CLARK FORKLIFT OH-377 EC-6080 3648 Volt OVERHAUL MANUAL

OH-377 EC-60/80 36/48 Volt

CUARK

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Technical Pu�lications Lexington, KY 40508

INDUSTRIAL TRUCK DIVISION SAFETY INSTRUCTIONS FOR MAINTAIKING Il\DUSTRIAL 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 recOfmlendation in tnis manual and the following practices.

I.

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

2.

O nly qua! ified and authorized personnel should be permitted to maintain, repair, adjust, and inspect industrial trucks.

J.

Before Leaving The Truck:

4.

A.

Stop truck.

8.

Fu 11 y I 0\-ier the I oad 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 wneels

If

truck Is on a ramp, or being worked on.

Before Working On Truck: A.

Raise 1-1heels free of floor or disconnect power source.

8.

Use chocks or other positive truck positioning devices.

C.

Block load engaging rr,eans, innermast(s), or chassis before working under them.

Befort: working vn engine fuel system uf ga:.ul ine p<mered 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 attacl-nients should be conducted in an authorized, safe clearance are.a. �.

Before Stertlng To Operete The Truck; A.

Be in operating position.

8.

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

C.

Place directional controls in neutral.

O.

Start engine or turn on power.

E.

Before opor�ting truck, chock functioning of I ift �nd tilt systems, direction�! and speed controls, steering, warning devices, brakes, and any attachment. (If used)

F.

Release parking brake.

- continued -

INDUSTRIAL TRUCK DIVISION SAFETY INSTRUCTIONS FOR NAINTAINING INDUSTRIAL TRUCKS 6.

Avoid fire hazards and have fire protection equipment present. Do not use an open f 1 ame to check 1eve I , or for 1 eakage, of fue 1, electrolyte or coolant. Do not use open pans of fuel or flammable cleaning fluids for cleaning parts.

7.

Properly ventilate work area, vent exhaust fumes and keep shop clean and floor dry.

8.

Handle LP gas cylinders with care.

9.

Brakes, steering mechanisms, control mechanisms, warning devices, 1 ights, governors, I ift overload devices, guards and safety devices shoul d be inspected regularly and maintained rn a safe operating condition.

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

10. All parts of 1 ift and til t 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 wirh 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 lmit 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. Modifications and additions which affect capacity and safe truck operation should not be performed by the custcrner 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 qua! ity equal to that provided in the original equipment.

INDUSTRIAL TRUCK DIVISION CUSTOMER SERVICES GROUP

TABLE OF CONTENTS

STEER PUMP MOTOR OVERHAUL . . . . . .

DRIVE MOTOR OVERHAUL A.C. DRIVE & PUMP MOTOR OVERHAUL PUMP MOTOR OVERHAUL .

DRIVE MOTOR OVERHAUL DRIVE MOTOR OVERHAUL GENERAL MOTOR MAINTENANCE 200 AM� CONTACTOR OVERHAIIT� 100 A.i.'1P CONTACTOR OVERHAUL G.E. ELECTRICAL CONTACTOR OVERHAUL IDENTIFICATION OF FILTERS & DIODE BLOCKS r..E. 300 SCR CONTROL G.E. 310 SCR CONTROL SCR PANEL OVERHAUL DRIVE AXLE OVERHAUL .

OVERHAUL PROCEDURES FOR AXLE ADAPTOR TYPE . .

BRAKE MASTER CYLINDER OVERHAUL .

DISC WHEEL BRAKE OVERHAUL .

CHAR-LYNN POWER STEERING GEAR OVERHAUL POWER STEERING PUMP OVERHAUL SPOOL VALVE POWER STEERING - SSG POWER STEERING CYLINDER . . .

POWER STEERING PUMP OVERHAUL POWER STEERING CYLINDER . .

HYDRAULIC PUMP OVERHAUL .

PARKER HYDRAULIC GEAR PUMP OVERHAUL HYDRAULIC VALVE OVERHAUL HYDRAULIC VALVE OVERHAUL HYDRAULIC CONTROL VALVE - PH HYDRAULIC SYSTEM SCHEMATIC GREER BLADDER ACCUMULATOR OVERHAUL TILT CYLINDER OVERHAUL . . .

UPRIGHT LIFT CYLINDER OVERHAUL LUBRICATION SPECIFICATIONS

GROUP

. ..

.....

. .

Code: OH-377, REV JUL 80

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...

.

16 16 16 16 16 16 16 17 17 17 19 19 19 19 20 20 23 23 25 26 26 26 26 26 29 29 30 30 30 31 32 32 34 40

SECTION 8

12 13 14 16 18 27 3

4 14 3 6

7 8 6 7 3 11 2 3

6 7

8 13

1 8 l

2 7 1 1

6 1

4

Contents, Page 1

INDUSTRIAL TRUCK DIVISION SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK

GROUP

m

DISASSEMBLY OF STEER PUMP MO TOR: STEP 1.

D isassemble steer pump and flex coupling from steer pump motor as outlined in GROUP 26.

STEP 2.

Remove brush hole cover band from c01TTT1utator brush holes and lift out brushes from brush holders, taking care not to distort brush springs.

Disconnect leads.

STEP J.

Place pump motor in a vise with soft Jaws and loosen and remove screws from drive end frame. Hatch mark body and drive end frame. Tap drive end frame lightly with a soft hammer and draw end frame away from body.

N O T E

The armature assembly wil I separate from the coomJtator end frame and come out of the motor body with the drive end frame. Draw it out carefully past the pole shoes and the field coils to prevent damage to windings.

STEP 4,

Remove the armature assembly from the end frame.

STEP 5.

Using an appropriate puller, remove the drive end bearing from the armature shaft and remove the coornutator end bearing spring washer (s) from the corrm.Jtator end.

STEP 6.

Loosen and remove c0111T1Utator end frame­ to-body screws and lockwashers, match mark and separate the coornutator end frame from the body.

STEP 7.

Loosen and remove the brush holder ring retainer screws and lockwashers and remove the brush holder mounting ring.

Remove brush spring clips from split posts where brush springs are mounted; remove brush springs.

STEP 8.

Remove bearing cover from coomutator end frame only if necessary,

STEP 9.

Remove brushes and leads from brush holder ring, if present (STEP 2),

STEP 10. Place motor body in a pole shoe screw­ driver (Fig. 6994) with spreader between pole shoes to prevent loosened shoe from dropping and damaging coil on opposite side of body, I f pole shoe screwdriver is not available, use impact wrench. Remove pole shoes and field coils, as well as field terminal assembly and armature terminal assembly

Fig, 6994 C LEANING AND INSPECTION: STEP 1.

loose dirt with air solvents �n electric after inspection for nicks in insulated

STEP 2. Inspect al 1 parts for distortion, abnormal wear or discoloration indicat­ ing possible arcing.

STEP 3,

Use a straight edge to check brush holders for alignment.· Realign with a screwdriver as necessary.

STEP 4,

Examine armature windings and core for signs of rubbing against pole shoes; check faces of pole shoes also, Minor problems and defects can be corrected with shellac or insulating varnish; replace the armature in all cases of serious damage.

STEP 5.

Check alI connections for poor solder work or broken wires.

STEP 6,

Check ail insulation for cracks or damage, Including inner surface of motor body,

STEP 7.

Check coils for damaged wrappings, and repair with coil wrapping material,

REASSEMBLY: STEP 1.

Reinstall the c01TTT1Utator end frame bearing into end frame using an arbor press; reinstal l felt and cover.

STEP 2.

lnstal I brush springs on mounting posts of brush holder mounting ring.

from body.

Code: O H-336, MAR 74

Blow off dust and hose, Do not use motor parts until discoloration and areas.

Copyn11htcd Ma1cr1al lntcnde.l for CLARK de�ler.H•nly Do nor adl urd1,1ribu1c

Section 8, Page 3

INDUSTRIAL TRUCK DIVISION SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK

STEP 3.

Reinstal l mounting ring assembly to comrutator end frame with screws and lockwashers, cross-tightening evenly unti 1 secure 1 y drawn down; ins ta I I brush l eads with screws and l ockwashers, but allow brushes to hang out brush holes temporarily.

STEP 4.

Install coiIs and pole shoes into body, using pole shoe screwdriver to tighten pole shoe screws with pole shoe spreader between shoes until screws are tight; also instal 1 field terminal assembl y and armature terminal assembly into body.

STEP 5.

Using appropriate arbor press, install ball bearing on armature shaft with shielded side of bearing to inside at drive end.

STEP 6.

Install armature in bearing in drive end frame and instal I thrust washers on shaft at coJ11T1Utator end. Check match marks and install drive end frame screws.

STEP 7.

Tip up commutator end of armature and careful l y lower body and coil assembl y over armature.

STEP 10.

If poorly seated brush is discovered, insert a brush seating stone (see note) into brush hole as close as practicabl e to heel of poorly seated brush in such manner as to cause the brush seating material to be rel eased under the brush; press down on brush while running motor and moving stone slowly back and forth on commutator bars unti I brush has 7CJ% to 80"/4 mating surface with the co1TmJtator. Blow out seating material with a,r to cl ean up motor when finished.

N O T E Brush seating stones are available in two sizes. Part 1801202 stone is 1/2 x J/4 x 4-3/411 and should be used on 810 diameter and smal l er motors.

Part 1801203 stone is 1/2 x 1 x 4-J/411 and shoul d be used for motors over 81 1 diameter.

STEP 11. When satisfactory brush seating is achieved, reinstal I brush hole cover band with cover band screw and nut.

CAUT I O N AVOID ANY FRICTION BENEEN ARMATURE WINDINGS AND COILS OR PO LE SHOES. STEP 8.

STEP 9.

With thrust washers in place and shaft end inserted into bearing in COllm.Jtator end frame, make sure match marks are al igned and press or drive parts together until frame-to-body screws and l ockwashers can be installed.

Tighten all frame-to-body screws on both end frames.

C) ;,, 0 C -0

Insert brushes into brush holders, making certain the springs wi I I push the brushes Into equal contact with the commutator as brushes wear in, without cocking or interference from brush leads. Test rotation of armature by inserting a finger in through one of the brush holes (before connecting motor to power) and rotating commutator bars against brushes.

Section 8, Page 4 Copyn11htcd Ma1cr1al lntcnde.l for CLARK de�ler.H•nly Do nor adl urd1,1r1butc

"' N 0 0

Code: OH-336, MAR 74

INDUSTRIAL TRUCK DIVISION

GROUP �

CUSTOMER SUVIC[S ENGINHRINS D£PAITll[NT, BATTLE CIEEK

SPECTFICATIO�S FOR STEER PUMP MOTOR BRUSH SPRI�G

CLARK

PART

VOLTAGE

PRF.SSIJRF.

(OUNCES)

FI.ELD COIL RESISTANCE @ (20 ° C.] 68 ° F.

SHUN'T FIELD RESISTANCE @ [20 ° c.]

68 ° F.

ARMATURE RESISTANCE @ [20 ° C:.]

68 ° F.

STALL TORQUE (100 amps 12 motor volts)

ROTATION VIEWED FROM DR Tl.IE

END

FAN

NUMBER

VENTED

1709053

Encl.

36/48

33-38 NOTE 3

.0028 ohms@ (25 ° C) 77 ° F

27 ohms [25 °cJ 77 ° F

• 022 ohms [25 ° C] 77@F

135 ft. lb . ccw NO (1250 amps 36 motor volts)

1776012 Open

36/48

18-25 NOTE l

.012 ohms

50.0 ohms

.09 ohms

8. 0 ft.lb.

ccw

YES

1776013

Encl.

36/48

18-25

.012 ohms

50.0 ohms

.09 ohms

8.0 ft.lb.

ccw

NO

1798691

Open

36/48

33-38 NOTE 3

.0028 ohms@ [25 ° C) 77 ° F

. 022 ohms 27 ohms (25 ° Cj 77 ° F [25 °C) 77 ° F

2321,850

Opan

36/l,8

33-38

.006 ohms.

l7.0 ohm11

.09 ohms;

5 ft.lb.

CCIJ

YES

2324856

Encl.

36/48

33-38 NOTE 2

.006 ohms

17.0 ohms

.09 ohms

s

ccw

NO

NOTE l

NOTE 2

COOLED

NO 135 ft.lb.

CC\./ (1250 amps 36 motor volts)

ft.lb.

NOTES: 1.

Replace brushes when worn to . 25 inches (longest side) or 13 ounces brush spring pressure.

2.

Replace brushes when worn to . 80 inches (longest side) or 16 ounces brush spring pressure.

3.

Replace brushes when worn to a length of . 62 inches (longest side) or 16 ounces brush spring pressure.

Code: OH-336, REV SEP 80

lopyn htcd !\!Jtmal l111,'1111-,J forCL.\RI-. Je3lenunh Ill, nu1 •ell (ltd 1,1nbu1e

Section 8, Page S

INDUSTRIAL TRUCK DIVISION NOTES

1146-Z

REV OCT 72

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r:rr;m llEim

INDUSTRIAL TRUCK DIVISION SERVICE ENGINEERING DEPARTMENT, aATnE CREEK

GROUP

m

GROUP 16 S T E E R

P U M P

M O T O R

O V E R H A U L

SECilON 8

T A B L E

Code: OH-336, REV SEP 80

O F

C O N T E N T S

Exploded Vieu

2

Disassembly of Steer Pump Motor

3

Cleaning and lnspec�ion

3

Specifications

5

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Section 8, Page l

INDUSTRIAL TRUCK DIVISION SERVICE ENGINEERING DEPARTMENT,

,..

- - --

\ � � �

NOTE:

NON SERVICEABLE

ITEMS MARKED "N"

F

- - -:�OL - �� S U ED

E

BATTLE CREEK

SHOE�

S O v--- OE /" _) H LE'-P :,,,,

.,.

6.23'i ASSEMllY COMPl.m

-16.200

16.224

16.256

\

\-16.224

HUSH HOLDU AHO

HUSH KIT INClUDES

ITEMS

MAIKfD ••1•

HUSH AND SPIING

ICIT

INCLUDU

....._

ITEMS

MARKED "K"

- 16.219

--16.218

16.259

Fig. 13910 Steer Pump Motor 16. 200

NOTOR ASSEMBLY, STEER PUHP

16.224

16.201

FASTENER. STEER PUHP HOTOR OR ENO FRA11E

16.234

16.209

ARHATURE, STEER PUHP HOTOR

16.251

16. 212

WASHER, STEER PUHP HTR CONN END BEARING

16. 218

BRUSH KIT, STEER PUHP MOTOR

16.261

FASTENER, STEER PUMP NOTOR BRUSH HOLDER

20N

16.208

16.211 16. 213

BEARING, STEER PUMP HOTOR DRIVE ENO

BEARING. STEER PUMP MOTOR CONN ENO COIL SET, STE£R PUHP HOfiiii FIELo.

16.219

BRUSH HOLDER KIT, STEER PUHP HOTOR

16. 223

COVER SET, STEER PUMP HOTOR BRUSH HOLE

16. 221

16.237

FASTENER, STEER PUNP MTR BRUSH HOLE COVER

TERHINAL KIT. STEER PUMP MOTOR

FASTENER, STEER PUHP HOTOR BRUSH

FASTENER, STEER PUHP MTR COHM ENO FRAHE

COVER, STEER PUMP HTR COHM ENO BEARING

16.259

FRAHE ASSEriBLY, STEER PUMP MTR tOHM END

19N

BODY, STEER PUHP MOTOR

FRAHE, STEER PUHP HOTOR DRIVE END

SEAL, STEER PUHP HOTOR DRIVE ENO BEARING

FRAflE, STEER PUNP NTR COM ENO

.....,6.200

_,6.259

'In< NOT SOLO, USE ITEN NUMBER LISTED

Section 8, Page 2

C."opyn�h11.-d Ma1en�I inLeruleJ for LLARK dealmi oni) Do n111 M!II or d1 1ribu1�

"" Q'\

16.256

16. 258

G"J

Code: OH-336, MAR 74