CLARK FORKLIFT OH 540 TM 247 OVERHAUL MANUAL

Overhaul Manual

OH 540 TM 247

,,��,.....,,., CLqRK

Intended for CLARK d�alers only Do 1101 :odll>r d1 tnbulc

Service Publ1cab0ns Department Battle Creek, M'Ch!Qan 49016

CIARK

OH This manual includes COMPONENT REMOVAL AN D OVERHAUL P ROCEDURES

for TM 15 - 17 - 20 36-Volt Fork Lift Trucks Code: OH-540, NOV 85

Copyrighted Material Intended for CLARK dcJlcrs onh Do not sell or distnbutc

Page i

CL'IRK

OH CONTENTS

GROUP Section COMPONENT REMOVAL AND OVERHAUL PROCEDURES 12 13 14 16 16 16 16

19 19

1 6 1

22R/22 23R/23 24R/24 27 1 7

20 lOR/10

23 3 23 17R/17 23 18R/18 25 lOR/10

26 26 26

2 8 9R/9

30 31

9R/9 1

34

9R

39 39

1 2

BATTERY REMOVAL ACCELERATOR CONTROL MAINTENANCE ELECTRICAL SYSTEM WIRING DIAGRAMS

STEER PUMP MOTOR MOTOR DRIVE LIFT PUMP MOTOR GENERAL MOTOR MAINTENANCE

EV-100 SCR CONTROL COMPONENT ARRANGEMENT CONTROL PANEL REMOVAL DRIVE AXLE

BRAKE BLEEDING PROCEDURE BRAKE CALIPER ASSEMBLY BRAKE MASTER CYLINDER STEERING GEAR CONTROL

STEER WHEEL BEARINGS STEER AXLE, STEERING LINKAGE, STEERING TRUNNION STEERING CYLINDER

26 14R/14 29 lOR/10

STEER PUMP LIFT PUMP

32 llR/11

TILT CYLINDER

38 38 38

40

1 2 3

5

HYDRAULIC VALVE (MAIN HYDRAULIC VALVE) HYDRAULIC SYSTEM SCHEMATIC DIAGRAM

UPRIGHT REMOVAL COUNTERWEIGHT REMOVAL BATTERY PLATE ADJUSTMENT MACHINE JACKING ANO BLOCKING OVERHEAD GUARD REMOVAL HOOD REMOVAL SPECIFICATIONS

NOTE - "R" denotes Removal Procedure for components

Page ii

Copyrighted Material Intended for CLARK dealer.; onl) Do not sell or distribute

Code: OH-540, MAR 86

OH

PICTORIAL INDEX

/�

39

0

t,·::;,!..

K.---.j-�.. ....,..

/4

:I

TYPICAL FORK TRUCK BASIC GROUP NUMBERS

:�

' .

i

I

I

I

'• �

...�

12

• •

I

..

\_ 2

3 8

3

0l/2i 0

I2 13 14 16 17 19 20 22 23 25 26 29

0

32 334 38 39

11AITU'\' ACCELDATOR CONTl\01. ASSEMBLY WIRING MOTORS DRIVE K:>TOR CUT-OIIT, DlllCTlONAl. CONTl\01.S CONTACTORS, cm,no1.s DltlVE AXLE llltAIIS llRAJ:ES, IIRE£1.S/TIRES STEERING COLUMN, 1.INXAGE STEER AXLE, C'YI.INDER, PUKP, LINES ll'lllRAUI.IC Pl/KP 6 Fll.TER BYDRAUl.lC VAi.VE 6 1.Ull(ACE TII.T CYI.INDElt UPRIGHT 6 1.IFT CYLINDER F1WU: 6 COUNTERWEIGHT SIIEET KE:TAI., SEAT 6 OVERHEAD GUARD

Code: OH-540, MAR 86

Copyrighted Material Intended for CLARK dealer,; only Do nol sell or distribute

30

. r3

'

8

V

29

6

'--26

29

Page ii:

CIARK

OH

FOREWORD Clark Equi pment Company welcomes you to the growing group of professi onal people who own, operate and mai ntain Clark lift trucks. We take great pride in the long tradition of quali ty products and superior value that the Clark name represents. Thi s manual has been written to help you main­ tai n your Clark lift truck in an eff i ci ent and safe opera­ ting conditi on.

The correct maintenance and care of your lift truck is not only i mportant for economy and utili zation reasons, i t is essenti al for your safety. A faulty lift truck i s a poten­ tial source of danger to the operator, and to other person­ nel worki ng near i t. Approved methods of servi ce and cor­ rect procedures of repa i r are important for the safety of personnel and the safe operati on of a lift truck.

Genui ne Clark parts should always be used when replacements are needed. Substi tute parts from other sources may not be designed like ori ginal parts and may not meet OSHA or other safety requi rements.

The mechanic i s cauti oned and expected to always work i n a safe manner by using the correct procedure. If a mechani c does net understand a safety procedure when performi 'ng main­ tenance on a truck, the maintenance supervi sor should be consulted for assi stance. Do not take chances which may result i n injuri es.

Your local Clark dealer i s prepared to help you with trai ned servi ce personnel who know your lift truck and can keep i t operati ng safely and effici ently.

Page i v

Copyrighted Material Intended for CLARK dealer,; only Do nol sell or distribute

Code: OH-54O, MAR 86

OH

HOW TO USE THIS MANUAL Thi s manual i s intended to be used by persons who are trai ned and authori zed to do lift truck mai ntenance.

The purpose of this manual i s to outli ne the recommended procedures for removal and overhaul of major components of the lift truck. It is wri tten to show and descri be the removal, disassembly, repai r and assembly steps that are normally required to servi ce these components.

The detai led procedures are arranged i n sequence by num­ bered GROUP and Secti on. The GROUP numbers are the same as the component group in the Master Parts Book.

Component specificati ons, informati on notes and safety messages are included at the proper step of each procedure.

To be better prepared to do the necessary overhaul work, please take time to read the entire procedure, includi ng any speci al i nstructi ons, before doi ng any work.

Truck specificati ons are i ncluded i n GROUP 40 at the back of the manual for easy reference.

Please refer to the Operator's Manual, located on the truck, and the Pl anned Mai ntenance and Adjustment proce­ dures manual for additi onal informati on and instructi ons on the operati on and mai ntenance of your truck.

If you have need for -more i nformation on the care and repair of your truck, please contact your authorized Clark dealer.

Code: OH-540, MAR 86

Copyrighted Material Intended for CLARK dealer,; only Do nol sell or distribute

Page v

PM

OWNER SAFE MAINTENANCE PRACTICES Powered industrial trucks may become haz­ ardous if adequate maintenance is not done. Therefore, suitable maintenance facilities, personnel, and procedures must be provided.

5. Befor e Leaving The Truck: 1) Stop truck.

2) Fully lower the load engaging means.

Maintenance and inspection of all powered industrial trucks should be done in agreement with the recommendations in this manual and the following practices:

3) Put directional control in neutral.

4) Apply the parking brake.

1. A scheduled preventive maintenance, lubrication, and inspection program must be followed.

5) Stop the engine or turn off power.

2. Only qualified and authorized personnel should be permitted to maintain, repair, adjust, and inspect industrial trucks.

7) Put blocks at the wheels if truck is on a ramp, or being worked on.

3.

Operation to check performance of the truck or attachments must be done in an authorized, safe, clear area.

6) Lock the control or ignition circuit.

6. Before Working On Truck: 1) Raise wheels free of floor or disconnect power source.

4. Before Starting To Drive The Truck:

2) Use blocks or other positive truck positioning devices.

1) Be in operating position.

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

3) Put directional control in neutral.

4) Start engine or turn on power.

5) Before operating truck, check functioning of lift and tilt systems, directional and speed controls, steering, warning devices, brakes, and any attachments.

3) Put blocks under the load engaging means, innermast(s), or chassis before working under them.

7. Before working on engine fuel system of gasoline powered trucks with gravity-feed fuel systems, be sure fuel shutoff valve is closed.

8.

Before working on engine fuel system of LP-gas powered trucks, close LP-gas cylinder valve and run engine until there is no more fuel in the system and engine stops running.

6) Release parking brake.

S<;1pyright"'1 Material

10 2 3- Z . 1 lmeRlt:<MoMI1t18�alers only Do not sell or distribute

PM

OWNER SAFE MAINTENANCE

PRACTICES

9. Avoid fire hazards and have fire protec­ tion equipment available. 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 flammable cleaning fluids for cleaning parts.

16.

10.

Provide ventilation to the work area, vent exhaust fumes, and keep shop clean and floor dry.

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

Handle LP-gas cylinders with care.

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

18. 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 electrical insulation.

11.

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

12.

13. All parts of lift and tilt mechanisms and frame members must be carefully and regu­ larly inspected and maintained in a safe operating condition.

Special trucks or devices designed and approved for hazardous area operation must receive special attention to make sure that maintenance keeps the original, approved safe operating features.

14.

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 until the leak has been corrected.

15.

All hydraulic sytems 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 developed to the extent that it would create a hazard.

19. Industrial trucks must be kept in a clean condition to minimize fire hazards and help in the detection of loose or defective parts.

20. Modifications and additions which affect capacity and safe truck operation must not be done by the customer or user without the manufacturer's prior written approval. Capacity, operation and maintenance instruction plates, tags or decals must be changed accordingly.

21. 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.

Copyrighted Material lntct<fil��r-<+-:-tK d<Qr,vo,OCT lYo nol sell or d1str'ibute

86

INDUSTRIAL TRUCK DIVISION

A

WARNING

SAFETY SIG NS AND SAFETY MESSAGES STAY ALERT! Follow safety rules, regulations and procedures. Accidents can be avoided by recognizing dangerous procedures or situations before they occur.

Improper or careless techniques will cause accidents. Don't take chances with incorrect or damaged tools and equipment. WORK SAFELY and follow the safety signs and their messages.

READ and understand the procedures for safe lubrication, adjustments and maintenance outlined in this manual.

Safety signs and messages are also put on the forklift truck to provide instructions and to identify specific areas where potential hazards exist.

Study and follow the instructions, signs and messages. Serious injury or death to you or other persons may result if these messages are not followed.

IMPORTANT -- This message is used when special precautions should be taken when dis-assembling or assembling components to avoid damage or malfunction.

NOTICE ----- This message is used when special instructions or identification is required relating to tools, pressure readings, capacities and other special data.

CAUTION ---- This message is used as a reminder of safety practices which can result in personal injury if proper precautions are not taken.

WARNING

This message is used when a hazard exists which can result in injury or death, if proper precautions are not taken.

DANGER ----- This message is used when an extreme hazard exists which will result in death or serious injury if proper precautions a re not taken.

Copy1!lf��� Material 1322�nded fodtJ.UR84ealers only Do not sell or distnbute