CLARK FORKLIFT E235 EV-1 PMA436 Planned Maintenance and Adjustment Manual

Planned Maintenance & Adjustment Procedures

PMA 436 E235 EV 1

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333 West Vine Street Lexington ' KY 40507-1640

INDUSTRIAL TRUCK DIVISION

MARKETING TRAINING DEPT

Page Page Page Page Page

GROUP NO. 01 12 13 13 13 13 16

16 19 19 19 19 20 20 22 23 23 23 25 25 26 29 30 32 32 34 34

34 34

34

34 34

SECTION NO. 6 7 25 26 27 28 27

4 36 37 38 40 5 8 7 19 20 21 10 11

12 7 7 2 6

1 2 3 5 6 7

40

10 11 2 3

40

4

34

40

40

40 40 40

Page i

1 2-5 6 7 8-67

11 12 17 18

ILLUSTRATION OF MACHINE PICTORIAL INDEX IMPORTANT LISTING OF CAUTIONS FOR SCR TRUCKS FOREWORD - PLANNED MAINTENANCE SECTION PLANNED MAINTENANCE PROCEDURES DESCRIPTION

LUBRICATION CHARTS & COLD STORAGE LUB. CHARTS ELECTRIC TRUCK BATTERY SERVICE PROCEDURES PUMP MOTOR OPERATING SWITCH ADJUST PROCEDURES SCR CONTROL (ACCELERATOR LINKAGE, IMS & 2MS) ELECTRIC DRIVE MOTOR (BRAKE) CUT-OFF SWITCH ELECTRIC DRIVE MOTOR (SEAT BRAKE) CUT-OFF SWITCH ELECTRIC MOTOR MAINTENANCE and GEA-7053 COMMUTATOR (MULTI-COLOR) CHECK CHART ELECTRIC DRIVE MOTOR BRUSH REMOVE/REPLACE EV-1 COMPONENT IDENTIFICATION CHECKING EV-1 SCR COMPONENTS TROUBLE SHOOTING EV-1 INITIAL ADJUSTMENT PROCEDURES DRIVE UNIT LUBRICATION AXLE ENDS - LUBRICATION INSTRUCTIONS WHEELS & TIRES - SOLID OR CUSHION TIRE & RIM SERVICE BRAKES-PEDAL FREE TRAVEL-MASTER CYL. BLEEDING THE BRAKE SYSTEM SEAT BRAKE & LINKAGE CHECK & ADJUST PROCEDURES STEER LINKAGE CHECK & ADJUST. PROCEDURES (LOT 4315-4860) STEER LINKAGE CHECK & ADJUST. PROCEDURES (LOT 5040 & Above) STEER WHEEL BEARINGS, CLEAN/REPACK/ADJUST HYDRAULIC SUMP TANK & FILTER SERVICE PROCEDURES HYDRAULIC SYSTEM PRESSURE CHECKS TILT CYLINDER DRIFT TEST TILT CYLINDER CHECK & ADJUST PROCEDURES 4 & 6 ROLLER CARRIAGE CHECK & ADJUSTMENTS UPRIGHT ROLLER CHECK & ADJUST/STD & HI-LO UPRIGHT LIFT CHAIN CHECK & ADJUST PROCEDURES BLEEDING COMPOUND LIFT CYLINDERS CHECKING UPRIGHT DOWNDRIFT LIFT CHAIN MAINTENANCE TSU OPERATION CHECKS & CARRIAGE ADJUSTMENTS TSU ROLLER ADJUSTMENT PROCEDURES SUGGESTED EQUIPMENT FOR ELECTRIC TRUCK P.M. PM-INSPECTION & DRIVERS DAILY INSPECTION FORMS FIRE EXTINGUISHER RECOMMENDATIONS LUB. SPECIFICATIONS & RECOMMENDATIONS LUBRICATION CHART KEY TRUCK SPECIFICATIONS DECALS, NAME PLATES/UPRIGHT DECK & SERIAL NOS. MEASURING VOLTAGES WITH VOLT-OHM METER MEASURING RESISTANCE WITH VOLT-OHM METER

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Code: PM-436, REV APR 84

PM

OWNER SAFE

MAINTENANCE

Powered industrial trucks may become haz­ ardous if adequate maintenance is not done. Therefore, suitable maintenance facilities, personnel, and procedures must be provided.

5. Before Leaving The Truck: 1) Stop truck.

2} Fully lower the load engaging means.

Maintenance and inspection of all powered industrial trucks should be done in agreement with the recommendations in this manual and the following practices:

3) Put directional control in neutral.

4) Apply the parking brake.

5) Stop the engine or turn off power.

1. A scheduled preventive maintenance, lubrication, and inspection program must be followed.

2. Only qualified and authorized personnel should be permitted to maintain, repair, adjust, and inspect industrial trucks.

3. Operation to check performance of the truck or attachments must be done in an authorized, safe, clear area.

PRACTICES

6) Lock the control or ignition circuit.

7) Put blocks at the wheels if truck is on a ramp, or being worked on.

6. Before Working On Truck: 1) Raise wheels free of floor or disconnect power source.

2) Use blocks or other positive truck positioning devices.

4. Before Starting To Drive The Truck: 1) Be in operating position.

3) Put blocks under the load engaging means, innermast(s), or chassis before working under them.

2) Push clutch (or brake pedal on

automatic transmission and electric trucks).

4) Start engine or turn on power.

7. Before working on engine fuel system of gasoline powered trucks with gravity-feed fuel systems, be sure fuel shutoff valve is closed.

5) Before operating truck, check functioning of lift and tilt systems, directional and speed controls, steering, warning devices, brakes, and any attachments.

8. Before working on engine fuel system of LP-gas powered trucks, close LP-gas cylinder valve and run engine until there is no more fuel in the system and engine stops running.

3) Put directional control in neutral.

6) Release parking brake.

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OWNER SAFE MAINTENANCE PRACTICES 9. Avoid fire hazards and have fire protec­ tion equipment available. Do not use an open flame to check level or for leakage of fuel, electrolyte or coolant. Do not use open pans of fuel or flammable cleaning fluids for cleaning parts.

16. All hydraulic sytems must be regularly inspected and maintained in conformance with good practice. Tilt cylinders, valves, and other like parts must be checked to make sure that "drift" has not developed to the extent that it would create a hazard.

10.

Provide ventilation to the work area, vent exhaust fumes, and keep shop clean ;•.nd floor dry.

17. Capacity, operation and maintenance instruction plates, tags, or decals must be maintained in legible condition.

�andle LP-gas cylinders with care.

Do not drop, dent, or damage in any way.

18. Batteries, motors, controllers, limit switches, protective 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.

11.

12. Brakes, steering mechanisms, control mechanisms, warning devices, lights, governors. lift overload devices, guards and safety devices must be inspected regularly and maintained in a safe operating condition.

13. All parts of lift and tilt mechanisms and frame members must be carefully and regu­ larly inspected and maintained in a safe operating condition.

14. Special trucks or devices designed and approved for hazardous area operation must receive special attention to make sure that maintenance keeps the original, approved safe operating features.

Fuel systems must be checked for leaks and condition 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.

19. Industrial trucks must be kept in a clean condition to minimize fire hazards and help in the detection of loose or defective parts.

20. Modifications and additions which affect capacity and safe truck operation must not be done by the customer or user without the manufacturer's prior written approval. Capacity, operation and maintenance instruction plates, tags or decals must be changed accordingly.

21. Care must be taken to make sure that all replacement parts are interchangeable with the original parts and of a quality equal to that provided in the original equipment.

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MODELS EC20, EC25, ECS30 WITH EV-1 CONTROL

ILLUSTRATION OF MACHINE

Code: PM-436, JAN 80

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INDUSTRIAL TRUCK DIVISION MARKETING TRAINING DE.PT

Group

Section

1.

Pump Motor Operating SW'itch Check & Adjust Procedure

13

25

2.

Tilt Cylinder Drift Test

32

2

2.

Tilt Cylinder Check & Adjustment Procedures

32

6

3.

Hydraulic Sump Tank - Fill

29

7

4.

Hydraulic Sump Tank Filter Service Procedures

29

7

5.

Hydraulic Sump Tank Drain

29

7

6.

Electric Truck Battery Service Procedures Remove/Replace

12

7

7.

Hydraulic System Pressure Checks-Main Hydraulic Pump

30

7

7.

Hydraulic Lift & Tilt Circuits

30

7

16

27

Seat Brake & Linkage Check & Adjust Procedures

23

21

10.

EV-: Component Identification

19

36

10.

Checking EV-1 SCR Components

19

37

10.

EV-1 Initial Adjustment Procedures

19

40

11.

PMT/SRO - Trucks So Equipped

PM-Procedures

12.

Electric Drive Motor Brush - Remove/Replace

16

4

13.

Steering System Check & Adjust Procedures (Lot 4315 through Lot 4860)

25

10

13.

Steering System Check & Adjust Procedures (Lot 5040 and Above)

25

11

14.

Steering Wheel Bearings - Clean, Repack & Adjust

26

12

15.

Elec. Drive Motor (Seat Brake) Cut-Off SW'itch Adjust

13

28

16.

Elec. Drive Motor (Service Brake) Cut-Off Svitch Adjust

13

27

17.

SCR (Accelerator) Control, lMS, 2MS & Linkage Checks & Adjustments

13

26

8.

Electric Motor Maintenance and Commutator & 12. Check Chart 9.

Page 2

Cop)ri11h1«l Mn1e11al

lnwt<led forCL \RKduk,�only

IJo no111ell or di11nbu1e

Code: PM -436, REV FEB 83

CIARK

PM

PICTORIAL INDEX

Code•. PM- 4 36, JAN 80

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Page 3

INDUSTRIAL TRUCK DIVISION

MARKETING TRAINING DEPT.

Group 23

Section 19

19. Bleeding Brake System

23

20

22.

34

1

34

2

34

3

22. Upright - Bleeding Compound Lift Cylinders

34

5

22. Upright - Downdrift Test

34

6

22.

34

7

34

10

34

11

20

5

23

19

20

8

22

7

01 40

6 4

19. Brake Pedal Free Travel {Cylinder By-Pass Port)

22.

Upright - Std. & Hi-Lo Carriage Roller Check & Adjust Upright - Std. & Hi-Lo Roller Check & Adjust

22. Upright - Lift Chain Check & Adjust

Lift Chain Maintenance

22. Upright - FFL Triple Stage Operational Checks & Adjust, Carriage Chain Adjust, Racking & Load Testing, Lift Cylinder & Tilt Cylinder Drift Tests & Carriage Roller Check & Adjustment Procedures

22. Upright - FFL Triple Stage Roller Check & Adjust 23.

Drive Unit Service Procedures

24. Service Brakes 25. Axle End Service Procedures 26.

27.

Wheels & Tires

Lubrication Charts Lub. Chart Key - Lub. Specifications

SPECIFICATIONS AND REFERENCE DATA SAFETY INSTRUCTIONS for Industrial Trucks PM-Inspection & Drivers Daily Inspection Fonns Fire Extinguisher Recommendations EC500 E Truck Specifications Decals, Name Plates, Upright Deck Number & Serial Number Data <:11nncc:t-c,i ..J\,,l �:;:-J\,'--'""'

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Measuring Voltages with Volt-Ohm Meter (V-0-M) Measuring Resistance with Volt-Ohm Meter (V-0-M)

P.M. PROCEDURES - P.M. Check Sheet & Visual Inspection Operational Tests Cleaning, Inspection & Lubrication ELECTRICAL TESTS PERIODIC ELECTRICAL TESTS

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3

40 40

11 12

40

13 17 18

40 40 Page Page Page Page Page

8 17 16 45 55

Code: PM-436, REV APR 84

CL'IRK

PM

PICTORIAL INDEX

Code: PM-436, JAN SO

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Page 5

INDUSTRIAL TRUCK DIVISION SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK

IMPORTANT

THE. RJUOWlNG IS A LIIT OF 'CAlll10NS' CONNECTED WITH THE OPERATION AND MAINTENANCE OF TRUCKS EQUIPPED WITH. SOLID STATE CON7ROL

WELDING ON TRUCKS I. 2.

3.

Make sure truck has no grounds.

Disconnect truck bettcry.

Protect electrical wiring and components from weld splatter with shield.

If the ab9ve Is not followed ••• damage can result to wiring and elec­ trical components on a solid state controlled truck.

DO NOT STtAM CLEAN Do not steam clean a solid state controlled truck as excessive moisture will Interfere with proper operation of the solid state components.

CHECK POLARITY Battery Polarity must be correct or the truck will not operate.

USE THE TRUCK BATTERY ONLY Do not use a motor generator unit such as ready power to move and/or check this truck as serious damage may occur.

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CAUTION OISCOffNICT IIATTUIT IUOM HANOI.ING [UCTIIICAL COWOftlNTS IIO\..UUn 111\JST II COllll[CT TO -Vlll'T OAMAGe

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ONLY APPROVED SOLVENTS St-OULD BE USED TO CLEAN SCR COMPONENTS • • • USE CLARK #1801146 DEGREASER, 1 OR THE EQUIVALENT TO ••• I MS-180 FREON TF DEGREASER : AND CLEANER. I

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Code: PN-330, REV JUL 75