CLARK FORKLIFT PMA-321 S203040 SP 202530 SERVICE MANUAL - PDF DOWNLOAD

PMA-321 S20/30/40 SP 20/25/30

C URRK

Technical Pu�lications Lexington, KY 40508

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.

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

5. Before Leaving The Truck: 1) Stop truck.

2) Fully lower the load engaging means.

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.

4. Before Starting To Drive The Truck: 1) Be in operating position.

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

6) Lock the control or ignition circuit.

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

2) Use blocks or other positive truck positioning devices.

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

4) Start engine or turn on power.

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

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

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.

3) Put directional control in neutral.

6) Release parking brake.

1023-Z.l

R�V OCT 86

PM

OWNER SAFE

MAINTENANCE

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.

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.

11.

Handle LP-gas cylinders with care.

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

18.

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.

19.

12.

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

13.

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.

15. 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.

PRACTICES

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

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.

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

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.

20.

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.

21.

1023-Z.2 REV OCT 86

mm

INDUSTRIAL TRUCK DIVISION

�

SERVICE ENGiNEERING DEPARTMENT, BATTLE CREEK

GROUP

m

POWRWORKER PICTORIAL INDEX

GROUP 34 LIFT CYLINDER

GROUP 34 UPRIGHT & LIFT CARRIAGE

GROUP 34 LIFT CHAIN

GROUP 29 HYDRAULIC SUMP TANK FLUID STRAINERS GROUP 30 Tl LT VALVE GROUP 30 LIFT VALVE

GROUP 12 BATTERY GROUP 23 BRAKE

GROUP 35 LOAD WHEELS

POWRWORKER 11S" MODEL PICTORIAL INDEX Code: PMA-321

JUN 73

I NOEX - 1

GROUP 13 TILT VALVE SWITCH (PUMP MOTOR SWITCH)

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INDUSTRIAL TRUCK DIVISION SERVICE ENGINEERING DEPARTMENT,

BATTLE CREEK

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GROUP 34 UPRIGHT & LIFT CARRIAGE GROUP 34 UPRIGHT LATCH

� GROUP 34 LIFT CHAIN GROUP 34 LIFT CYLINDER ---+--l-tt-t"" GROUP 13 TILT VALUE SWITCH (PUMP MOTOR SWITCH)

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GROUP 25 C TROL HANDLE ASSY. \

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GROUP 34 LIFT CHAIN GROUP 30 TILT 1/ALVE

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GROUP 16 MOTOR, PUMP DRIVE GROUP 17 CONTACTOR BOX ASSY. .

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GROUP 20 DRIVE UNIT

GROUP 16 MOTOR, PUMP DRIVE GROUP 29 HYDRAULIC SUMP TANK DRAIN PLUGS

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GROUP 29 HYDRAULIC SUMP TANK FLUID STRAINERS

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I f-GROUP 35 LOAD WHEEL

GROUP 23 DRIVE WHEEL \ \ & TIRE GROUP 29 HYDRAULIC PUMP

GROUP 29 STABILIZER

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GROUP 13 MOTOR CUT-OFF (BRAKE) SWITCH/

13023 M-321-73 FP POWRWORKER "SP" MODEL PICTORIAL INDEX JUN 73

INDEX - 2

Code: PMA-321

r:mm mm:Jm.·

INDUSTRIAL TRUCK DIVISION SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK

SP20 and SP30 MODELS MACHINE REAR MACHINE FRONT

S20 and S40 MODELS

Fig. 12724.

Code: PM-321

Powrworker "S" & "SP" Models JUN 73

Page 5

INDUSTRIAL TRUCK DIVISION

MARKETING TRAINING DEPT.

T A B L E

O F

C O N T E N T S

P LANNED MAINTENANCE PROCEDURES

11 p 11

M

PAGE NO(S) 1-45

GROUP NO. SECTION NO. Powrworker 1 1S 11 Model Pictorial Index Powrworker 11SP 11 Model Pictorial Index Lubrication Chart(s) & Specifications Battery ......... .

El�ctric Battery Powered Industrial Trucks - UL583 .•... • • Electric Drive Motor (Brake) Cut-off Switch Pump Motor Operating Switch Electric Motors Electric Contactors ....

Drive Unit .....

Drive Wheel & Tire ..

Brake .. . ...

Hydraulic Sump Tanks Vertically Mounted Tanks Horizontally Mounted Tanks Hydraulic System Pressure Checks Single Pump Installation Dual Pump Installation ....

Upright & Carriage Roller Check & Ajd. 4 & 6 Roller Carriages ..•.

Standard & Hi-Lo Upright Rollers Lift Chain Adjustment • ...

Upright Down Drift and Tilt Cylinder .

Bleeding Compound Lift Cylinders Lift Chain Maintenance ...• Trail (Load) Wheels • ..

Decals - Plates - Upright Deck And Serial No. Location .

Truck Specifications . .. .

PM Inspection and Drivers Daily Inspection Fonns Fire Extinguisher Recommendations .

Page 6

IND IND 01 12

1 1

12 13 13 16 17 20 23 23

2 1 2 1 1 1 1 2

29 29

1 2

30 30

1 2

34 34 34 34 34 34 35

1 2

40 40

1 2

40

3

3

4 5 7 1

Code: PM-321, REV FEB 84

mm Imm

INDUSTRIAL TRUCK DIVISION SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK

PM

F O R EW O RD PLANNED MAINTENANCE SECTION The purpose of this section is to provide the basic step by step procedures which should be followed in servicing the vehicle.

The section is fully pictured and contains, in the Appendix/s, specifications and other data including lubrication guides.

About Planned Maintenance Planned Maintenance Is a program in which inspections, minor adjustments, lubrication, oil changes, and replacement of filters are performed on a scheduled and systematic basis. A solid PM program should incorporate a method of record keeping which enables you to better determine PH schedules and enables you to track the maintenance costs per machine.

An effective PM program should incorporate two basic phases: 1.

An inspection performed by the driver or maintenance man at the beginning of each shift. This is a quick visual check for obvious damage and leaks a check of engine oil and water levels, lights, instruments and warn­ ing devices.

2.

The Planned Maintenance routine is based on 50 to 250 operating hours •••• with the interval being determined by operating conditions.

Records will tell you how often PM should be done. Jf an operation is clean and not punishing, a PM interva] can be extended. If an operation is extremely dirty and punishing, the PH interval may have to be reduced. Thus the PM interval can be tailored to answer the needs of your operation.

If the PH is religiously followed, needs for repair, major adjustment and component replacement will be discovered automatically and such work wi11 be done only as needed.

For instance, brake checks which are part of the PH wi 11 uncover the need for. adjustments and/or repairs which may be required periodically. Who can say? The point is that this will be done only when needed and that 1 s true for all systems and components.. Thus in this program we are ab le to eliminate 500, 1000 and 2000 hour inspections and the things normally covered in these inspections wil 1 be done only when the PH uncovers the need for repairs.

The objectives of PM are: 1.

2.

3.

4.

To reduce costly unscheduled downtime.

Reduce maintenance costs.

Increase vehicle productivity.

Above al 1, to increase personal safety of drivers and other personnel.

Inspection Forms To insure that the daily inspection and PH are properly performed, we recorrrnend the use of the inspection forms In the GROUP 4o. Such forms not only provide a guide for the inspections and procedures but serve as a record in tracking maintenance requirements for each vehicle. Moreover, they will assist you in determining when to schedule a vehicle for major repairs, which can be done without the disruptive effect of unscheduled downtime.

Inspection Forms may be purchased from your local CLARKDealer.

Code: PH-32 1

JUN 73

Page 7

-

INDUSTRIAL TRUCK DIVISION SERVICE ENGINEUINO DEPARTMENT, BATTLE CRER ABOUT PM

A special coding system on the PM check sheet allows the PM man to efficiently report truck condition, with a mlni,rum number of words. As the PM ls performed, a check Is made on the check sheet indicating truck condition regard• ing a potential problem, or needs urgent repair.

Whenever a system or component is faulty or un· safe, it must be noted on the PH check sheet, and reported to the designated authority at the conc.luslon of the PH.

Fig. 12618

What should a comp.Jete electric truck PH Include? The best answer Is to go througt. a PM based on the knowledge and experience of PM men, service managers, engineers. and service engineering personnel.

Fig. 12619

VISUAL INSPECTION

First, make a quick overall inspectio� for OIL

LEAKS.

If oil leaks are found, at this time, or later In the PM, tix the minor leaks; and report on the check sheet any leaks which wl 11 requ.ire major repair.

Fig. 12620 JUN 73

Page 8

Code: PM-321