CLARK FORKLIFT OH-321 S203040 SP 202530 OVERHAUL MANUAL

OH-321 S20/30/40 SP 20/25/30

CUARK

Copyrighted Maleriol lnt�nded for CLARK deol�rs only Do nol sell or dis1ribu1c

Technical Pu�lications Lexington, KY 40508

INDUSTRIAL TRUCK DIVISION

MARKETING TRAINING DEPT.

FOREWORD Use of This Manual This manual contains information which will help a trained technician perform overhaul procedures on lift truck com­ ponents.

This manual is divided into groups which include the components of a lift truck system, The groups describe removal, inspection, bench overhaul, installation and testing procedures.

Read, understand and follow the pro­ cedures and safety messages found in this manual. Wear body protection and always use the correct tool for the

job. Follow the safety messages and work with safety in mind to avoid accidents and prevent personal injury.

Clark lift trucks are designed to rigid specifications with quality components.

However, through use, parts will even­ tually r·equire replacement or rebuild.

OSHA requires that all replacement parts meet original design, quality and safety requirements. Clark lift truck dealers can provide genuine Clark replacement parts which meet these specifications.

Please direct all inquiries.or comments regarding the content of this manual to: Clark Equipment Company Marketing Training & Communications Dept.

Maintenance Writing Group 525 North 24th Street Battle Creek, MI 49016

Code: OH-525, MAR 82

Cop}righted Mnte,inl Intended for CLARK denier.; only Do not sell or distribute

Page i

INDUSTRIAL TRUCK DIVISION MARKETING TRAINING DEPT.

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WARNING

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WARNING

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WARNING

SAFETY MESSAGES

SAFETY AND YOU

THE SAFETY ALERT SYMBOL IDENTIFIES IMPORTANT SAFETY MESSAGES IN TH IS MANUAL AND ON THE LIFT TRUCK. READ, UNDERSTAND AND FOLLOW ALL MESSAGES TO AVOID PERSONAL INJURY.

LIFT TRUCK MAINTENANCE

DO NOT WORK ON TH IS TRUCK UNLESS YOU ARE TRAINED AND AlITHORIZED AND KNOW THE CORRECT MAINTENANCE PROCEDURES.

BATTERY SERVICE

BATTERY SERVICE MUST BE DONE

BY TRAINED PERSONNEL. BATTERY ACID CAN CAUSE SEVERE BURNS AND INJURY.

Page ii

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WARNING

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WARNING

PERSONAL INJURY

WEAR EYE GLASSES, SAFETY SHOES ANO CORRECT FITTING CLOTHING �EN WORKING ON LIFT TRUCKS. INJURY CAN RESULT IF YOU DO NOT WEAR PROTECTION.

A� PRESSURE

WEAR EYE PROTECTION & PROTECTIVE CLOTHING WHEN CLEANING OR DRYING WITH AIR PRESSURE. REDUCE PRESSURE TO [207 kPa] 30 PSI. IEBRIS REMOVED WITH AIR PRESSURE CAN CAUSE INJURY.

m

CAUTION

BEAR�G DAMAGE

DO NOT LET THE BEARING SPIN �EN DRYING WITH AIR PRESSURE. llA.MAGE TO THE BEARING WILL RESULT IF IT SPINS ORY.

Cop) righted Mat.,nal Intended for CLARK dcal�rs only Do not sell or distribute

Code: OH-525, MAR 82

INDUSTRIAL TRUCK DIVISION

MARKETING TRAINING DEPT.

m

SAFETY MESSAGES

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WARNING

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WARNING

ELECTRICAL BURNS

DISCONNECT THE BATTERY BEFORE YOU REMOVE THIS PART FRO,, THE TRUCK. SEVERE BURNS CAN RESULT FROM CONTACT WITH ELECTRICAL SYSTEMS.

EXPLOSIVE GASES

00 NOT SMOKE OR HAVE OPEN FLAMES OR SPARKS IN BATTERY CHARGING AREAS OR NEAR BATTERIES. AN EXPLOSION CAN RESULT AND CAUSE INJURY OR !l:ATH.

m

WARNING

SULFURIC ACID

THE BATTERY CONTAINS CORROSIVE ACID �urn CAN CAUSE INJURY. IF ACID CONTACTS YOUR EYES OR SKIN, FLUSH IMMEDIATELY WITH WATER AND GET MEDICAL ASSISTANCE.

Code: OH-525, MAR 82

Copyrighted Maleriol lnt�nded for CLARK deol�rs only Do nol sell or dis1ribu1c

m

WARNING

ELECTRICAL BURNS

DISCONNECT THE BATTERY AND REMOVE ALL JEWELRY BEFORE WORKING ON ANY ELECTRICAL SYSTEM. SEVERE BURNS CAN RESULT FROM CONTACT WITH ELECTRICAL SYSTEMS

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WARNING

HYDRAUUC FUJI) PRESSURE

DO NOT USE YOUR HANDS TO CHECK FOR HYORAULIC LEAKAGE. FLUID UNDER PRESSURE CAN PENETRATE YOUR SKIN ANO CAUSE SERIOUS INJURY.

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CAUTION

NAMEPLATES & DECALS

00 NOT OPERATE A LIFT TRUCK WITH DAMAGED OR LOST tICALS ANO NAMEPLATES. REPLACE THEM IMMEDIATELY. THEY CONTAIN IMPORTANT INFORMATION.

Page iii

INDUSTRIAL TRUCK DIVISION

MARKETING TRAINING DEPT.

T AB L E

0 F

C O N T E N T S GROUP

Pump Motor Overhaul

Section

16

Drive Motor Overhaul

2

16

5

17

18

Drive Unit Overhaul •

20

1

Cessna "G" Series Gear Pump Overhaul

29

ContactorBox Overhaul H.B.

lA Contactor Overhaul

.................

17

H.B. Forward and Reverse Contactor Overhaul

17

MotorBrake Overhaul

23

..........

Hydraulic Valve Overhaul Hydraulic Valve Overhaul

Hydraulic Cylinder Overhaul .

Lift and Lower Solenoid Valve Overhaul Upright Lift Cylinder Overhaul

..............

• • • • Lubrication Specifications and Recommendations Lubrication Chart Key

Wiring Diagrams • •

30 32 32

Reach Cylinder Overhaul Tilt Cylinder Overhaul

30

.

20 1 1 1

2 2

4

32

15

34

1

33 40

.....................

1

1

4

IN-13335

IN-13336

IN-14381

IN-14729

IN-15753

IN-15930 IN-16098

IN-17201

IN-17202

IN-18422

Page iv

Copyri�hted Moteriol Intended for CLARK dealers onl) Do not sell or distribute

Code: OH-321, REV JUL 82

INDUSTRIAL TRUCK DIVISION

MARKETING TRAINING DEPT.

S20/30/40

SP20/25/30

Code: OH-321, JUL 82

Page v C<,P) ri2hll'U �11i.,n1l ln1c1iJcJ r,,r CLARK Jcakr; uni) Do 11,,1 sell "' Jismbu1e

CLqRK

INDUSTRIAL TRUCK DIVISION

JWNER SAFE MAINTENANCE PRACTICES (CONT.) 6

Avoid fire hazards and have fire protection equipment availab le.

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.

7.

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

8.

Handle LP gas cylinders with care.

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

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

10. All parts of lift and tilt mechan­ isms and frame members must be carefully and regularly inspected and maintained in a safe operating condition.

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

12. 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.

13. All hydraulic systems 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 devel­ oped to the extent that it lNC>uld create a hazard.

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

15. 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 elec­ trical insulation.

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

17. Modifications and additions which affect capacity and safe truck ope· ration must not be done by the customer or user without manufacturers prior written ap­ proval. Capacity, operation and maintenance instruction plates, tags or decals must be changed accordingly.

18. 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.

1023C�yri �� 81 B ( ACK) lntendcaior :A°RK dealers onTy Do not sell or distribute

INDUSTRIAL TRUCK DIVISION

OWNER SAFE MAINTENANCE PRACTICES Powered industrial trucks may become hazardous if adequate maintenance is not done. Therefore, maintenance facilities, personnel and procedures must be provided.

Maintenance and inspection of all powered industrial trucks should be done in agreement with the recommenda­ tion in this manual and the following practices.

1.

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

3.

Before Leaving The Truck:

4.

A.

Stop Truck.

B

Fully lower the load engaging means.

C.

Put directional controls in neutral.

D.

Apply the parking brake.

E.

Use blocks or other positive truck positioning devices.

C.

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

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

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

2.

B.

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.

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

S.

Before Starting To -�perate The Truck: A.

Be in operating position.

B.

Stop the engine or turn off power.

Push clutch (or brake pedal on automatic transmission and electric trucks).

C.

F.

Lock the control or ignition circuit.

Put the directional controls in neutral.

D.

Start engine or turn on power.

G.

Put b locks at the wheels if truck is on a ramp, or being worked on.

E.

Before operating truck, check functioning of lift and tilt systems, directional and speed controls, steering, warning devices, brakes, and any attachment. (If used)

F.

Release parking brake.

Before Working A.

On

Truck:

Raise wheels free of floor or disconnect power source.

- continued 1O23-Z

RE'V0 �E}pu�at�·nlONT)

Intended for CLARK dealers only Do not sell or distnbutc

CLqRK

EQUIPMENT

INDUSTRIAL TRUCK DIVISION SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK

GROUP 16 P UM P

M O T O R

O V E R H A U L

SECTION 2

CLARK PART NUHBERS: 899329 899334

Refer to your Machine Record Card to Verify Applications

TA B L E

Code; OH-321

O F

C O N T E N T S

Exploded View

2

Disassembly

3

Cleaning

3

Inspection

3

Reassembly

4

Specifications

6

JUN 73

Section 2, Page 1

Copyriil,1ed Malcrial ln1cndcd for CL.\RK dealers only Do not sell or d 1s1nbu1e

GROUP

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INDUSTRIAL TRUCK DIVISION SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK

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a, 0 0 0

Fig. #12586 JUN 73

Section 2, Page 2

Copyrighted Material lntl!nded for CLARK dealers only Do nol sell or distribute

Code: OH- 321