CLARK FORKLIFT PMA 445 ST 245 Planned Maintenance and Adjustment Manual

Planned Maintenance & Adjustment Procedures

PMA 445

ST 245

CUARK

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333WestVineStreet Lexington, KY 40507-1640

Copyrighted Material lntend<d for CLARK deniers only Do not sell or distribut<

INDUSTRIAL TRUCK DIVISION

MARKETING T<AI I G DcPT.

TABLE OF CONTENTS (By Group Number) Use of Manual and PM Information Safety Mess ages Illustration of Machine Pictorial Index Planned Maintenance Procedures

1300-Z

Pages Page Page Pages

iii & iv 1 2

3 - 37

GROUP Section Lubrication Charts Electric Truck Battery Electric Battery Powered Industrial Lift Trucks - U.L. 583 2 12 Pump Motor Switch Adjustments 1 13 Drive Motor (Brake) Cut-Off Switch Adjustments 2 13 General Motor Maintenance 27 16 Contactor Panel Box (With lA Contactor) 1 17 Solenoid Contactor Adjustment 2 17 SCR Control Troubleshooting 1 19 SCR Panel Component Identification 5 19 7 Checking H.B. SCR Components 19 Drive Unit 1 20 Drive Wheel and Tire 1 23 Brake 2 23 Hydraulic Tank and Filter Maintenance 1 29 Hydraulic System Pressure Checks 1 30 Tilt Cylinder Drift Test 2 32 Carriage Lift Chain Check and Adjustment 34 1 Upright Drift Test 3 34 Lift Chain Maintenance 7 34 Load Wheels 1 35 Jacking and Blocking Procedures 38 1 Decals, Nameplates, and Serial Number Data 1 40 Suggested Equipment for Electric Truck P.M. 40 2 PM Inspection and Driver's Daily Inspection Forms 3 40 Fire Extinguisher Recommendations Lubrication Specifications and Recommendations 4 40 Lubrication Chart Key Truck Specifications 5 40 Hydraulic Diagram Wiring Diagrams IN-17872 01

12

1

1

IN-19893

IN-20197

Code: PM-445, REV FE B 84 p. s. L.

Copynt1hlcd 1alenJI lnlendcJ for CL.ARK deAlcB onl)

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Page i

INDUSTRIAL TRUCK DIVISION

MARKETING RAINING DEPT.

TABLE OF CONTENTS (Alphabetical Order) GROUP Section Battery - Electric Truck Brake Carriage Lift Chain Check and Adjustment Checking H.B. SCR Components Contactor Panel Box {With lA Contactor) Decals, Nameplates, and Serial Number Data Drift Test - Tilt Cylinder Drift Test - Upright Drive Unit Drive Wheel and Tire Electric Battery Powered Industrial Lift Trucks - U.L. 583 General Motor Maintenance Hydraulic System Pressure Checks Hydraulic Tank and Filter Maintenance Illustration of Machine Jacking and Bl ocking Procedures Lift Chain Maintenance Load Wheels Lubrication Charts Lubrication Specifications and Recommendations Lubrication Chart Key PM Inspection and Driver's Daily Inspection Forms Fire Extinguisher Recommendations Pictorial Index Planned Maintenance Procedures Safety Messages SCR Panel Component Identification Solenoid Contactor Adjustment Switch Adjustments - Drive Motor (Brake) Cut-Off Switch Adjustments - Pump Motor Troubleshooting - SCR Control Truck Specifications Hydraulic Diagram Use of Manual and PM Information Wiring D iagrams

Page ii

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1 12 23 2 34 1 7 19 17 1 40 1 2 32 34 3 1 20 23 1 12 2 27 16 1 30 29 1 Page 1 38 1 7 34 1 35 1 01 40 4 40

3

Page 2 Pages 3 - 3 7 Pages iii & iv 5 19 2 17 2 13 13 1 19 1 5 40 1300-Z IN-17872 IN-19893 IN-20197

Code.• PM - 445 • REV FEB 84 p • s • L •

INDUSTRIAL TRUCK DIVISION MARKEilNG TRAlN'NG D=Pi.

SAFETY MESSAGES

m

PLEASE READ AND UNDERSTAND THE SAFETY MESSAGES SHOWN BELOW BEFORE YOU DO ANY WORK ON A LIFT TRUCK.

m

WARNING

PERSONAL INJURY

LIFT TRUCK MAINTENANCE

WEAR EYE GLASSES, SAFETY SHOES AND CORRECT FITTING CLOTHING W-IEN WORKING ON LIFT TRUCKS. INJURY CAN RESULT IF YOU DO NOT WEAR PROTECTION.

DO NOT WORK ON TH IS TRUCK UNLESS YOU ARE TRAINED AND AUTHORIZED AND KNOW THE CORRECT MAINTENANCE PROCEDURES.

m

WARNING

SULFURIC ACID

WARNING

m

WARNING

DO NOT SMOKE OR HAVE OPEN FLAMES OR SPARKS IN BATTERY CHARGING AREAS OR NEAR BATTERIES.AN EXPLOSION CAN RESULT AND CAUSE INJURY OR DEATH.

WARNING

BATTERY SERVICE

ELECTRICAL BURNS

BATTERY SERVICE MUST BE DONE

BY TRAINED PERSONNEL. BATTERY ACID CAN CAUSE SEVERE BURNS AND INJURY.

Code: P;"-1-501, MR 82 P. S. L.

m

EXPLOSIVE GASES

THE BATTERY CONTAINS CORROSIVE AC ID WH !CH CAN CAUSE INJURY. IF ACID CONTACTS YOUR EYES OR SKIN, FLUSH IMMEDIATELY WITH WATER ANO GET MEDICAL ASSISTANCE.

m

WARNING

DISCONNECT THE BATTERY BEFORE YOU REMOVE THIS PART FROM THE TRUCK. SEVERE BURNS CAN RESULT FROM CONTACT WITH ELECTRICAL SYSTEMS. j

Copyn11h1.d Molerul Intended for CL\RK c.leoler<onlv Do 0111 •�II or dl<lrihut�

Page i.i.i

INDUSTRIAL TRUCK DIVISION MARKETING iAAIN!NG D:0-

SAFETY MESSAGES

m

PLEASE REA!:> AND UNDERSTAND THE SAFETY MESSAGES SHOWN BELOW BEFORE YOU DO AJIT WORK ON A LIFT TR�CK.

m

WARNING

ELECTRICAL BURNS

ELECTRICAL SHOCK

REMOVE All JEWELRY BEFORE WORKING ON ANY ELECTRICAL SYSTEM. SEVERE BURNS CAN RESULT FROM CONTACT WITH ELECTRICAL SYSTEMS.

m

DISCONNECT THE BATTERY AND DISCHARGE THE CAPACITOR BEFORE HANDLING SOLID STATE COMPONENfS. INJURY CAN RESULT FR(),1 AN ELECTRICAL SHOCK.

m

WARNING

HYDRAULIC FLUD PRESSURE

00 NOT OPERATE A LIFT TRUCK WITH DAMAGED OR LOST CICALS ANO NAMEPLATES. REPLACE THEM IMMEDIATELY. THEY CONTAIN IMPORTANT INFORMATION.

m

WARNING A� PRESSURE

WARNING

FALLWGFORKS

WEAR EYE PROTECTION & PROTECTIVE CLOTHING w-tEN CLEANING OR DRYING WITH AIR PRESSURE. REDUCE P�ESSURE TO (207 kPa] 30 PSI. 11:BRIS REMOVC:D WITH AIR PRESSURE CAN CAUSE INJURY.

Pa_ge iv

CAUTION

NAMEPLATES & DECALS

DO NOT USE YOUR HANDS TO CHECK FOR HYDRAULIC LEAKAGE. FLUID UNDER PRESSURE CAN PENETRATE YOUR SKIN AND CAUSE SERIOUS INJURY.

m

WARNING

00 NOT WALK OR STAND UNDER RAISED FORKS. THE FORKS CAN FALL AND CAUSE INJURY OR DEATH.

Copyn11h1eJ �latenal lnt<nd,"1 for CLARK dral<r. onl) £).., 1101 .,..11 or di11r11>u1�

Code: ?M-501, MAR 82 P .S.L.

INDUSTRIAL TRUCK DIVISION MARKETING TRA!NI 'G DE0-.

PLANNED MAINTENANCE PROCEDURES This manual provides detailed instructions for performing Planned Maintenance Procedures which include: minor adjustments, lubrication, system fluid and filter changes, and truck specifications.

WHY A PLANNED MAINTENANCE PROGRAM? Planned Maintenance is a program designed to reduce major failures and costly down­ time by scheduling periodic inspections, lubrication, adjustments and testing on a schedule determined by your use and application of your lift truck. A good PM program will alert you of the need for minor adjustments and repairs and will greatly reduce the potential for a major failure in the future.

An effective program

must

include

the following

daily and periodic functions:

1.

A daily inspection, prior to each shift which will include a visual inspection for damage, leakage, fluid levels and safety items.

2.

A scheduled monthly or 250 hour program based on your operating conditions and performed according to the instructions in this manual.

INSPECTION FORMS Daily and monthly inspection forms are an IMPORTANT part of your PM program and will provide you with the necessary details for keeping accurate records on the condition and service requirements of your truck. Inspection forms can be obtained from your local Clark dealer. (See GROUP 40 for sample forms).

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300'i':@11htcd 1alenJI lnlcndcJ fo.-<.:L.ARK deAlcB onl)

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DEC 81

ClqAK

EQUIPMENT

INDUSTRIAL TRUCK DIVISION SERVICE ENGINEERING DEPARTMENT, SAHU CREEK

WDRKSAFILY DRIVE SAFELY BE CAREFUL

ALWAYS GIVE MACHINE SERIAL NUMBER

WHEN ORDERING PARTS

Rev OCT 73

1127-Z

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PM

[ Fig. 23840

ST 245-20/25/30/40 Resistor and SCR Controlled [1000-1800 Kg.] 2,000 through 4,000 lb. Capacity

Code: PM-445,

JUN

82 P.S.L.

<.up)nghkd Matenul lntcnd<d lbr CL\RK dcol�, onl) llo not ,c,11 or d1,tribut.:.

Pagel

PM

PICTORIAL INDEX

I

1-34

0 BASIC GROUP NUMBERS 12. - BATTERY 13. - SWITCHES, ACCELERATING CONTROL ASSE.'lBLY 14. - HIRING 16. - MOTORS (ELECTRICAL) 17/19. - CONTACTORS/CONTROLS 20. - DRIVE AXLE 23. - BRAKES 29. - HYDRAULIC Pln-1?, Sill1P & FILTER 30. - HYDRAULIC VALVES AND LlNK._�GE 32. - TILT CYLINDER 34. - UPRIGHT & LIFT CYLINDER 3 5. - L0..1..J !-!HEELS 38. - FW1E & COUNTERWEIGHT fig. 23842 Page 2

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Code: PM-445, JUN 82 P.S.L.