CLARK FORKLIFT OH-420 EC500 355 3648 VolT OVERHAUL MANUAL

OH-420 EC500 355 36/48 Volt

CUARK

COfl) n11hted Maie,1.11 Intended for CLARK deal"" ool" Do nol sdl oc tl,srnl>utc

Technical Pu�lications Lexington, KY 40508

CLARK

GROUP

T A B L E GROUP

SECTION

16

O F

C O N T E N T S

PAGE 1 - 5

PMA-321

Electric Motor Maintenance

16

5

1 - 13

PMA-340

Electric Motor Remove & Repair

16

6

1 - 3

PMA-340

E.M. Brake Drum Removal

16

12

- 9

OH-337

Drive Motor Overhaul

16

15

- 9

OH-384

Lift Pump Motor Overhaul

16

17

- 9

OH-420

Pump Motor Overhaul

19

3

- 27

OH-377

Identification of Filters

19

36

1 - 17

PMA-418

EV-1 Component Identification

19

37

- 23

PMA-418

Checking EV-1 SCR Components

20

5

1 - 10

OH-369

Axle End Overhaul

20

7

1 - 13

OH-377

Axle Adaptor Type Differential

23

2

- 5

OH-224

Brake Master Cylinder

23

9

- 9

OH-337

Overhaul for Brakes With Auto/Adj

23

10

- 7

OH-337

Wheel Cylinder Overhaul

26

3

- 5

OH-336

Power Steering Pump Overhaul

26

6

1 - 18

OH-377

Pov,.,er Steering Gear SSG

26

12

- 5

OH-420

Power Steering Cylinder Overhaul

29

4

- 5

OH-336

Hydraulic Pump Overhaul (Hydreco)

29

10

1 - 7

OH-393

Hydraulic Pump Overhaul (S-15, S-20)

30

2

1 - 14

OH-332

Hydraulic Valve Overhaul

30

7

- 8

OH-377

Hydraulic Control Valve

32

5

- 9

OH-334

Tilt Cylinder Overhaul (411 Barrel, 1- 1 / 211 Rod )

Code: OH-420, APR 78

Copynghtul M,uw.:il Intended for CL\RK dc�lcr, only Do nol &ell or di>1rlbu1e

Page 1

INDUSTRIAL TRUCK DIVISION CUSTOMER SERVICES GROUP

T A B L E GROUP

SECTION

PAGE

32

6

1 - 9

32

7

1 -

a

34 40

12

40

13

Page 2

0 F

C O N T E N T S

OH-334

Ti It Cylinder Overhau I (411 Barre I, 1- 1/411 Rod)

12

OH-420

Ti It Cy! inder Overhaul (3-1/411 Barrel, 1-1/411 Rod )

52

OH-336

Lift Cyl 1nder

- 2

PMA-340

Decals, Name Plates

7

PMA-340

Suggested Equipment

1 -

Cop\'nghl�d M.>l�n�I Int mkd 1....- rt,\ RI. de.iiCB ""h 11,, 11<>1 i,dl "' di.in hut,

Code: OH-420, APR 78

INDUSTRIAL TRUCK DIVISION SAFETY INSTRUCTIONS

FOR MAINTAINING INDUSTRIAL TRUCKS

Powered industrial trucks may become hazardous if adequate maintenance is neglected. fore, adequate maintenance facil !ties, personnel and procedures should be provided.

There­

Maintenance and Inspection of all powered industrial trucks should be performed in confor­ mance with the recommendation 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.

S�fore Leaving The Truck: A.

Stop truck.

B.

Fully lower the 1 oad engaging means.

c.

4.

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.

8.

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 ls depleted and engine stops running.

Operation to check performance of the truck or attachments should be conducted in an authorl�ed, safe clearance area.

5.

Before Starting To Operate The Truck; A.

Be in operating position.

B.

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 lift and tilt systems, directional and speed controls, steering, warning devices, brakes, and any attachment. (If used)

F.

Release parking brake.

- continued 1023-Z(.-p���M��'1T��� (FRONT) lntt'llJ..,J

t.,.. CLARK ds�l

Oo n.(,1 •1!11 o, d1�tnbut�

• .,J\

mm mm:mm

INDUSTRIAL TRUCK DIVISION

mm mm:mm

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 fla11111able 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, lift overload devices, guards and safety devices should be inspected regularly and mointoined in a sofe operating condition.

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

10. Alf parts off 1ft 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 cyl lnders, 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 decal s should be maintained in legible condition.

15. Batteries, motors, controllers, 1 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. Modifications and additions which affect capacity and safe truck operation should not be performed by the custaner 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 qual lty equal to that provided in the original equipment.

1023-Z Co186l/hl0Clt\"68•l(BACK) lmmdcd for CLARK dc�k-o. onl} Do not •�II or dis1nbu�

m-m Emal

INDUSTRIAL TRUCK DIVISION SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK

GROUP

m

GROUP 16 SECTION 1 ELECTRIC MOTOR MAINTENANCE

Fig. 12704 REMOVE ALL JEWELRY BEFORE EXAMINING ELECTRICAL COMPONENTS

Code: PMA-321, REV NOV 74

lup, nvhk.l Matc,rul lntC!'IIJcJ t.,r l'L!\lll.. d.:�lc:B only Do not -.ell or dt..inbw�

Section I, Page 1

INDUSTRIAL

TRUCK DIVISION

CUSHiiili SEiViCiS tiiQiiiEEiiii& iitfAiTiiiUii. DAii1£ t«EEK

� �

M O T O R S ROUTINE MAINTENANCE SCHEDULE WITH RECORDED F INOINGS ••. IS THE BEST WAY TO REDUCE COSTLY SHUT­ DOWNS AND THE REPAIR OF EQUIPMENT DURING OPERATING HOURS. THE GOAL OF ANY AAINT ENANCE PROGRAM LONG-LIFE ANO TROUBLE-FREE OPERATION •.. IS RELATED TO THE TIME SPENT MAKING INSPECTIONS

AND CORRECT!NG M!NOR PROBLEMS 45 THEY OCCUR, OPERATING CONDITIONS: Since the operating environment of lift truck motors varies widely, the following recommendations should be applied as actual conditions dictate.

NOAAAL SERVICE ••. baslcal ly, an eight-hour day of mostly indoor or outdoor material handl­ ing.

EXTREME SERVICE

SEVERE S ERVICE •.• extended operating hours, or constant usage.

1. Ousty or sandy locations, i.e., cement plant, lumber or flour mills, coal dust Of stone-crushing areas.

2. High temperature areas; i.e., steel mil ls, foundries, etc.

3.

Sudden temperature changes (continuous indoor-outdoor movement) i.e. refrigeration piant, etc, ROUTINE INSPECTIONS:

ALWAYS DISCONNECT BATTERY BEFORE DOING ANY WORK ON ELECT�IC HOTO�S. Wipe off dust, dirt, oil, water, etc., from surface of motor.

Remove any debris from air vents and around motor frame to prevent overheat­ ing.

Blow out open motors with clean, dry compressed air (30 PSI max. (207 kPa)).

CLEANLINESS

The presence of oil could indicate bad bearings or a leaking hydraulic system.

Determine the cause and correct before extensive damage occurs.

INSULATION RESISTANCE

The easiest method to test motor for a ground Is using a V-0-M, SIMPSON 6P or equivalent.

(Meggers, Bell testers or lamo circuits will give a slgnal if a definite 9round is present •.. but should be �sed only if motor is totally disconnected from the electrical system).

The V-0-H will give a reading which, when recorded and compared with previous read!ngs, will indicate the overall condition of the insvlation and m�y indicate future failure.

CHECK MOTOR WINO I NG IN­ SULATION AS FOLLO,,IS: NOTE:

1. Disconnect battery.

2. Disconnect external �.otor terminals ... TAG, if necessary.

Refer to wiring diagram supplied with truck.

CALIBRATE THE METER ON THE Rxl0,000 SCALE. 3. Conneet one lead to ALL MOTOR TERMINAL STUDS •.. leave the other lead on the motor frame and read ohms scale.

Section 1, Page 2

C'"l'�"llhlol\l lai,;nal ln1,-ndcd ,,. Cl:\K� dc�lcni 11nlv llo nrot ac:ll °' d11tnlxM

Cocie: PrlA-3 2 i , REV NOV 79

C') ;z, 0 C: O'\

INDUSTRIAL TRUCK DIVISION

GROUP mJ

SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK

4.

A resistance reading of 50,000 ohms or greater indicates satisfactory motor con­ dition. Record reading for future reference.

A resistance reading Jess than 50,000 ohms, and AIR CLEANING the motor does not improve the reading, motor should be removed from truck for repair.

5.

Reconnect terminal leads, using a torque wrench.

LEADS to 16-POUND FEET or 22 N·m MAXIMUM.

Torque DRIVE MOTOR TERMINAL

TO AVOID STRIPPING TERMINAL THREADS OR CRUSHING INSULATION PARTS ••. TIGHTEN BOTTOM NUT SNUG ONLY. HOLD WITH WRENCH ANO TORQUE TOP NUT TO THE TORQUE SPECIFIED ABOVE.

INSPECTION CHART

SERVICE CONDITIONS

INSPECTION FREQUENCY (OPERATING TIME)

NORMAL

.

-------------

.

-

- -

---

- - - -

-

- - -

EXTREME

..

MOTOR LOCATION

1000 Hours

Routine

Motor in truck

30,000 Hours

Periodic

Motor removed

500 Hours

Routine

Motor in truck

As required by inspection.

Periodic

Motor removed

250 Hours

Routine

Motor in truck

As required by inspection.

Periodic

Motor removed

-------

SEVERE

.

RECOMMENDED INSPECTION

---

- -

- - -

------

MOTOR BRUSHES ••. 1. Disconnect battery.

2. Remove brush cover bands, if so equipped.

3. Lift brush springs and remove brush from brush box.

00 NOT REMOVE SHUNT RETAINER SCREW UNLESS NEW BRUSHES ARE NECESSARY. 4. Clean brushes, holders, and wipe the commutator with a dry, lint-free cloth. DO NOT USE A LUBRICANT OF ANY KIND ON OR AROUND THE COMMUTATOR. Code: PMA-321, REV JUN 77

Cop)TIJ!hlL-<l Mnteml Intended for CL/\RK deal<:t> onl� IJo no1 &ell or d, inouh.

Section I, Page 3

INDUSTRIAL TRUCK DIVISION CUSTOMER SERVICES EIIGINEUfll& 0£PARTl1£11T. UTTLE CREEK

S.

Check appearance of commutator and the brush The best signs of good commutation are dark, polished c011YT1utator and uniform glossy brush Refer to the COM.�UTATOR CHECK CHART ... last section.

6.

CHECK BRUSH LENGTH ... record brush length at each inspection.

This is the best indicator of brush wear. It wl l I help determine If sufficient length is present until the next inspection.

riding surfaces. brownish, highly wearing surfaces. page in this

8RUSHES SHOULO BE REPLACED WHEN WORN TO LESS THAN ONE HALF OF THEIR ORIGINAL LENGTH. 7.

CHECK BRUSH SHUNT for good contact wlth brush hoider. Hake certain shunt is not damaged or burned. This may cause pressure spring to carry current and lose tension.

8.

If brushes do not need to be replaced •.. lift brush spring and place brush into brush box. Make sure pressure spring is on the brush harrrner plate and brush slides freely in brush box.

9.

CLEAN AND CHECK BRUSH BOX and CROSS CONNECTOR SCREWS tighten If necessary. Check and tighten, If necessary, all cap screws around motor frame.

CLEAN ANO I NSPECT COVER I,

ENCLOSED MOTORS:

Inspect covers for bent or broken spacers.

2.

Inspect covers for broken or damaged insulating gaskets.

3.

Reassemble covers in the original position supplied.

MAKE SURE OPENINGS ARE COMPLETELY COVERED ANO COVER IS TIGHT FOR AN ALL-AROUND GOOD CONTACT WITH MOTOR FRAME.

BRUSH REPLACEMENT . •• Brushes can be replaced without re:r.ovlng ��tor from truck.

I.

Disconnect battery.

2.

Rer.t0ve brush hole

BRUSH SHUNT

0

cover.

3.

Refer to MOTOR BRUSHES on previous page.

4.

Remove shunt retainer screw and remove brush from brush box.

REPLACEMENT BRUSHES MUST BE SAME SIZE AN O GRAOE AS THE OLD BRUSHES REMOVED.

S.

SHUNT RETAINING SCREW

BRUSH BOX RETAINING SCREW

COMMU­

iATOR -..._..... �,.,

PRESSURE SPRING

HAMMER--�:­ PLATE

8RUSHES----.J/

Seat new brushes to contour of commutator by using a brush seating stone.

Fig. 11270

BE SURE TO BLOW STONE DUST OUT OF THE MOTOR USING LOW PRESSURE ORY AIR AFTER BRUSHES HAVE BEEN SEATED. Section l, Page 4

Cop)nat,1cJ l\blrnal ln�n,kd Int' Cl \RK ck�lcro ,,nl, L>o nL•I II"' d1 tnl>ui.-

Code: PMA�32I, REV AUG 75

C "0