1. FF-650 Repair Procedure—CMP 30 Frame Reason for Repair—CMP 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 Required—Portable 5 or 6 in. Grinder, Oxy-Acetylene Cutting Torch, 1 1/8 in. or 30 mm. ¾ Drive Socket—Extension—Breaker Arm, Jack Stands, Wire Brush, Duct Tape, and Clark Green paint. Method—The 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 Procedure—CMP 30 Frame Specific Tasks 1.Remove the counterweight, keeping track of the number of shims used to mount the counterweight on each side. 2.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. 3.Remove steer tires. 4.Cover Steer cylinder and piston rod to prevent sparks and torch drippings from damaging the piston rod and seals

3. FF-650 Repair Procedure—CMP 30 Frame Specific Tasks 5.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 Procedure—CMP 30 Frame Specific Tasks 6.If the frame is cracked, grind out the crack approximately.18 in deep to prepare for rewelding the crack.

5. FF-650 Repair Procedure—CMP 30 Frame Specific Tasks 11.Using the torch, remove the welds holding the Shim retainer plate, remove and discard this plate.

6. FF-650 Repair Procedure—CMP 30 Frame Specific Tasks 12.Grind clearance on the Support Plates to clear welds at top of sideframe. 13.Grind as necessary to get a close fit between the tank, rear frame plate, top of frame, and counterweight block. 14.Place reinforcing plate in position and mark weld areas and grind off paint.

7. FF-650 Repair Procedure—CMP 30 Frame Specific Tasks 15.Grind off paint on top of frame near weld areas. 16.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. 17.Tack 2827410 in position on the side at the open space on the side of the reinforcing plate.

8. FF-650 Repair Procedure—CMP 30 Frame Specific Tasks 18.If there is a crack at the top of the side Filler Plate 2827410, fill this with a small pass weld. 19.Finish weld on the underside of the reinforcing plate. 20.Finish weld the top surfaces and all around the counterweight mounting plate

9. FF-650 Repair Procedure—CMP 30 Frame Specific Tasks 21.Wire brush, remove weld spatter, and clean weld area with solvent to prepare for painting. 22.Repeat the same welding process on the opposite side. 23.Paint welded areas while masking (hold up some cardboard) with to prevent overspray on radiator, etc. 24.Reconnect SECM and Neutral Shift Controller 25.Install counterweight. Use Duct Tape to secure counterweight shims 26.Torque counterweight bolts to 338-375 N.m 249-277 ft-lbs.