FF-650 Repair Procedure

1
FF-650 Repair ProcedureCMP 30 Frame

• Reason for RepairCMP 30 models with Serial
  Numbers in the range of 2453 through 3354 in Lot
  9587, 0008 through 0120 in Lot 9773, and 0787
  through 0822 in Lot 9586 have frames welded with
  a reinforcing gusset missing in the area where
  the rear frame assembly attaches to the top
  surface of the side frame. In applications
  operating in uneven terrain or rough ground
  conditions an early failure can cause rear corner
  of the side frame to break. Continued operation
  can result in leaks in the hydraulic and fuel
  tanks.
• These frames must be repaired at the earliest
  opportunity whether they have failed or not to
  prevent tank leaks. The following procedure will
  ensure that the frames can be restored to the
  original design integrity and provide the long
  service life expected from Clark products.
• Tools RequiredPortable 5 or 6 in. Grinder,
  Oxy-Acetylene Cutting Torch, 1 1/8 in. or 30 mm.
  ¾ Drive SocketExtensionBreaker Arm, Jack
  Stands, Wire Brush, Duct Tape, and Clark Green
  paint.
• MethodThe general task will be to remove the
  counterweight and steer tires to gain access to
  the area and weld in reinforcing plates. Trucks
  will need to be moved to a location with a hoist
  to remove the counter weight and access to the
  tools required. The parts required for each
  truck, one each of 8063039 and 8036040 LH and RH
  Side Frame Support and two of 2827410 Filler
  will be shipped to you free of charge.

2
FF-650 Repair ProcedureCMP 30 Frame

• Specific Tasks
• Remove the counterweight, keeping track of the
  number of shims used to mount the counterweight
  on each side.
• Jack the rear of the truck up and chock the drive
  tires securely to prevent the truck from rolling.
  Use the Jack Stands or other appropriate blocking
  under the steer axle to raise the truck, then
  remove the jack. If the frame is cracked, this
  will push the cracked area back together.
• Remove steer tires.
• Cover Steer cylinder and piston rod to prevent
  sparks and torch drippings from damaging the
  piston rod and seals

3
FF-650 Repair ProcedureCMP 30 Frame

• Specific Tasks
• Disconnect the SECM and Neutral Shift Controller
  to protect them from voltage spikes from welding
  cover the SECM the connector socket with Duct
  Tape.

4
FF-650 Repair ProcedureCMP 30 Frame

• Specific Tasks
• If the frame is cracked, grind out the crack
  approximately .18 in deep to prepare for
  rewelding the crack.

5
FF-650 Repair ProcedureCMP 30 Frame

• Specific Tasks
• Using the torch, remove the welds holding the
  Shim retainer plate, remove and discard this
  plate.

6
FF-650 Repair ProcedureCMP 30 Frame

• Specific Tasks
• Grind clearance on the Support Plates to clear
  welds at top of sideframe.
• Grind as necessary to get a close fit between the
  tank, rear frame plate, top of frame, and
  counterweight block.
• Place reinforcing plate in position and mark weld
  areas and grind off paint.

7
FF-650 Repair ProcedureCMP 30 Frame

• Specific Tasks
• Grind off paint on top of frame near weld areas.
• Tack 8036039 Reinforcing plate in position,
  making sure that the plate is tight against the
  underside of the counterweight mounting plate and
  against the back of the tank.
• Tack 2827410 in position on the side at the open
  space on the side of the reinforcing plate.

8
FF-650 Repair ProcedureCMP 30 Frame

• Specific Tasks
• If there is a crack at the top of the side Filler
  Plate 2827410, fill this with a small pass weld.
• Finish weld on the underside of the reinforcing
  plate.
• Finish weld the top surfaces and all around the
  counterweight mounting plate

9
FF-650 Repair ProcedureCMP 30 Frame

• Specific Tasks
• Wire brush, remove weld spatter, and clean weld
  area with solvent to prepare for painting.
• Repeat the same welding process on the opposite
  side.
• Paint welded areas while masking (hold up some
  cardboard) with to prevent overspray on radiator,
  etc.
• Reconnect SECM and Neutral Shift Controller
• Install counterweight. Use Duct Tape to secure
  counterweight shims
• Torque counterweight bolts to 338-375 N.m 249-277
  ft-lbs.