CLARK FORKLIFT OH-437 NP and NS 300 Lot 3205 and Up OVERHAUL MANUAL

OH-437 NP and NS 300 Lot 3205 and Up

·

·

CUR RK

Cop)'nghtcd Matenal Intended for CLARK dealers only Do not sell or distribute

Technical Publications Lexington, KY 40508

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 reconvnendation in this manual and the following practices.

1.

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

2.

Only qua! ified 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. s.

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 Copyrighlcd Ma1crial

1i0�� for CllB'iOD.frile6&n�RONT) Do nol sell or distribule

Imm

�

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 flall11lable 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, I ights, governors, lift overload devices, guards and safety devices should be inspected regularly and maintained In a safe operating condition.

10.

All parts of 1 ift 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.

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

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.

1J. 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 t.hat "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, 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 customer or user without manufacturers prior written approval.

Capacity, operation and maintenance instruction plates, tags or decals should b e 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.

1023•2

RE�'ni%�h�§ J.».f..fu�)

lnt,'ndc'<I for lL\RK dealer, onlv Do not sell or d1s1nbuu,

INDUSTRIAL TRUCK DIVISION CUSTOMER SERVICES GROUP

TABLE OF CONTENTS Accelerating Control (HMS) Drive Motor Overhaul • • • Commutator Check Chart • • Steer Pump Motor Overhaul General Motor Maintenance • Pump Motor Overhaul Forward-Reverse Contactors • • • lA and Pump Contactors • • • • • G.E. Electrical Contactors • • • Square D Electrical Panel NS300 - Lots 3205-3496 NP300 - Lots 3205-3491

Group

Section

13 16

10

2

• • • • • • • • • • • • •

16 16 16 17 17 -17 19

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

19

5

Drive Axle Overhaul • • • • • • • •.• Drive Motor Brake Overhaul • • • • • • NP300 - Lo·ts 3205-3207 NS300 - Lots 3210-3211

20 23

4 8

Drive Motor Brake Overhaul • NP300 - Lot 3490 & above NS300 - Lot 3495 & above

23

19

G,E. SCR Panel Overhaul • • • • NS300 - Lot 3497 & above NP300 - Lot 3492 & above

• • • •

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

Power Steering Pump Overhaul Steer Torque Generator Overhaul Lift Pump Overhaul . • • • Reach & Tilt Pump Overhaul .

Hydraulic Valve Overhaul . • • • Cessna Reach & Tilt Valve Dual Tilt Cylinder Overhaul • • Reach Cylinder Overhaul • • • • NP300 - Lots 3205-3492 Reach Cylinder Overhaul NP300 - Lot 3995 & above

• • • •

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

• • • • • • • •

•

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

Upright Lift Cylinder Overhaul .

Lubrication Specifications • • •

Code: OH-437, JUL 80

• • • • • •

Copyrighted Moterinl Intended for CLARK deolers only Do not sell or distribute

26 26 29 29 30 30 32 32

26 27 28 12 13

14 1

3

15 15 16 2

10 3 4

32

12

34 40

1 4

Contents, Page 1

INDUSTRIAL TRUCK DIVISION NOTES

1146-Z

REV OCT 72 Copynghted Matcri.tl Intended for CL\RK dealer> only Do not �ell or dl\t11l,utc

mm:rm

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INDUSTRIAL TRUCK DIVISION

GROUP

m

SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK

GROUP 13 ACCELERATING HAND

CONTROL

MASTER

ASSEMBLY

SWITCH

OVERHAUL

(HMS)

SECTION 2

TABLE

OF

CONTENTS:

ExplodedView

2

Disassembly

3

Assembly Trouble Shooting

Code: OH-33O, JUL 74 Copyrighted M,tcriol Intended for CLARK dealers onh Do not .ell oo dt,tnbute

3

- 4 5

Section 2,

Page

1

INDUSTRIAL TRUCK DIVISION SERVICE ENGINEERING DEPARTMENT, BATTU CREEK

13,594 F 91 .O59F F

o��- -.-� /

60 .135

0

ASS(.YILY COMl>Utl DOU HOT INCLUDf IIIMS MA.KID •••

i

.,

;'J1

L1 3.4L8

13.572

HAND MASTER SWITCH (HMS) ACCELERATING CONTROL ASSEMBLY 13.400 IJ.402 13.439 13.448 13.558

1J.S68 1).572 13.5gt.

60. 132 60.1)3 60.1)4 60.1)5 60.136 60.1)7 91.058 91.059

CONTROL ASSENBLY, ACCELERATING COVER, ACCELERATING CONTROL ASSENBLY BOLT, ACCELERATING CONTROL COVER 80Li, ACCELERATING CCNTROL ASSEH!!LY CAN, ��ITC� OPERATING

C'> ;,:, 0 C: -0

CAN, SWITCH OPERATING BRACKET, ACCEL CONTROL ASSEN NOUNTING BOLT, ACCEL COflTROL SI/ITCH BRACKET NODULE, ACCEL CONTROL SPEED CONTROL NODULE, ACCEL CONTRC� F\10 � REV S\!ITCH

NOOIJLE, ACCEL CONTROL SI/ITCH OPER SPRING STOP, SWITCH OPERATING CAN NODULE, IA SWITCH CAPACITOR, IA SWITCH NODULE LOCK\IASHER, ACCEL CONn SW BRKT FAST �UT, ACCEL COIITL SW BRACKET FASTENER

Fig, 15086 Section 2, Page 2

Cop,Tiihted l>btcnal lntenJ.:d fo, CL \Rli. dc�l<N onl\ Do n,,t ,di or J1,1nbu1c

Code: OH-3)0, JUL 74

INDUSTRIAL TRUCK DIVIS ION SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK

GROUP

ID

DISASSEMBLY OF HAND MASTER SWITCH (HMS) ACCELERATING CONTROL:

N O T E Disassemble only as far as necessary to replace the suspected component.

STEP 1.

Remove the mounting screws (J).

(Fig. 15087)

STEP 2.

Remove speed control module (P).

(Fig. 15087)

Fig, 15087

C A U T I O N DO NOT DISTURB INSIDE ASSEMBLY.

THIS

IS A FACTORY CAL IBRATED MODULE, STEP 3.

Remove black contact module (G) and transparent contact module (F).

(Figs. 15088 and 15089)

STEP 4.

Remove next assembly detent module (B). '(Fig. 15090)

STEP 5.

If device has a handle, remove setscrew and remove handle from shaft (M).

STEP 6,

Now, remove spring return module (A) by removing screws (K) from bracket (L).

(Fig. 15095), Retainer, if used, will be loose.

Fig. 15088

Fig. 15089

ASSEMBLY OF HAND MASTER SWITCH (HMS) ACCELERATING CONTROL: o.. :::, 0

"'

STEP 1.

Assemble spring control module (A) to bracket (L) by placing E-ring retainer in position and assembling bracket with scr·ews (K), tightening to 18-21 pound inches. Notice that (A) and (L) are keyed, (Fig. 15095)

STEP 2,

To assemble detent module, align detent cam in housing (B). (Fig. 15090).

With cam in this position, insert stop cam (E) with spaces equal as shown (C) and insert this assembly on shaft (M).

STEP 3,

To assemble the transparent contact module, insert cam A1 (normall y used in this position) into (F), making the orientation of the index mark on the cam and contact module (Fig, 15089), and place on (B). Module (F) is keyed and is transparent,

(!)

Fig, 15090

Fig. 15095 Code: OH-330, JUL 74

Cop)'Tightcd Material Intended for CLARK dealers onlv Do not sell or distribute

Section 2, Page 3

INDUSTRIAL TRUCK DIVISION SERVICE ENGINEERING DEPARTMENT, BATnE CREEK

STEP 4.

To assemble the black contact module, insert triple cam AlO (normally used in this position) into module (G), positioning index marks on cam and contact module as indicated (Fig. 15102) and place (G) against (F), a keyed part.

STEP 5.

Place transducer module (P) in position to engage end of cam (U). (Fig. 15101) The flat on shutter (T), a plastic semi-circle, l!lJSt be approximately parallel to the terminals in the hous Ing. Insert two screws (J) and tighten to 3-7 pound inches torque value.

FLAT SIDE OF SHUTTER

FOUR Tf:Rl-llNALS

OVERTIGHTENING WILL PREVENT HANDLE FROM RETURNING TO NEUTRAL.

Fig. 15101 FORWARD-REVERSE CONTACT MODULE

STATIC RETURN-FINAL (IA) cot.TACT MODULE

C, ;,o 0 C -,:,

'Al" CAM (2-CAM)

Fig. 15102 Section 2, Page 4

C•'P) nghtcd Mnten,I

lnt<n<led for CLARK dealers only Do not .di or distnbute

Code: OH-330, JUL 74