CLARK FORKLIFT OH 386 EC 235 ER & EV 1 OVERHAUL MANUAL

Overhaul Manual

OH 386 EC 235 ER & EV 1

CLqRK

C.OJl)Ol!hted Ma10:rul lntcndo:d for CLARK dealcrs oolv Do no1 sdl o.- tl,sml>utc

333 West Vine Street Lexington. KY 40507-1640

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 wrking 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 prevent. ive maintenance, lubrication, and inspect ion 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 unt. il there is no more fuel in the system and engine stops running.

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

S.

Befor_e Starting To _Qperate The Truck: A.

Be in operating position.

B.

Stop the engine or turn off power.

Push clutch (or brake pedal on aut. omatic transmission and electric true ks) .

C.

F.

Lock the control or ignition circuit..

Put the directional controls in neutral.

D.

Start engine or turn on power.

G.

Put blocks 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 On Truck: A.

Raise wheels free of floor or disconnect power source.

- continued ) l��yr�ht_,.M.Yen�EP 83 (FRONT

lnLcnJcd forCLJ\RK dealers onh Do no1 sel I or d1stribut�

INDUSTRIAL TRUCK DIVISION

OWNER SAFE MAINTENANCE PRACTICES (CONT.) 6

Avoid fire hazards and have fire protection equipment available.

Do not use an open flame to ch eck 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.

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

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 f:rame 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 unti1 the leak has been corrected.

1023-Z

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 would create a hazard.

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 operation must not be done by the customer or user without manufacturers prior written ap­ proval. Capa city, 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.

REV c.$,�;g1�J ��K)

�,tended for C:LARK dc�lcr, only Do no1 .ell or di,1rlbu1e

ClARK

GROUP

T A B LE GROUP

SECTION

16

O F

C O N TE N T S

PAGE - 5

PMA-321

Electric Motor Maintenance

16

5

1 - 13

PMA-340

Electric Motor Remove

16

6

- 3

PHA-340

Brake Drum Removal

16

12

- 9

OH-337

Drive Motor Overhaul

16

13

I - 13

OH-3 77

A.C. Drive Motor Overhaul

16

15

- 9

OH-384

Lift Pump Motor Overhaul

19

3

- 27

0H-377

Identification of Filters

19

4

- 8

OH-386

Clark EC250 SCR Control Panel

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

20

7

1 - 13

OH-377

Axle Adaptor Type Differential

23

2

- 5

OH-224

Brake Master Cylinder Overhaul

23

9

- 9

OH-337

Overhaul for Brakes with Auto/Adj

23

10

1 - 7

OH-337

Whee 1 Cy Iinder Overhau 1

25

5

1 - 15

OH-367

Saginaw Manual Steering Gear

29

4

- 5

OH-336

Hydraulic Pump Overhaul

30

2

1 - 14

OH-332

Hydraulic Valve Overhaul

30

7

- 8

0H-377

Hydraulic Control Valve

1 - 14

OH-322

Greer Bladder Accumulator Overhaul

- 9

OH-334

Ti It Cylinder Overhaul

- 52

OH-336

Upright Lift Cylinder Overhaul

32 32

6

34 12

- 2

PHA-340

Decals, Name Plates

40

13

1 - 7

PMA-340

Suggested Equipment

<.:or,yri11ht,J Muh.'nal lnttndcd for CLARK d��lm nnl� Do nol ,di or dl,tribulc

Repair

Overhaul

40

Code: OH-386, JAN 79

&

Page 1

INDUSTRIAL TRUCK DIVISION SERVICE ENGINEERING DEPARTMENT, BATTLE CR.EEK

GROUP

m

GROUP 16 SECTION 1 ELECTRIC MOTOR MAINTENANCE

Fig. 12704 REMOVE ALL JEWELRY BEFORE EXAMINING ELECTRICAL COMPONENTS

Code: PAA-321, REV NOV 74 Copynl!hk-J Mn1c.nal Intended for CLJ\RK dC4lers onh Do no1 sel I or d1smbut�

Section I, Page I

INDUSTRIAL TRUCK DIVISION

e

20

�\ 21

5

__.

--- --

__.- ---

-

I I

c-

g0

Fig. # 12583

JUN 73

Section 1, Page 2

CopynghlL'<l Maten.ii Intended for CL/\RK dealc:o onh ·

Do not &ell or .i,�in'buh.

Code: OH-321

INDUSTRIAL TRUCK DIVISION

GROUP

m

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 less 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. Torque DRIVE MOTOR TERMltlAL LEADS to 16-POUND FEET or 22 N·m MAXIMUM. TO AVOID STRIPPING TERMINAL THREADS OR CRUSHING INSULATION PARTS ••• TIGHTEN BOTTOM NUT SNUG ONLY. HOLD WITH WRENCH AND TORQUE TOP NUT TO THE TORQUE SPECIFIED ABOVE.

INSPECTION CHART

SERVICE CONDITIONS

NORMAL

SEVERE

EXTREME

RECOMMENDED INSPECTION

MOTOR LOCATION

1000 Hours

Routine

Motor I n truck

30,000 Hours

Per lodic

Motor rem011ed

500 Hours

Routine

Kot or in truck

As required by r nspect ion .

Periodic

Motor removed

250 Hours

Routine

Motor in truck

As required by inspection.

Periodic

Motor re11011ed

INSPECTION FREQUENCY (OPERATING TIME)

MOTOR BRUSHES .•. I. Disconnect battery.

2. Remove brush cover bands, if so equipped.

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

00 NOT REMOVE SHUNT RETAINER SCREW UNLESS NEW BRUSHES ARE NECESSARY. 4. Clean brushes, holders, and wipe the conmutator with a dry, lint-free cloth. 00 NOT USE A LUBRICANT OF ANY KIND ON OR AROUND THE COM/'IUTATOR. Section I, Page 3

Code: PMA-321, REV JUN 77 Copynl!hk-J Mnli!ml Intended for CLJ\RK dealen onh Do no1 sel I or d1snibut�

INDUSTRIAL TRUCK DIVISION CUSTOIIIU SUYICES ENGINEUIN5 DEPARTIIIENT, BATTLE CREEK

5.

Check appearance of convnutator and the brush The best signs of good coovnutatlon are dark, polished convnutator and uniform glossy brush Refer to the COMMUTATOR CHECK CHART .•• last section.

6.

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

This is the best indicator of brush wear. It will help determine If sufficient length Is present until the next inspection.

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

BRUSHES SHOULD BE REPLACED WHEN WORN TO LESS THAN ONE HALF OF THEIR ORIGINAL LENGTH. 7.

CHECK BRUSH SHUNT for good contact with brush holder. Make 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 ••• 1 ift 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 AND INSPECT 1.

COVER

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 AND COVER IS TIGHT FOR AN ALL-AROUND GOOD CONTACT WITH MOTOR FRAME.

BRUSH REPLACEMENT ••• Brushes can be replaced without removing motor from truck.

1.

Disconnect battery.

2.

Remove brush hole cover.

3.

Refer to MOTOR BRUSHES on previous page.

4.

Remove shunt retainer screw and remove brush from brush box.

8RUSH SHUNT

REPLACEMENT BRUSHES MUST BE SAME SIZE AND GRADE AS THE OLD BRUSHES REMOVED, 5.

SHUNT RETAININO SCREW

BRUSH BOX RETAINING SCREW PRESSURE SPRING

HAMMER PLATE

BRUSHES-----"

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 DRY AIR AFTER BRUSHES HAVE BEEN SEATED. Code: PMA-321, REV AUG 75

Section I, Page 4 Copyn11htro Makruf Intended for CL'\RI{ d�al= onlv Do nol s�II or d1 1rlbu1e

INDUSTRIAL TRUCK DIVISION SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK

BRUSHES V.ORN UNEVEN

--�

GROUP ITT

REPLACE BRUSH IF

CHIPPED

CHECK TENSION OF EACH SPRING

IF SPRING TENSION IS NOT THE SAME FOR EACH BRUSH, REPLACE SPRINGS.

REPLACE BRUSH IF -------- PIGTAIL IS LO.OSE IN Tf£ BRUSH.

BROKEN

REPLACE BRUSH IF OIL SOAKED

IF BRUSH PIGTAIL IS LOOSE AT Tf£ BRUSH t-OLDER TIGHTEN SCREW.

REPLACE BRUSHES WHEN 'NORN TO HERE. NEW BRUSHES

TiiE DRIVE MOTOR BRUSHES SHOWN HERE SHOULD HAVE ... BEEN REPLACED LONG AGO. � BRUSHES IN A CONDITION AS THIS, MAY RESULT IN REPLACING THE HOTOR ARMATURE.

Code: PMA-321, REV MAY 76

REFER TO THE C<»UiUTATOR CHECK CHART

Section I, Page S lOf)\flJhitd fot�rfal lnt<ntl..•.11,..- CI.ARK tkJkn t1nly I)., nu1 .cll orJ1 111b"L"

GEA-7053

SATISFACTORY COMMUTATOR SURFACES

UGHT TAN FILM ovtt � <.onwa.no.to, 1,urfoce is OM of mony not'l'ftOI <Oftei� often s.t-e.n ot'I o wel,.k,.tlO!O.ftll\9 motfw...

MOTTLID SURFACE withrandomf-ilm pctt• SLOT IAA-MAltKING, o dishrfy dor\ct tWffl is probably most fr�utnrly obRtYed filfT\ appitars o,, bat1 in c dtflf"lir• panwn tondlrion of ,o,,..mutarou fn il"ldu.ury. t•lot� 10 ni..unbet of <Ofldutt0t1. pff tJoL

HIEAVY FllM tct1 cppe.or ov..,. •ntir• one of .W'Ot:rv cmd normal commufa­ end J iawlonn_ is quii.: o«e'Ph:ibt•.

'°'

WATCH FOR THESE DANGER SIGNS

STlllAlCING on the co'""'- w,f.,.. oJe""" ,t.. be vlnnine of __,, ....oJ tromlft 10 dte co,boo ... b,us a-k ..,. chart Mlow l<H po,,.'bl,, cou,

"°"'

COPl'fll DUG, on obno,,.,.,f bvil<k,p o1 coinfflUlatOf ..,.,,oriol, m01t """" ot r,g edge al bar. Cor,. dition IJ ,ore b-..t CDc.., cau:w la.lhov� , not dte<lct'ct

lo,.,.

---

......__

THklADING of commutator with fine linn rewtn wh.ern exceulve mctoJ tro,nfer o<.wn. It usually leodJ to rt1Ytfodng of COl"t'VnUloto, and rapid brvsh w�.

PITCH IAII-M.\lll(INO produces low o, b.imed ,poll on rh• <ommutotor 1urfoct, tl,e "41.mber of then mo.rlc­ ings equolt holf or oU the numbc-r of poles on the motor

C AUSES OF POOR COMMUTATOR CONDITION _.., ..,_u:w NlofoA. 11w dri,.,. �.,._ •,ay lft,..,..__ -...1 ............ - ,......., ·­ 4Aat• - �1,1;M,. t::-iH el ...... � ,_ ..._.._,., .. ._.

4..........,.. - � tt-ef y99 <- tek• ......,........ .....,.. ,.,...w,«,.... ,...,..,..

• .,...••

GllOOVING " o ,....i.-,..,J co,,d o• «wHd bt abt0d11• mat•rtal if'I th.• b:n,,J.h or otmot• .,.,.,._ d 9roove1 f°"", uott <OfftOT't'e oction.

HfAVY SLOT IAll-"'-'IIKING con Involve

.,,1,;ng ol � ode- ol co"""vrotcr bcr. Pc,­

tem ti n4and to number of c.o.ndvaon p« slot.

How ro Ger th• Mo1t Yoh,• from thh, Chart r w...,... .. ...,. c.-. ........ o..i. 0-,t • , • ....,., ..,.,. ..,.. v._.....,_W. -� , ...

6-1, .. l!w-y ........ ,.. Uo• ••\• 1ir-4...,.,. � n,,, U..-t _. .,. .... � .. - ..4Uo ....-s-� ....,....,, -t.....

��.a-._. ""'-�

..

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

�"-&Nnert11.tle•�_...,..._�., ...... �!t-t "'""'.....,... ..... .......,. �.,,...,... ..,._ """'" &I. ...i ..,,._ -• 0.-.. fk.<wlc .,._. • c�•

li_ .. ,....,..�� •• � ........ __.L,_,__._.._,,

-..,---.-4 ........ �..... ---�

MH,.,._ ...,._....,..,-.... """111,,, ,..,_ 1Hwtit �•Nfl • ,_ '--•••Nt• ��-. _.._,. .,.... a..,..tt O•f'l�•I Uen,t,

...,ow... ... �

Cv!::>on Ptoduc:s

General ::!ectric Company :':ast Stroucs:>.:rg, ?a i 83C 1

j

Copynl!ht,

Mn1�al

Intended for CL'\RK dealers onh Do no1 sel I or d1stribut�