CLARK FORKLIFT OH-327 NST, NS, NSP 203040 OVERHAUL MANUAL

OH-327 NST, NS, NSP 20/30/40

C UARK

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.

TABL E

C O N T E N T S

0 F

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

. . . . .

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

Accelerator Control Assembly Overhaul Accelerator Control Assembly Overhaul Accelerator Control Assembly Overhaul Drive Motor Overhaul General Motor Maintenance Pump Motor Overhaul Pump Motor Overhaul Overhaul Procedures Forward and Reverse Contactors lA/Pump Contactors H.B. Electrical Contactor Overhaul Forward and Reverse Contactors H.B. Electrical Contactor Overhaul lA and Pump Contactors Model 200 SCR Control Panel Identification Model 210 SCR Control Panel Identification Drive Unit Overhaul .

Brake Master Cylinder Overhaul Brake Cylinder Overhaul • • MotorBrake Overhaul Cessna " G" Series Gear Pump Overhaul • • • • • Lift Pump Overhaul • • • • • • • • • • • Reach and Tilt Pump Overhaul • • • • • • • Hydraulic Pump Overhaul Cessna "B" Series .

Hydraulic Valve Overhaul Hydraulic Control Valve • • • • • • • • • • • • Tilt Cylinder Overhaul • • • • • • • • • • Upright Lift Cylinder Overhaul Lubrication Specifications and Recommendations Lubrication Chart Key Wiring Diagrams • • • • • • • • • • • • • • • •

. . .

Code: OH-327, NOV 81

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• • • • • • • • • • • • • • • • • • • • • •

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

GROUP

SECTION

13 13 16 16 16 16 17

13

1 4 5 5 27 28 34 2

17

12

17

13

19 19 20 23 23 23 29 29 29 29 30 .30 32 34 40

12 1 14 31 39 1 15 16 25 2 7 6 1 4

11

IN-16348 IN-17132 IN-17163 IN-17179 IN-17882 IN-19411 IN-20018

Page i

INDUSTRIAL TRUCK DIVISION SAFETY INSTRUCTIONS FOR MAINTAINING INDUSTRIAL TRUCKS Powered industrial trucks may become hazardous if adequate maintenance is neglected. fore, adequate maintenance facilities, personnel and procedures should be provided.

There­

Maintenance and inspection of all powered industrial trucks should be performed in confor­ mance with the recorrrnendation in this manual and the following practices.

1.

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

2.

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,

Place directional controls in neutral.

D.

Apply the parking brake.

E.

Stop the engine or turn off power.

F.

Lock the control or ignition circuit.

G.

Block the wheels if truck is on a ramp, or being worked on.

Before Working On Truck: A.

Raise wheels free of floor or disconnect power source.

B.

Use chocks or other positive truck positioning devices.

C.

Block 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, be sure fuel shutoff valve is closed.

Before working on engine fuel system of LP gas powered trucks, close LP gas cylinder valve and run engine until fuel in system is depleted and engine stops running.

Operation to check performance of the truck or attaclYnents should be conducted in an authorized, safe clearance area.

5.

Before Starting To Operate The Truck; A.

Be in operating position.

8.

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

C.

Place directional controls in neutral.

D.

Start engine or turn on power.

E.

Before operating truck, check functioning of 1 ift and tilt systems, directional and speed controls, steering, warning devices, brakes, and any attachment. (If used)

F.

Release parking brake.

- continued Cop, ri11h1ed Mnkrrnl

1Q2.lrr.kd f�11lfil1\i0Clle'68. Jifi?ONT) Do not sell or distribule

INDUSTRIAL TRUCK DIVISION SAFETY INSTRUCTIONS FOR MAINTAINING INDUSTRIAL TRUCKS 6.

Avoid fire hazards and have fire protection equipment present. 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 flanrnable cleaning fluids for cleaning parts.

7.

Properly ventilate work area, vent exhau�t fumes and keep shop clean and floor dry.

8.

Handle LP gas cylinders with care.

9.

Brakes, steering mechanisms, control mechanisms, warning devices, lights, governors, 1 ift overload devices, guards and safety devices should be inspected regularly and maintained in a safe operating condition.

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

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

11. Special trucks or devices designed and approved for hazardous area operation should receive special attention to ensure that maintenance preserves the original, approved safe operating features.

12. Fuel systems should be checked for leaks and condition of parts. Extra special consideration should be given in the case of a leak in the fuel system. Action should be taken to prevent the use of the truck until the leak has been corrected.

13. All hydraulic systems should be regularly inspected and maintained in conformance with good practice. Tilt cylinders, valves, and other similar parts should be checked to assure that "drift" has not developed to the extent that it would create a hazard.

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

15. Batteries, motors, controllers, I imit switches, protective devices, electrical conductors and connections should be inspected and maintained in conformance with good practice. Special attention should be paid to the condition of electrical insulation.

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

17. Modif ications and additions which affect capacity and safe truck operation should not be performed by the customer or user without manufacturers prior written approval.

Capacity, operation and maintenance instruction plates, tags or decals should be changed accordingly.

18. Care should be taken to assure that all replacement parts are interchangeable with the original parts and of a quality equal to that provided in the original equipment.

<;rp�ne,hc'-ll l\ii!JcrpL �., 10231fu�ndd11it\l· �.�R�gea\Mm\'1� Do not sell or distribute

CIARK

GROUP

OH

F O R This overhaul manual has been written to aid the mechanic in the disassembly and assembly of the main components of the specific truck that this manual includes. Every improvement has been made to help the mechanic to discharge his duties in a safe and practical procedure.

This manual has been written in groups and sections with a table of contents for easy reference.

Each section includes many photographs and drawings to directly show how to do these operations.

The mechanic is told to always use Genuine Clark Parts when replacements are needed. "Look alike" parts from other supplies never work as well as the original parts.

Specifications and notes on safety have been included as needed for each step to be done. The mechanic is told to use safety and accuracy in his work because we cannot control his work and procedures.

Code: OH-51O, JAN 81 P.S.L.

If the mechanic does not understand the right procedure in the maintenance of this truck, he is told to see his immediate supervisor instead of risking injury of personnel.

Approved methods of service and correct procedures of repair are important for the safe operation of all trucks as well as the safety of personnel and the mechanic doing the work. This manual gives directions for service and repairs with procedures that are tested.

There are many different procedures, tools, and parts for servicing vehicles, as well as in the ability of the mechanic doing the work. This manual cannot be written for all such variations. Any mechanic who works differently from this manual must first make sure that he works safely and accurately.

(op�nshtcd Malcn•I lntendeJ for CL.\RK deal= only Do not sell or di5tribulc

FOREWORD

CIARK

GROUP 13

GROUP 13 SECTION

l

A C C E L E R A T O R

C O N T R O L

A S S E MB L Y

Copyri11htcd M:umal Code: OH-3 2 7, REV NOV 81 p. S. L. Intended for CL\RK dealers only Do not sell or distnbute

O V E R H A U L

Section 1, Page 1

GROUP 13

\\lJ,,

E

F

Q/

H

II HH

I

GG

G

-

P

FF

-BB ' o�

EE DD

� ---1 Q

.,,

R---ce

-,

s

, I

e

Ly

V

w Fig. 22658

A. Flat washer B. Reel c. Return spring D. Pin E. Clamp F. Bevel gear G. Bronze bearing H. Actuating lever I. Pin J. Bevel gear K. Pin L. Spacer

Section 1, Page 2

M. Bearing N. Gear shaft o. Cam assembly P. Upper cam setscrew Q. Lower cam setscrew R. Bottom plate s. Locating stud T. Holder plate u. Lockwasher V. Bolt w. Star washer X. Potentiometer

Y. Microswitch retaining screw

z.

Potentiometer nut

AA. Bearing

BB. Spacer Switch DD. Star washer EE. Screw FF. Insulator GG. Top plate HH. "U" Bracket II. Locator JJ. Shaft

cc.

<:ode,' OH- 32 7 ' REV NOV 81 p • S • L •

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

,�

GROUP I -.,

REPLACEMENT OF UPPER CONTROL "U"

BRAC KET ASSEMBLY: l.

Disconnect battery. Remove the linkage of the speed control assem­ bly from the actuating lever.

A. Linkage nut B. Lever 2.

Fig. 22656

See the exact position of the cam in the lower assembly, and the position of the bevel gears. Dis­ connect and remove the upper con­ trol "U" bracket assembly.

Fig. 22657 A. "U" bracket to backplate screw

B. "U" bracket assembly Bevel gears D. "U" bracket to top plate screw

c.

E. Cam

3.

Replace the "U" bracket assembly.

Carefully mesh the bevel gears with­ out changing the position of the cam assembly. Put in the screws, washers, and lockwashers and tighten with your fingers.

S Cop)ri&ht..-d Malerial O e •• OH - 327 • REV NOV 81 P. .L Cd Tn1cndcd fo, CL\RK dealer, onl) Do nol sell or distribute

Section 1, Page 3

CLARK

GROUP 13 4.

Adjust the "U" bracket assembly so that the bevel gears mesh correctly.

N O T E The return spring will return from the forward or reverse position to the neutral position if the bevel Tighten the gears mesh correctly. screws and check again for correct operation.

If necessary, loosen the screws and adjust again.

5.

Check the position of the switches.

The two direction lobes of the cam must be centered on the switch rollers. The ends of the upper cam lobe must be the same distance from the roller on the lA switch. If nec­ essary, loosen the two Allen head screws that hold the bottom part of the control assembly to the upper "U" bracket, and adjust again by lowering the bottom part of the con­ trol assembly and turning the cam until the lobes are centered.

NOT E

The potentiometer will need to be adjusted again to get correct ohm­ meter readings across the terminals (instructions on the following pages) if the cam has been adjusted again.

6.

A. Lower plate B. Loosen this setscrew C. Loose� this nut D. Pull the plate down

Fig.

22659

Install the speed control assembly linkage to the actuating lever.

Connect battery.

Test for correct operation of the speed control.

Section 1, Page 4

Code•' OH- 32 7 ' REV NOV 81 p • S • L •

Cop)ri�hlcd Motcn31 Intended for CLARK de.:ilers onl) Do not sell or di.stnbutc