CLARK FORKLIFT PMA 343 CTA 3040500 SERVICE MANUAL - PDF DOWNLOAD

Planned Maintenance & Adjustment Procedures

PMA 343 CTA 30/40/500

Service Pubilcauons Department Batlle Creek.

Michigan 49016

PM

CTA 30,40,50D

Code: PM-343, JUN 77 Page 1

INDUSTRIAL TRUCK DIVISION CUSTOMER SERVICES GROUP

ILLUSTRATED INDEX

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o

Pl=IQP.2

0--11

26

Code: PH-343. JUN 77

CL'IRK

1.

2.

3.

4.

5.

6.

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8.

9.

10.

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14.

15.

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17.

18.

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20.

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22.

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24.

25.

26.

PM I N D E X

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Code: PM-343, JUN 77

. .. . .. .. . . .

. GROUP 12, Sect on 1 . . GROUP 23, Sect on 1 ...... . . . .

• GROUP 23, Sect on 3 ..... ...

23, Sect on 2 . . . . . . . . .. .. .. .• GROUP GROUP O1, Sect on 2 ....... . . . . • GROUP 20, Sect on 1 . . . . . .

GROUP 00, Sect on 1 . . .. .. GROUP .. ... ......

00, Sect on 2 . . . . . . . . . • . . . . . . . • GROUP 00, on 3 . . . . . . . . . . . . . . . . . . GROUP 00, Sect Sect on 4 .. .

01, Sect on 1 . . . . . . . . . .. .. . . . .. .• .. .. .. GROUP GROUP 40, Sect on 4 ... ...

• GROUP 40, Section 1 .. . . . . . . . .

13, Section 1 . . . . . . . . . . . . . .. GROUP GROUP 23, Section 4 ..... . . . . GROUP 40, Section 3 . . . . . .. .. .. . .. . . . GROUP 40, Section 2 .. .... .

1 1, Section 1 . .. GROUP . . . . . .

GROUP 26, Section 1 . . . ........... ..

GROUP 25, Section 1 . . . . . . . . .. . . . .. .. GROUP 26, Sect on 2 ......•. . GROUP 06, Sect on 4 . .... .

06, Sect on 2 . . . . . .. . .. .. .. .. GROUP GROUP 06, Sect on 3 ..

06, Sect on 1 . . . . . . . . . .. . . . . . . . . .. GROUP GROUP 22, Sect on 1

Alternator Testing Brake Bleeding .

Brake Adjustment Brake Pedal Adjustment • Cooling System Maintenance • .

Differential Draining Engine Trouble Shooting Engine Tune Up Fuel Nozzle Servicing Fue 1 System Priming • Lubrication Charts Lubrication Key Name Plates/Machine Stampings Neutral Start Switch Parking Brake Adjustment • Safety/Inspection Forms Specifications • • • Starter Maintenance Steering Adjustments Steering Gear Steer Wheel Bearings • Transmission Drain and Refill Transmission Fluid Aeration Check • Transmission Oil Cooler Transmission Pressure Checks Wheels & Tires

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INDUSTRIAL TRUCK DIVISION CUSTOMER SERVICES £116111££11116 0£PIITl£11T. BATn£ CRUii

CLqRK'

EQUIPMENT

F O R EWO R D PLANNED MAINTENANCE SECTION The Planned Maintenance Procedures located in the front of this book provide a basic �tep by step guide which should be followed in servicing the vehicle. Adjustment Procedures, specifications and other data Including lubrication guides, are found In the rear of this book and are listed under GROUP and Section Numbers. Refer to the Index or the Product Identification Card, 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 PH 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 PH 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 warning 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 PH should be done. If an operation Is clean and not punishing, a PH Interval can be extended. If an operation is extremely dirty and punishing, the PH Interval may have to be reduced, Thus the PH Interval can be tailored to answer the needs of your operation.

If the PH ls religiously followed, needs for repair, major adjustment and component replacement will be discovered automatically and such work will be done_only as needed. For

Instance, brake checks which are part of the PM will 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 able to eliminate 500, 1000 and 2000 hour Inspections and the things normally covered in these Inspections will be done only "'1en the PH uncovers the need for repairs.

The objectives of PH are: 1,

To reduce costly unscheduled downtfme.

2. Reduce maintenance costs.

3, Increase vehicle productivity.

4,

Above all, to lncrease personal sefety of drivers and other personnel.

Inspection Forms To Insure that the dally Inspection and PH are proper 1 y performed, we recannend the use of the Inspection forms In GROUP 40. Such forms not only provide a guide for the Inspections and pr<0eedures, but serve as a record In tracking maintenance requirements for each vehicle.

Horeover, they will assist you in determlnlng 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 CLARK Dealer.

SPECIAL NOTICE TO ALL USERS OF THIS MANUAL. IF ••• In the process of using this manual for PH procedures, adjustments, references, etc ••• you find that this manual can be Improved l.!l any way. put your Ideas In writing and send them to: CUSTOMER SERVICES ENGINEERING CLARK EQUIPMENT COMPANY BATTLE CREEK, MICHIGAN (49016) We can 1 t promise that your Idea will be u sed, but It will be seriously considered. If you do submit any such Ideas, please understand that Clark Equipment C0111pany can use It without obi lgatlon.

Page 4

Code: PH-366, REV MAY

77

PM

PERFORMING A PM: First check the oil level and add oil if necessary.

Fig. A0753 Check the fluid level of the transmission.

Use only type "F" automatic transmission fluid (Ford specification ESW-M2C33-F).

Fig. A0751 Check the water level.

Fig. A0755 Check the fuel level.

Fig. A0787

Code: PM-343, REV AUG 81 P.S.L.

Page 5

INDUSTRIAL TRUCK DIVISION CUSTOMER SERVICES GROUP

Check the brake pedal firmness by pressing down on the pedal with your foot ••• hold for at least 10 seconds. Pedal must be solid, must not be spongy or drift under foot pressure. Brake pedal sponginess indicates air in the system.

See GROUP 23, Section 1.

Make sure no brake lines are hitting anything.

,i-:r.

�� '.,.

-�t\t Fig. 17359

Next ••. set the parking brake, start the engine, shift into gear, and slowly rev up the engine to make sure the brake holds. If it does not, it should be adjusted or repaired before placing machine into service. Make sure all cotter pins and nuts are securely fastened. See GROUP 23, Section 4.

Fi�. A0329 Check the seat mounting security and the seat adjuster for proper forward and back operation.

Fig. 17349 Check the neutral start switch by trying to start the engine in forward and reverse. The engine should not start with the transmission in gear.

If it does, see GROUP 13, Section 1.

-Fig. A0765

· ·2

Code: PM�343, JAN 79 REV

PM

Next, check instruments, horn, head and tail lights, indicator lights and warning lights.

Fig. A0787 Make sure the hour meter starts.

Fig. A0786 Check tires for excessive wear and cuts. Pry out of tire treads any objects which could damage the tires. Also check wheel lug nuts for tightness and make sure none are missing. Check tires for proper pressure. Replace any tires which are worn beyond safe limits. See GROUP 22, Section 1•

Fig. A0773 Check steering for excessive hand wheel play.

The steer tires should move as soon as the hand whee 1 is moved •

Fig. A0743

Code: PM-343, JUN 77

Page 7

INDUSTRIAL TRUCK DIVISION CUSTOMER SERVICES GROUP

Then check drive tire inside turning diameters which should be about equal in forward left and right turns. While driving, listen for unusual drive train noise.

Fig. 9854 If the steer tires do not move soon after the hand wheel is moved, then some adjustment needs to be done to the steer gear or steer linkage.

See GROUP 26, Section 1.

Fig. 9846 Make a visual check of the truck. Look for signs of obvious leaks under the transmission, engine and differential.

Fig. AO737 Check the filler screen to be sure it is in place and not damaged. Check O-ring seal to be sure it is not damaged {must be located between cap screen and the filler neck).

�.8.!i!il!i§.

DO NOT WELD IN THE VICINITY OF THE FUEL TANK. Fig. AO3OO

Code: PM-343, JAN 79 REV