety Standard For Powered Industrial Trucks). Published by: American Society of Mechanical Engineers, Three Park Avenue, New York, NY10016. NFPA 505-1982: Fire Safety Standard for Powered Indus- trial Trucks: Type Designations, Areas of Use, Mainte- nance and Operation. Available from: National Fire Protection Assoc., Inc., Batterymarch Park, Quincy, MA 02269. General Industrial Standards, OSHA 2206: OSHA Safety and Health Standards (29 CFR 1910), Subpart N-Materi- als Handling and Storage, Section 1910.178 Powered Industrial Trucks. For sale by: Superintendent of Docu- ments, U.S. Government Printing Office, Washington, DC 20402.
- 5. Group SA, Safe Maintenance SM 715, Dec ’04 Lifting, Jacking, and Blocking • SA-2-1 Raising Drive Wheels................................................................. 2 Chaining the Upright in Raised Position.................................. 2 Raising Rear of Truck................................................................. 3 Raising Entire Truck................................................................... 4 Shipping Tie-Down Instructions ............................................... 4 WARNING! Lifting or jacking any large piece of equipment such as a fork truck presents obvious hazards. It must be done with great care and forethought. Consult the truck weight information in Group 40, Specifications, to ensure that your lifting equipment is of adequate capacity. Section 2 Lifting, Jacking, and Blocking
- 6. Group SA, Safe Maintenance SA-2-2 • Lifting, Jacking, and Blocking SM 715, Dec ’04 CAUTION! To perform these service procedures, first: . Park truck on a level surface. . Put the upright in a vertical position and lower the carriage fully down. . Return control handle to neutral and turn key switch OFF. WARNING! Defective equipment can cause accidents. All tools and lifting equipment must be in good condition, meet the load capacity require- ments and have OSHA labels when required. Tools with defects can fail, causing severe injury or death. Raising Drive Wheels This procedure uses the upright to lift the drive wheels off the floor. 1. Park the truck safely. 2. Turn key switch ON. Tilt the upright fully back. 3. Put a solid 100 x 100 mm (4 x 4 inch) hardwood block under the front section of each upright rail. Put a 3.6 mm (0.125.0.250 inch) steel plate on top of each block. 4. Tilt the upright fully forward. This will raise the drive wheels off the floor. 5. Block the truck under the frame behind the drive wheels with solid blocking. 6. Turn key switch OFF. 7. Check for safe clearance between drive wheels, block and floor. 8. Check the stability of the truck. Be sure that the blocks are located securely under the frame before operating the drive motor or working on truck. 9. Lower the drive wheels to the floor by reversing this procedure. . Turn key switch ON. . Tilt upright fully back. . Turn key switch OFF. 10. Remove the blocks from under the frame and upright rails. Chaining the Upright in Raised Posi- tion This procedure provides safe clearance for access from the front of truck to components on or near the drive axle. 1. Park truck safely. 2. Put blocks at front of and rear of drive wheels. 3. Raise upright carriage. 4. Chain the center inner rail tie bar to the top outer rail tie bar as shown. Triple Stage Uprights: Chain the center intermediate rail tie bar and the lower inner rail tie bar to the top outer rail tie bar. 5. Reverse the procedure to remove the chains. WARNING! Keep hands, tools, etc. out of upright.
- 7. Group SA, Safe Maintenance SM 715, Dec ’04 Lifting, Jacking, and Blocking • SA-2-3 Raising Rear of Truck The truck may be raised at the rear by jacking and block- ing under the frame just beyond the counterweight. Refer to truck data plate for truck weights. WARNING! An incorrectly installed counterweight can move or fall unexpectedly. NEVER LIFT OR BLOCK A TRUCK USING THE COUN- TERWEIGHT. Failure to follow procedures outlined in this manual can result in injury or death. 1. Park truck safely. 2. Put blocks at front and rear of drive wheels. CAUTION! If possible, remove the battery from truck to reduce weight for added safety and ease of jacking. 3. Put a floor jack under the frame just beyond the coun- terweight. WARNING! Never lift the truck by the counterweight. NOTE If there is insufficient clearance under frame for your jack, the truck may first be driven onto shims, such as 25 x 150 x 300 mm (1 x 6 x 12 in) pieces of board, to increase the truck frame under-clearance. 4. Jack up one side of the truck about 50 mm (2 in) and put a block under the frame to hold that elevation. Then move the jack to the other side and jack and block it. Continue to alternate the procedure from side to side, increasing elevation not more than 50 mm (2 in) each time. Raise the truck no higher than necessary to perform the maintenance work. Make sure the left and right sides of the truck are finally blocked in a level working position. CAUTION! Before performing any maintenance work, check the truck for stable condition on the blocking by determining that it will not rock on blocks. 5. When maintenance work is completed, lower the rear of truck to the floor by reversing the above procedure and lowering each side of the truck 50 mm (2 in) at a time: • Put jack under frame and raise truck. • Carefully remove blocks and lower truck. • Remove jack and blocks from drive wheels.
- 8. Group SA, Safe Maintenance SA-2-4 • Lifting, Jacking, and Blocking SM 715, Dec ’04 Raising Entire Truck Refer to truck data plate for truck weights. 1. Park truck safely. Lower upright fully. If necessary, drive truck onto boards to increase under-clearance. WARNING! SIDE-TO-SIDE TIPOVER. When jacking side of truck, be sure upright is lowered fully. Do not raise one side of the truck more than about 50 mm (2 in) higher than the other, to avoid tipping truck over laterally. END-TO-END TIPOVER. If the upright and drive axle are removed while the truck is blocked up, the truck will tip backward due to the heavy counterweight. Upright and counterweight must both be removed before attempting to raise the truck for drive axle removal. The back of the truck must be sup- ported by blocking under the steer axle to prevent movement. If the counterweight is removed while the truck is up on blocks, the weight of the upright and drive axle will cause the truck to fall forward. 2. Put the jack under side frame, near the center of the truck. IMPORTANT Be sure to put the jack squarely and fully under the main side structure of the frame. 3. Carefully raise the truck one side at a time, only as high as necessary to do the maintenance work, and not more than 150 mm (6 in) total. 4. Put blocks under the side frame, at each side of the jack. Spread the blocks close to the steer and drive wheels for maximum stability. 5. If using one jack, lower the truck onto the blocks and move the jack to the opposite side. Repeat the lifting procedure. 6. Put the same size blocks under each side of the truck so it will be leveled. CAUTION! Before performing any maintenance work, check the truck for stable condition on the blocking. 7. When maintenance work is completed, lower the entire truck to the floor by reversing this procedure. Lower the truck one side at a time, while carefully removing the blocks. Be sure no tools or equipment are under the truck or wheels. NOTE Depending on jack height, shims under the tires may be needed for clearance to allow removal of jack. Shipping Tie-Down Instructions 1. Front of Truck a. With Upright and Carriage Installed • Lower the carriage fully. • Put a tie-down (e.g., chain) between the carriage fork bars. b. Without Upright and Carriage Installed • Put a chain across the truck floor plate. Protect truck from chain damage by using covered chain or protective material under the chain at contact points. 2. Rear of Truck • Attach the tie-down to the toe-pin in top of coun- terweight.
- 9. Group SA, Safe Maintenance SM 715, Dec ’04 Towing • SA-3-1 If your truck is disabled but can be moved freely on its own wheels without further damage, use the following procedures to tow the truck safely to a repair area. WARNING! It is important for your safety and to the care of your lift truck to use the proper equipment and carefully follow these recommendations for safe towing. Do not tow a lift truck if there is a problem with the brakes or tires, or if the steering cannot be operated. Do not tow the disabled truck up or down ramps or steep inclines. Do not attempt to tow the disabled truck if traction or weather conditions are poor. 1. Be sure to apply the parking brake or block the drive wheels on the disabled truck while working around it. 2. When possible, raise the carriage (forks) on the dis- abled truck 300 mm (12 in) from the floor or ground. Secure the carriage on the upright with a chain. 3. Use a truck for towing that is of equal or larger capac- ity than the disabled truck. Carry a partial load on the tow truck for improved traction. 4. Check that the counterweight bolts on both trucks are in place and properly torqued. These bolts are made of special, high-tensile steel and are not commer- cially available. When necessary, replace these bolts only with a genuine Clark replacement part. 5. Use an approved, solid metal tow bar with towing couplers that connect to the towing pins in the coun- terweights. NOTE DOT-approved towing equipment is available from your Clark dealer. 6. Release the parking brake on the towed vehicle. Place directional control lever in neutral. 7. Tow the disabled truck backwards. An operator must be on the disabled truck. CAUTION! The power steering and braking will not operate on the disabled truck. The steering handwheel will be difficult to turn and the service brakes will require additional pedal force. 8. Tow the truck slowly. Careful towing is necessary to prevent injury to personnel or damage to the disabled truck. The truck should be towed at a speed of less than 8 kph (5 mph, or a moderate walking speed) with a driver in place and steering the disabled truck. IMPORTANT Do not lift the disabled truck or any wheels off the floor while the truck is being towed. 9. Park the disabled truck in authorized areas only. Fully lower the forks on the floor, leave the directional control in neutral, turn the key switch to OFF, and engage the parking brake. Remove the key and, when necessary, block the wheels to prevent the truck from rolling. WARNING! Always engage the parking brake when park- ing a lift truck. The truck can roll and cause injury or death to personnel near it. Section 3 Towing
- 10. Group 25/26, Steering SM 715, Jun ’05 ➀ Steering System Specifications and Description • 25-1-1 Specifications Steering System Type: Load sensing hydrostatic power steering with variable ratio.(TMX Truck) Steering System Type: Dynamic signal load sensing steering with variable ratio.(EPX Truck) Steering System Relief Pressure Setting: 8340-8830 kPa (1210-1280 psi). Steer Cylinder Type: Double acting, piston-type. Steer Axle: Single wheel (optional dual-wheel) mounted on trunnion at center rear of truck. Service Intervals Check the steering system relief pressure annually or after every 2000 hours of operation. Make a visual inspection of steering control unit hydraulic fittings periodically to ensure that the fittings are tight with no leakage. Fastener Torques Steering Handwheel Nut: 35-40 N.m (25.5-29.5 ft-lb) Steering Column Cover Hex Bolts: 2-3 N.m (18-27 in.lb; 1.5-2.25 ft-lb) Directional Control Base Lock Nut: 0.8-1 N.m (7-9 in.lb; 0.6-0.75 ft-lb) Directional Control Base Flange Capscrew: 3.5-4.0 N.m (2.5-2.9 ft-lb) Ignition Switch Ring Nut: 10-14 N.m (7.3-10.3 ft-lb) Tilt Lock Assembly Base-to-Cowl Bolts: 20-25 N.m (14.8-18.5 ft-lb) Orbitrol Bracket Bolts: 34-38 N.m (25-28 ft-lb) Lower Column Assembly Base-to-Steering Gear Bolts: 34-38 N.m (25-28 ft-lb) Universal Joint Pinch Bolt: 25-30 N.m (18.5-22 ft-lb) Wiring Harness Bracket Bolts: 11-13 N.m (8-9.5 ft-lb) Description All truck models have a hydrostatic power steering sys- tem, which is supplied with oil pressure from the main hydraulic system pump. The steering handwheel operates the power steering gear (steering control valve) shown on page 2, which directs oil flow to the steering cylinder on the steer axle. The steering cylinder operates the steering linkage and steer wheel described on page 3. A steering system pressure relief valve, contained in the steer gear assembly, prevents over-pressurization of the steering system. The pressure relief setting can be tested using the gaugeinserted into the pressure line into the steering gear. The steering gear shaft is connected to the handwheel by means of a jointed shaft. When the steering handwheel turns, it causes the steering gear’s spool valve to shift from its closed neutral position to a “turn” position. This shift- ing of the spool directs flow to one end or other of the steering cylinder, depending on the direction of the turn. The amount of flow, and the sharpness of the turn, depend on how far the handwheel is rotated. The more rapidly the handwheel turns, the more quickly the flow, and the turn, occur. The low pressure oil from the opposite side of the steering cylinder is returned through the opposite port in the steer- ing gear. As the steering handwheel stops turning, centering springs in the valve automatically center the spool, stopping the flow of oil to the cylinder. Stops in the steer cylinder limit the how far the steer wheels can be turned. It takes 5 turns of the hand wheel to turn from stop to stop. In the event of a pump failure, the steering gear acts as a limited emergency steering pump powered by manual rotation of the handwheel. An internal check valve auto- matically closes to divert the manually-generated oil flow to the proper port of the steer cylinder. The handwheel turning effort is considerably higher, however, than with power steering. Section 1 Steering System Specifications and Description
- 11. Group 25/26, Steering 25-1-2 • Steering System Specifications and Description SM 715, Dec ’04 The column tilt-lock mechanism allows the operator to adjust the steering column. The column tilt lever knob releases the adjustment setting and the column returns to the up position by the use of springs. The tilt lock mecha- nism, the directional control lever, and the ignition switch are protected by the steering column cover. The column cover can be removed for service to steering column components. The entire column can be removed for service or replacement. The steering gear, attached to the base of the column, can be removed without disassem- bling the other parts of the steering column. Steer Column and Steer Valve Horn Button Column Directional Control Lever Assembly Tilt Lock Horn Contact Ring Ignition Switch Wiring Harness Directional Control Switch Wiring Harness Tilt Lock Assembly Boot Steer Valve (hydraulic lines on page 4) Key Switch Hand Wheel
- 12. Group 25/26, Steering SM 715, Jun ’05 Steering System Specifications and Description • 25-1-3 (TMX Truck) The steer cylinder rod operates a drag link which pivots the steer trunnion and steer wheel mounted to it. A sensor mounted above the steer trunnion shaft, signals the position of the wheel to the electronic control, which then creates a speed differential between the two drive motors to facilitate cornering. Steer Linkage(TMX Truck) Steer Trunnion Bearings Steer Trunnion Mounting Plate Steer Drag Link Steer Trunnion Steer Wheel and Bearings Steer Cylinder (hydraulic lines on page 4) Steer Angle Sensor Assembly
- 13. Group 25/26, Steering 25-1-4 • Steering System Specifications and Description SM 715, Jun ’05 Steer Axle assembly(EPX Truck) Silent block Steer Axle Assembly
- 14. Group 25/26, Steering SM 715, Jun ’05 ➀ Steering System Specifications and Description • 25-1-5 Steer Angle Sensor Removal and Replacement Removal of entire assembly. Replacement is reverse order: A. Potentiometer wires. B. Fastener and washer C. Bracket/Assembly NOTE Potentiometer shaft holder (G) and fastener may remain on steer axle. NOTE Potentiome- ter (E) wire leads should point toward front of truck,. Removal and replacement (reverse order) of potentiome- ter only. Replacement is reverse order: A. Potentiometer wires. D. Cable clamp F. Locknut E. Potentiometer (EPX Truck) TMX Truck Torque to 40 - 45 N-M (30 - 33 lbs-ft) Torque to 20 - 30 N-M (15-22 lbs-f t) H : Steering sensor I : Fastener J : Steer Magnet
- 15. Group 25/26, Steering 25-1-6 • Steering System Specifications and Description SM 715, Jun ’05 ➀ Hydraulic Connections in Steering System(TMX) Hydraulic Connections in Steering System(EPX)
- 16. Group 25/26, Steering SM 715, Dec ’04 Steering System Troubleshooting • 25-2-1 No steering • Hydraulic fluid level very low. • Air in hydraulic oil. • Steering column sections not connected properly. • Hose broken. • Hydraulic pump contaminated or defective. • Priority valve spool stuck.(EPX) Hard steering • Hydraulic fluid level low. • Air in hydraulic oil. • Steering gear contaminated or defective. • Relief valve setting too low; adjust or replace. • System leaking. • Incorrect tire pressure. • Axle load too heavy. • U-joint misalignment. • Lack of lubrication. • Defective steering gear. • Spring in priority valve broken.(EPX) High number of handwheel turns • Steering cylinder seal leakage. • Worn steering gear. Steering handwheel spins freely • Air in system (cavitation). • Low oil supply. • Steering column detached from steering gear. • Defective steering gear. Jerky steering • Steering gear malfunction because of worn parts or contamination. Steering gear may require over- haul. Truck turns in wrong direction • Hydraulic lines not installed correctly. Handwheel kickback • Check valve faulty (or not in system). Slow steering response • Oil viscosity too high. • Contaminated or defective steering gear. Chatter conditions • Loose mountings or linkage. Make certain all mounting fasteners and other linkage is tight. • Pressure relief valve set too low and is out of adjustment; adjust or replace the relief valve. • nsufficient pump flow. Check pump for leaks and see Group 29, Section 3. Unsatisfactory steering in either direction • Air in system due to excessive wear in steering cyl- inder. Check for air in system. Excessive noise or foamy condition of hydraulic fluid indicates aera- tion. Check that air is not entering the system through poor threads, cracked, split, or worn hoses, bad pump seals, bad O-rings, bad gaskets, or loose connections on intake side of pump. Worn cylin- ders result in leakage past the piston. Overhaul (see Group 25, Section 7) or replace the steer cylinder. • Incorrect system pressure due to worn pump. Replace the relief valve or repair or replace the pump (see Group 29). Section 2 Steering System Troubleshooting
- 17. Group 25/26, Steering 25-2-2 • Steering System Troubleshooting SM 715, Dec ’04 Noise during turns • Worn bearing(s) in steering arm; replace bearings. • Worn pin in steering knuckle; replace pin. • Worn bearings in steering knuckle; replace bear- ings. • Steering knuckle is loose; tighten castle nut. Constant noise from steering axle • Loose or worn hub bearing cones. Adjust or replace hub bearing cones. Replace bearing cones and bearing cups as a set. Fluctuating pressure • Faulty operation of relief valve. Fluctuating pres- sure or loss of pressure in the system is usually caused by scales, chips, sludge, or filings that have lodged between the relief valve and seat. A dam- aged spring or worn valve may also be the cause of the trouble. Flush and refill the system and replace the hydraulic return line filter element. If condition still exists, replace the relief valve. Low pressure at the pump • Refer to the pump troubleshooting and overhaul procedures in Group 29. Low pressure at the steering gear • Refer to Section 5, “Steering Gear Overhaul.”Low pressure at the steer cylinder • Seals worn out at piston rod end of steer cylinder; replace seals.(TMX) Steer cylinder rod binding or sticking • Binding of linkage. With hydraulic flow shut off from the cylinder and the rod end uncoupled, the rod should slide freely in or out by hand. If the pis- ton is binding, overhaul or replace the cylinder.
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- 19. Group 25, Steering SM 715, Jun ’05 ➀ Steering Column and Component Removal and Replacement • 25-3-1 Steering Column and Component Removal ................................................... 2 Key Switch Removal ...........................................................................................2 Hand Wheel, Horn Contact Ring, and Directional Control Assembly Removal .2 Column Tilt Lock Assembly Removal ................................................................4 Steering Gear and Lower Steering Column Removal. .........................................4 Steering Column and Component Replacement ............................................ 6 Steering Gear and Lower Steering Column Replacement ...................................6 Column Tilt Lock Assembly Replacement. .........................................................7 Directional Control Assembly Reassembly..........................................................7 Directional Control Assembly and Key Switch Replacement .............................8 Steering Hand Wheel Replacement......................................................................9 IMPORTANT Before removing any component for overhaul, make sure the correct repair parts, seals, and gasket sets are available. Typical Steering Column Assembly Wire Harness Key Switch &Turn Signal SW Wire Harness Directional Control SW Direction Control Assembly Tilt Lock Assembly Tilt Lock Assembly Boot Direction Control & Turn Signal Assy Turn Signal Assy(EPG ONLY) Key Switch Horn contact Ring Column Lower Cover Lock Nut Section 3 Steering Column and Component Removal and Replacement
- 20. Group 25, Steering 25-3-2 • Steering Column and Component Removal and Replacement SM 715, Jun ’05 CAUTION! SAFE PARKING. Before working on truck: 1. Park truck on a hard, level, and solid surface, such as a concrete floor with no gaps or breaks. 2. Put upright in vertical position and fully lower the forks or attachment. 3. Put all controls in neutral. Turn key switch OFF and remove key. 4. Apply the parking brake and block the wheels. Steering Column and Component Removal Use the following steps to disassemble the steering col- umn for service to the: • Key Switch • Horn Button • Directional Control Lever Assembly • Column Tilt Lock Assembly • Upper and Lower Steer Column • Steering Gear. Determine which component requires service and check the procedure for removing that component. Read the pro- cedure completely before beginning disassembly. Key Switch Removal 1. Disconnect the battery. 2. Remove the four socket head bolts holding the two halves of the column cover together. The directional control assembly and the key switch are exposed. 3. Remove the lock ring nut securing the key switch to the lower cover. Label all wires and terminals for cor- rect reconnection when reassembling. Hand Wheel, Horn Contact Ring, and Directional Control Assembly Removal 1. Disconnect the battery. 2. Gently pry the horn button from the steering hand wheel hub using a small, flat-bladed screw driver. 3. Disconnect the horn wire from the steer column and unplug the horn contact wires from the terminal on the bottom of the horn button. 4. Remove the nut holding the hand wheel to the steer- ing column. 5. Use a wheel puller to remove the hand wheel from the steering column. Hand wheel has two M8X1.25 threaded inserts in the hub for this purpose.
- 21. Group 25, Steering SM 715, Dec ’04 Steering Column and Component Removal and Replacement • 25-3-3 6. Unplug the horn contact ring wire from the terminal on the bottom of the handwheel. 7. Using a 2.5 mm allen wrench, remove the four socket head bolts holding the two halves of the column cover together. Remove the top cover. Gently pull the bottom cover away. NOTE Use care when removing the bottom cover as the ignition switch wiring is attached. 8. Remove the horn contact ring. Unplug the wire from the terminal on the bottom of the ring. 9. Lift the directional control lever and boot off the diecast base. 10. Unplug wires from directional switches. Label all wires and terminals for correct connection when reassembling. Remove the direction control switches by removing the mounting screws on the base. Directional Control Lever Detent Spring Removal 11. If not already disassembled, remove the four socket bolts holding the two sides of the column cover together. Remove the top cover. 12. Pry the two retainer clips from the posts on the direc- tional control base securing the detent spring. Lift spring off posts.