the best repair manual

1. SM-596
ESM 12/25

2. Service
Manual
SM596
ESM-II 12 thru 25

3. Truck Models Covered by This Manual
This manual consists of a “base” module that pertains to
ESM-II models and other modules that pertain only to
specific models. Manuals shipped with the truck contain
the base module and the module 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 standard- You can quickly locate a specific point in the manual by
ized Groups. In this manual, Croups are similar to “chap- using the headers and footers that appear on every Section
ters.” Croups are listed in the indexes on the next page. page. The following illustration points out these areas.
Each Croup begins with a table of contents that shows the
Sections contained within the Croup. Lengthy Sections
also begin with a table of contents. Group ID’ ‘Group ID
Each Croup and Section has an identifying name and num-
ber, or “ID.”
Each page also has a unique ID. The page ID consists of
three numbers separated by hyphens. The three numbers
represent the Croup number, the Section number, and the
page number. For Example, “00-1-2” on the lower corner
of the page indicates Croup 00, Section 1, Page 2.
Page ID’ .Page ID
Sectioi ID Manual ID Se&ion ID
The Croup number sometimes has a letter or letters added
to it in parentheses if one or more variations of the Croup
exist. For example, if the truck has a standard transaxle,
Croup 06 is expressed as “06(S);” if the truck has a hydro-
static transmission, Croup 06 is expressed as “06(H).”
This manual is intended for the use of trained service
personnel. Please read Croup SA, “Safe Maintenance” and
the Operator’s Manual before working on or operating the
truck.
Copyright Clark Material Handling 1995 SM 596, Aug ‘95

4. C1RRK Foreword
Foreword
This service publication provides information covering nor-
mal service, maintenance and repair of the Clark industrial
lift trucks noted on the cover. It has been specifically
prepared to help owners and service personnel maintain
these trucks in efficient and safe operating condition.
This manual is intended for use by persons who are trained
and authorized to do lift truck maintenance. It is designed
to provide essential information about the correct and safe
service maintenance and repair of the truck by trained
mechanics or service technicians.
The Pictorial Contents lists components or systems by
Basic Group Number of Major Parts. Additional content
listings are placed at the beginning of each Section in the
manual.
General and detailed service and repair procedures are
outlined (as required) for each component or subsystem.
Some procedures include explanations that are common to
several components or subsystems.
Before beginning to work, the technician is cautioned
and expected to:
.
.
Do all necessary service work.
Take time to read entire procedures, including any
special instructions.
Procedures have been made easier to use by providing
specific steps only when necessary and general instructions
required to explain the activity, component, assembly, or
process being worked on. The technician is expected to
include obvious additional steps of standard procedure for
removal, disassembly, cleaning, inspection, reassembly, in-
stallation, etc., as needed.
To be better prepared to do the necessary service work, take
time to completely read the entire procedure, including any
special instructions, before starting any work.
NOTICE
The descriptions and specifications included in this manual were in effect at the time of printing. Clark
reserves the right to discontinue models at any time, or make improvements and changes in specifications
or design without notice and without incurring obligation. Specifications, torques, pressures,
measurements, adjustments, illustrations and other items may change at any time. Contact your
authorized CLARK dealer for information on possible updates or revisions.
SM 596, Aug ‘95 Foreword l i

5. CLllRK CONTENTS
CONTENTS
Group SA - Safe Maintenance
Group PS - Periodic Service
Group 12 - Battery
Group 13 - Electrical Control Handle
Group 16 - Electrical Motors
Group 17 - Electrical Schematics
Group 19 - Electrical Controls
Group 20 - Drive Axle
Group 22 - Wheels and Tires
Group 23 - Brake System
Group 25 - Steering Gear
Group 26 - Steering Axle
Group 29 - Hydraulic Pump, Sump and Filters
Group 30 - Hydraulic Control Valves
Group 31- Hydraulic Supply System
Group 32 - Cylinders
Group 33 - Selector Solenoid Valve
Group 34 - Upright
Group 40 - Specifications
SM 596, Aug ‘95 Contents-l

6. CONTENTS CIRRU
ESM-II Pictorial Contents
lectrical Control Valve
Pressure Swi
Group PS - Periodic Service
Group 12 - Battery
Group 13 - Electrical Control Handle
Group 16 - Electrical Motors
Group 17 - Electrical Schematics
Group 19 - Electrical Controls
Contents-2 SM 596, Aug ‘95

7. ClRRK- CONTENTS
Group 20 - Drive Axle
Group 22 -Wheels and Tires
Group 23 - Brake System
Group 25 - Steering Gear
Group 26 - Steering Axle
Electrical Contr Contactor Panel
Control
Handle
I Horn
scillator Card
Solenoid Function Control Card
Group 26 ’
Steering Axle
Wheels and Tires
SM 596, Aug ‘95 Contents-3

8. CONTENTS CIRRK
Group 29 - Hydraulic Pump,
Sump and Filters
Group 30 - Hydraulic Control
Valves
Group 31 - Hydraulic Supply
System
Group 32 - Cylinders
Group 33 - Selector Solenoid
Valve
Group 34 - Upright
Group 40 - Specifications
- Group34
Upright and Lift Cylinders
Contents-4 SM 596, Aug ‘95

9. Group 20, Drive Axle ElMIt
General Description
The drive axle consists of right hand and left hand axle end
assemblies. The two axle ends are fastened together to form
the drive axle assembly. Each axle end half contains a ring
gear and pinion and final drive gearing. The drive motors
are mounted directly to the axle ends.
Service Notes
The drive axle contains metric fasteners. Use only metric
tools to service unit.
Service instructions refer to one axle end, unless otherwise
noted
Drive Axle Maintenance
When troubleshooting a drive axle problem, it should be
kept in mind that the drive axle is only one main component
in a group of related powertrain components.
Proper operation of drive axle depends on condition and
correct function of other components of group. It is neces-
sary to consider transmission fluid, drive motors and con-
nections to properly diagnose and repair a problem.
Fluid Level Check
Check fluid level. It must be at correct level.
l Check fluid level by removing dipstick on the right
hand axle end. Wipe dipstick clean and reinstall.
l Remove dipstick and examine. Fluid level should be
between the two marks on dipstick. If fluid level is
low, add enough fluid to bring level up to full mark on
dipstick. DO NOT OVERFILL.
l Refer to Croup 40 Specifications, for recommended
transmission fluid specification.
Fluid Change Procedure
IMPORTANT
Drain drive axle when fluid is at operating
temperature.
A WARNING
Make certain blocks are secure and installed
under carriage so that carriage can not fall.
Raise upright carriage only to height that will permit
access to plugs on axle. Block carriage. Refer to
Croup SA, Lifting, Jacking, and Blocking.
Turn key switch OFF. Disconnect battery.
Place a low flat drain pan under drive axle. Pan should
have a capacity of more than 6.5 L (6.8 qt).
Remove dipstick cap. Remove drain plug from each
axle end and allow fluid to drain. While fluid is drain-
ing, check condition of vent in dipstick cap. Replace
dipstick cap if vent is damaged or plugged.
Install drain plugs.
Fill drive axle to proper level with specified fluid
through dipstick hole. DO NOT OVERFILL.
Connect battery, remove blocking and lower carriage.
- Combination
Fill Plug and
Drain Pan +
20-l-2 l Drive Axle SM 596, Aug ‘95

10. CLMK Group 20, Drive Axle
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Drive Axle Removal 13.
Park truck on hard, level surface.
Lower upright.
Remove forks.
Turn key switch OFF and disconnect battery.
Remove battery.
Block steer wheels front and rear.
Lift truck with ajack andput blocks under each side of
frame just behind drive wheels. Refer to truck jacking
in Group SA, Section 2, for details.
14.
A WARNING
Make sure blocks are secure and placed so
that there is clearance to remove axle
without interfering with blocking or truck.
Remove two front and top compartment covers.
Remove drive wheels.
Put a drip pan under drive axle to catch any fluid.
Remove upright. Refer to Group 34 Uprights, for
details.
Disconnect hydraulic brake lines.
15.
16.
17.
18.
Identifyanddisconnectmotorpowercables.Tiecables
out of way to avoid damage.
A WARNING
Use only approved hoist, chains and straps
to lift the drive axle and motors. Be sure
hoist and accessories have correct capacity
to safely support the load.
Put lift straps on drive motors andhook straps to chain
hoist. Remove slack from hoist chain to stablize drive
axle assembly.
/ ! CAUTION
To avoid injury, remove all the axle fasteners
in the order listed.
Remove axle rear mounting fasteners (items 90.358,
94.085 and 20.377) from each side of frame.
Remove axle front mounting fasteners (items 90.358,
94.085 and20.377) fromeach side of frame. Rockaxle
until axle is free of alignment pins.
Lower axle to floor and remove it from under truck.
Store axle in a safe manner.
If drive motors are to be removed, refer to Motors
Group 16 for details.
- 20.377
- 94.085
- 20.379
& - 94.085
Alignment Pin”
* Apply General Purpose Threadlocker *go-35
(Clark Part No. 1802300) to nut
threads prior to assembly.
* Alignment Pins:
When removing drive axle,
rock axle until free of the
alignment pins.
SM 596, Aug ‘95 Drive Axle l 20-l-3

11. Group 20, Drive Axle CMRK
Drive Axle Special Tools
Special Socket
/
1’ /-.
,‘A
/ j
I
‘$1 “J+
I& I
J
<
<,I
+’
I I
I
l,_-/’
_A’
‘. ._
20-l-4 l Drive Axle SM 596, Aug ‘95

12. C1cIRK Group 20, Drive Axle
Special Socket
71mm
t- (2-3/4”) 1 75.5mm ,
-.
__ --- -- -- -
xmlrrl
- (3-3/4”)
-I (2-7/8”) :
--J
VOO24C BB
SM 596, Aug ‘95 Drive Axle l 20-l-5

13. Group 20, Drive Axle ClMtU
Special Socket
QQ
t
31.5mm
(1 -l/4”)
f
19.5mm
(314”
(I-l 5/l 6”)
VOO24C CC
20-I -6 l Drive Axle SM 596, Aug ‘95

14. CUIRK Group 20, Drive Axle
Pinion RetainerTool
Application
A
50mm
(l-15/16”)
I
A-
20mm
@l/64”)
I
20mm_
20mm
d31/64”)
.
(&Eyp] (31/64’?+,
--_--_--_--_
t
L20mm
(31”64”)
SM 596, Aug ‘95 Drive Axle l 20-l-7

15. Group 20, Drive Axle ClMK
Drive Axle Disassembly
Disassemble drive axle only on a work table strong enough
to support the weight of the axle. Drain drive axle fluid, if
has not been done previously.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Block axle to stablilize it on the work surface.
Clean exterior of axle before beginning disassembly.
Remove drive motors, if they have not been removed
previously. Refer to Croup 16,Motor for details.
Examine entire assembly for damage. Note if there is
any evidence of cracks or broken parts.
Remove housing flange cap screws (items 20.227 and
20.228), refer to illustrations on next two pages.
With a drift pin and hammer, drive out housing flange
roll pins (item 90.663).
NOTE
Sealant was applied to the axle end
housing flanges at assembly. Force
may be required to separate the two
housings.
Separate the two axle end assemblies.
Remove the motor mounting flange cap screws (item
20.239).
t720.239 -
I
Use two mounting flange cap screws (item 20.239) to
remove motor mounting flange from axle housing.
Thread cap screws into tapped holes “A” in motor
mounting flange. Turn cap screws alternately into
tapped holes until mounting flange is extracted from
axle housing.
With special tool, remove pinion shaft lock nut (item
20.819).
11.
12.
13.
14.
15.
16.
17.
18.
19.
NOTE
In order to remove item 20.819, it
will be necessary to fabricate a tool
to keep the output shaft (item20.586)
from turning. Refer to Drive Axle
Special Tools.
Use a soft hammer to drive the pinion from the motor
mountingflange.Theupperbearingcone(item20.230)
willcome off thepinion shaft in theprocess. Clean and
inspect bearing for wear or damage. Replace as re-
quired. Bearing cone and cup should be replaced as a
set.
Remove backing washers (items 20.238 and 20.240)
and spacer (item 20.288). Press lower pinion bearing
cone (item 20.252) from pinion (item 20.248).
Draw pinion bearing cups (items 20.316 and 20.649)
from the motor mounting flange.
Loosen bevel gear nut (item 20.835), using fabricated
tool to keep output shaft (item 20.586) from turning.
Refer to previous pages.
Remove locking cap screw (item 95.782).
With special tool, remove output shaft nut (item
20.565). Use fabricated tool to keep output shaft (item
20.586) from turning.
Remove housing cover cap screws (item 20.546).
L 20.546
Use two housing cover cap screws (item 20.546) to
remove housing cover from axle housing. Install cap
screws into tapped holes “B” in housing cover (shown
above). Turn cap screws alternately into tapped holes
until housing cover is extracted from axle housing.
After the housing cover assembly is off, reach into the
axle end housing and remove loose inner bearing cone
(item 20.553)
With special tool, remove output shaft nut (item
20.520). Use fabricated tool to keep output shaft from
turning. Slide output gear (item 20.522) off shaft (item
20.586).
20-l-8 l Drive Axle SM 596, Aug ‘95

16. CUIRK Group 20, Drive Axle
20.586
DRIVE AXLE - RH
REV FEB 91
20-420
20.376 Axle Assembly, Drive RH
20.201 Shim, Differential Pinion Bearing Carrier
20.212 Seal, Differential Pinion Bearing Carrier
20.227 Fastener, Thick Flange to Axle Housing
20.228 Fastener, Thin Flange to Axle Housing
20.230 Cone, Differential Pinion Bearing
20.236 Carrier, Differential Pinion Bearing
20.238 Shim Kit, Differential Pinion Bearing Cage
20.239 Fastener, Differential Pinion Bearing Carrier
20.240 Spacer, Differential Pinion Bearing
20.248 Ring and Pinion Set, Differential
20.252 Cone, Differential Pinion Inner Bearing
20.288 Spacer, Pinion Bearing Cone
20.316 Cup, Differential Pinion Outboard Bearing
20.387 Housing, Drive Axle-RH
20.427 Plug, Drive Axle Drain
20.520 Retainer, Drive Axle Shaft Gear
20.522 Gear, Drive Axle Shaft
20.524 Bearing, Drive Axle Ring Gear Shaft
20.539 Housing, Drive Axle End-RH
20.542 Bearing, Drive Axle Shaft-Outer
20.544
20.546
20.553
20.565
20.579
20.586
20.636
20.638
20.646
20.647
20.649
20.666
20.667
20.668
20.819
20.835
20.837
22.270
90.663
95.782
Seal, Drive Axle Shaft
Fastener, Drive Axle End Housing
Cone, Drive Axle Shaft Inboard Bearing
Retainer, Drive Axle Shaft Bearing
Cup, Drive Axle Shaft inboard Bearing
Shaft, Drive Axle
Shaft, Drive Axle Ring Gear
Cone, Ring Gear Shaft Outboard Bearing
Cup, Ring Gear Shaft Inboard Bearing
Locator, Drive Axle Shaft Inboard Bearing
Cup, Differential Pinion Inboard Bearing
Spacer, Drive Axle Ring Gear Shaft Inboard Brg
Spacer, Drive Axle Ring Gear Shaft
Spacer, Drive Axle Shaft Inboard Bearing
Nut, Drive Axle Pinion Shaft Lock
Retainer, Drive Axle Ring Gear
Cup, Ring Gear Shaft Outboard Bearing
Seal, Drive Axle End Housing
Dowel Ring, Axle Housing Fastener
Fastener, Drive Axle Shaft Bearing Retainer
SM 596, Aug ‘95 Drive Axle l 20-I-9

17. Group 20, Drive Axle Cu1RU
20.239
20.246
20.635
,
7
20.669
i20.666
nne?,l
20.649 -
90.663-!l -20.636
20.427
REV FEB 91
20-421
20.248 7
L 20.370
20.566
DRIVE AXLE - LH
20.370 Axle Assembly, Drive LH 20.546
20.201 Shim, Differential Pinion Bearing Carrier 20.553
20.212 Seal, Differential Pinion Bearing Carrier 20.565
20.227 Fastener, Thick Flange to Axle Housing 20.579
20.228 Fastener, Thin Flange to Axle Housing 20.586
20.230 Cone, Differential Pinion Bearing 20.627
20.238 Shim Kit, Differential Pinion Bearing Cage 20.636
20.239 Fastener, Differential Pinion Bearing Carrier 20.638
20.240 Spacer, Differential Pinion Bearing 20.646
20.248 Ring and Pinion Set, Differential 20.647
20.252 Cone, Differential Pinion Inner Bearing 20.649
20.288 Spacer, Pinion Bearing Cone 20.666
20.316 Cup, Differential Pinion Outboard Bearing 20.667
20.388 Housing, Drive Axle-LH 20.668
20.427 Plug, Drive Axle Drain 20.669
20.520 Retainer, Drive Axle Shaft Gear 20.819
20.522 Gear, Drive Axle Shaft 20.835
20.524 Bearing, Drive Axle Ring Gear Shaft 20.837
20.540 Housing, Drive Axle End-LH 22.270
20.542 Bearing, Drive Axle Shaft-Outer 90.663
20.544 Seal, Drive Axle Shaft 95.782
Fastener, Drive Axle End Housing
Cone, Drive Axle Shaft Inboard Bearing
Retainer, Drive Axle Shaft Bearing
Cup, Drive Axle Shaft Inboard Bearing
Shaft, Drive Axle
Vent, Differential and Axle
Shaft, Drive Axle Ring Gear
Cone, Ring Gear Shaft Outboard Bearing
Cup, Ring Gear Shaft Inboard Bearing
Locator, Drive Axle Shaft Inboard Bearing
Cup, Differential Pinion Inboard Bearing
Spacer, Drive Axle Ring Gear Shaft Inboard Brg
Spacer, Drive Axle Ring Gear Shaft
Spacer, Drive Axle Shaft Inboard Bearing
Carrier, Differential Pinion Bearing
Nut, Drive Axle Pinion Shaft Lock
Retainer, Drive Axle Ring Gear
Cup, Ring Gear Shaft Outboard Bearing
Seal, Drive Axle End Housing
Dowel Ring, Axle Housing Fastener
Fastener, Drive Axle Shaft Bearing Retainer
20-l-10 l Drive Axle SM 596, Aug ‘95

18. CII1RK Group 20, Drive Axle
20.
21.
22.
23.
24.
25.
26.
27.
28.
Remove the output shaft (item 20.586) from housing
cover.
Press outer bearing cone (item20.542) off output shaft
(item 20.586). Clean and inspect bearing for wear or
damage. Replace as required. Bearing cone and cup
should be replaced as a set.
Remove oil seal (item 20.544) and outer bearing cup
(item 20.542) from housing cover (item 20.539).
Remove snapring andback-up ring (items20.647 and
20.668) from housing cover (item 20.539).
Pull inner bearing cup (item 20.579) out of drive axle
housing (item 20.388 or 20.387).
Remove and discard bevel gear nut (item 20.835).
Remove bevel gear and spacer (items 20.248 and
20.666) from output gear pinion (item 20.636).
From inside the drive axle housing, use a soft hammer
to remove the output gear pinion (item 20.636) out of
the housing (item 20.388 or 20.387). Remove loose
inner bearing cone (item 20.524) from housing. Re
move bearing cup (20.646)using apuller if necessary.
Clean andinspect bearing for wear ordamage. Replace
as required. Bearing cone and cup should be replaced
as a set.
Remove spacer (item20.667) from output gear pinion.
Press outer bearing cone (item20.638) off output gear
pinion (item 20.636). Remove outer bearing cup
(20.837) using a puller if necessary. Clean and inspect
bearing for wear or damage. Replace as required.
Bearing cone and cup should be replaced as a set.
Drive Axle Assembly
Assembly Notes
IMPORTANT
CLEANLINESS! Perform procedures in a
clean environment. Make sure all parts are
cleaned before disassembly and kept clean
during assembly.
Clean all parts with a good grade of solvent and dry
thoroughly. DO NOT let bearings spin if drying parts
with compressed air.
Remove all PermatexTM and General Purpose
Threadlocker residue from threads and machined sur-
faces.
Inspect allcomponents for wear or damage. Replace as
required.
Replace all oil seals and O-rings.
5.
6.
7.
Use PermatexTMand General Purpose Threadlocker
(Clark PartNo. 1802300) only where specified. Spray
threads of fasteners with Primer “T” 5 minutes before
applying Threadlocker.
All lead-in chamfers for oil seals and O-rings must be
smooth and free from burrs. Inspect at assembly.
Correct as necessary.
Coat all bearings with transmission fluid before in-
stalling.
Assembly
1.
2.
Install pinion bearing cups (items 20.837 and 20.646)
into drive axle housing (item 20.388 or 20.387).
Press outer bearing cone (item 20.638) onto output
gear pinion (item 20.636).
3. Slide spacer (item 20.667) onto output gear pinion
(item 20.636). Install pinion into drive axle housing
(item 20.388 or 20.387).
4.
5.
6.
Install inner bearing cone (item 20.524) onto pinion
(item 20.636). Install spacer (item 20.666), and bevel
gear (item 20.248), Apply Threadlocker (Clark Part
No. 1802300) to a new bevel gear nut (item 20.835)
and install. Tighten bevel gear nut to give a rolling
torque of 0.7 Nom (6.2 lb-in.) on the pinion bearing.
Install pinion bearing cups (items 20.316 and 20.649)
into motor mounting flange (item 20.236).
Press inner bearing cone (item 20.252) onto pinion
(item 20.248) and insert pinion into motor mounting
flange (item 20.236).
7.
8.
Slide backing washer (item 20.240), spacer (item
20.288), backing washer (item 20.238), and outer
bearing cone (item 20.230) onto pinion (item20.248).
Apply Threadlocker (Clark Part No. 1802300) to pin-
ion shaft lock nut (item 20.819) and install on pinion.
Tighten nut to give arolling torque of 0.5 N*m (4.4 lb-
in.) on the pinion bearing. Use special tool to torque
nut.
9. Check motor pinion and bevel gear mesh adjustment.
NOTE
Mesh adjustment is made with
motor mounting flange shims (item
20.201) and bevel gear spacer (item
20.666). Mark teeth of motor pinion
and bevel gear with gear checking
compound. Compare gears with
chart on following pages.
l Install flange and pinion assembly into axle end hous-
ing (item 20.388 or 20.387), using shim (item 20.201)
to align assembly with housing. Install and tighten
only two flange cap screws (item 20.239).
SM 596, Aug ‘95 Drive Axle l 20-l-l 1

19. Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.

20. Group 20, Drive Axle Emu
Tooth Bearing Contact Chart
Move Pinion AWAY from Gear in this direction
rofile
Convex Side
Pinion
Spiral Bevel and Hypoid Tooth
Ring Gear
Bearing Contact Patterns
see following page for
adjustments
Check Ring and Pinion Tooth Contact
l Paint ring gear teeth with thin coating of a mixture of
red lead and linseed oil. Rotate pinion shaft to cause
one full revolution of ring gear. Check tooth pattern
on ring gear and pinion to determine if proper pinion-
to-ring gear tooth engagement exists.
l Toe contact on both sides of gear tooth. To move
contact toward the heel, increase backlash within lim-
its by moving the gear away from pinion.
Contact Pattern 1
l Preferred Bearing Pattern on pinion and both sides
of gear tooth while under a light load.
Contact Pattern 2
Gear Set Noisy
1Pinion Pattern 1
20-l-12 l Drive Axle SM 596, Aug ‘95

21. CMRK Group 20, Drive Axle
l Heel contact on both sides of gear tooth. To move
contact toward the toe, decrease backlash within lim-
Ring Gear
Pattern
its by moving the gear toward pinion.
Move Gear TOWARD
the Pinion.
Contact Pattern 3
Gear Set Noisy
Could result in early gear
failure.
l Low contact on Gear and High contact on Pinion Contact Pattern 4
Correct by moving pinion away from gear. (Increase
mounting distance).
Move Pinion AWAY
from Gear.
+
Move Pinion INWARD
Gear
(
+
l High contact on Gear and Low contact on Pinion.
Contact Pattern 5
Correct by moving pinion in toward gear. (Decrease
mounting distance.)
SM 596, Aug ‘95 Drive Axle l 20-l-13

22. Group 20, Drive Axle ClRRK
.
10.
11.
12.
13.
14.
15.
16.
NOTE 17.
Do not install O-ring (item 20.212)
at this time.
Rotate the pinion several times in a clockwise or
counterclockwise direction and check against the tooth
bearing contact chart on previous pages. Pinion gear
backlash should be 0.198-0.102 mm (0.0078-
0.0040 in).
18.
Adjust pinion by changing thenumber of flange shims
(item 20.201). The bevel gear is adjusted by grinding
the gear spacer (item20.666) to the thickness required.
Use a surface grinder to remove material from the gear
spacer.
When gear mesh adjustment is correct, remove two
cap screws and flange and pinion assembly. Coat O-
ring (item 20.212) with transmission fluid and install.
ApplyGeneralPurposeThreadlocker(Clark#l8023OO)
to allflangecap screws (item20.239) andinstall flange
and pinion assembly. Torque cap screws to 67 Nom
(49.5 lb-ft).
19.
1.
Lock the bevel gear nut (item 20.835) by crimping the
nut into the groove in the end of pinion shaft (item
20.636).
Install inner bearing cup (item 20.579), backing ring
(20.668), and snap ring (item 20.647) into axle end
housing (item 20.388 or 20.387).
Install outer bearing cup and cone (item 20.542) into
output shaft housing (item 20.539 or 20.540). Apply
a thin coating of grease between the lips of oil seal
(item 20.544). Apply a thin layer of PermetexTM#K2to
the outside diameter of oil seal and install.
2.
Insert output shaft (item 20.586) through housing
(item 20.539 or 20.540). Do not damage oil seal (item
20.544) with splines of output shaft. Slide output gear
(item 20.522) onto shaft. Apply General Purpose
Threadlocker to nut (item 20.520) and install. Torque
nut with special tool to 200 N*m (147.5 lb-ft). Use
fabricated tool on page 20-l-7 to keep output shaft
from turning.
3.
4.
Apply a thin layer of PermetexTM#2 to machined
surface of housing cover (item 20.539 or 20.540).
Apply General Purpose Threadlocker to cap screws
(item 20.546) and install housing cover to axle end
housing (item 20.388 or 20.387). Torque cap screws
to 67 Nom (49.5 lb-ft).
5.
6.
Slide bearing cone (item 20.553) onto output gear
shaft. Apply General Purpose Threadlocker to nut
(item20.565). Install nut and torque to 68 N*m
(50.2 lb-ft) with special tool. Apply General Purpose
Threadlockerto locking screw (item 95.782).Locknut
(item 20.565) with screw. Torque screw to 13 N*m
(9.6 lb-ft).
Apply a thin layer of PermetexTM#2 to machined
surface of axle end housing flanges. Mate the two axle
end housings together and drive in roll pins (item
90.663). Apply General Purpose Threadlocker (Clark
#1802300) to cap screws (item 20.227 and 20.228)
and fasten axle end housings together. Torque
capscrews to 67 Nom (49.5 lb-ft).
Install drive motors. Refer to Group 16, Section 2.
Drive Axle Installation
Make sure truck is blocked in a secure manner and that
there is clearance tomove axle inplace fromunderside
of truck without disturbing blocking.
A WARNING
Use only approved hoist, chains and straps
to lift the drive axle and motors. Be sure
hoist and accessories have correct capacity
to safely support the load.
Put hoist straps on drive motors and hook straps to
chain hoist.
Position axle under truck with chain hoist.
Align drive axle slots with axle mounting alignment
pins, see next illustration.
n ! CAUTION
To avoid injury, install all the axle mounting
bolts in the order indicated.
Secure axle assembly to frame by first installing front
two fasteners on each side of frame.
Installreartwofastenersoneachsideofframe.Tighten
all nuts snug, then torque nuts to 408469 N*m
(301-339 lb-ft).
20-l-14 l Drive Axle SM 596, Aug ‘95