CLARK FORKLIFT PW 15 thru 18 SERIES PW 186 OVERHAUL MANUAL

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Overhaul Instructions

•

PW 15 thru 18 SERIES PW 186

Book No OH-62!1

INDUSTRIAL TRUCK DIVISION MARKETING TRAINING DEPT

FOREWORD Use of This �nual This manual contains information which will help a trained technician perform overhaul procedures on lift truck com­ ponents.

This manual is divided into groups which include the components of a lift truck system. The groups describe removal, inspection, bench overhaul, installation and testing procedures.

Read, understand and follow the pro­ cedures and safety messages found in this manual. Wear body protection and always use the correct tool for the

job. Follow the safety messages and work with safety in mind to avoid accidents and prevent personal injury.

Clark lift trucks are designed to rigid specifications with quality components.

However, through use, parts will even­ tually require replacement or rebuild.

OSHA requires that all replacement parts meet original design, quality and safety requirements. Clark lift truck dealers can provide genuine Clark replacement parts which meet these specifications.

Please direct all inquiries or comments regarding the content of this manual to: Clark Equipment Company Marketing Training & Communications Dept.

Maintenance Writing Group 525 North 24th Street Battle Creek, MI 49016

Code: OH-525, MAR 82

Page i

INDUSTRIAL TRUCK DIVISION

MARKETING TRAINING DEPT.

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m

SAFETY MESSAGES

WARNING

SAFETY AND YOU

THE SAFETY ALERT SYMBOL IDENTIFIES IMPORTANT SAFETY MESSAGES IN THIS MANUAL AND ON THE LIFT TRUCK. READ, UNDERSTAND AND FOLLOW ALL MESSAGES TO AVOID PERSONAL INJURY.

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WARNING

LIFT TRUCK MAINTENANCE

DO NOT WORK ON THIS TRUCK UNLESS YOU ARE TRAINED AND AUTHORIZED AND KNOW THE CORRECT MAIITTENANCE PROCEDURES.

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WARNING

BATTERY SERVICE

BATTERY SERVICE MUST BE DONE

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

Page ii

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WARNING

PERSONAL INJURY

WEAR EYE GLASSES, SAFETY SHOES AND CORRECT FITTING CLOTHING 1-1-lEN WORKING ON LIFT TRUCKS. INJURY CAN RESULT IF YOU DO NOT WEAR PROTECTION.

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WARNING AA PRESSURE

WEAR EYE PROTECTION & PROTECTIVE CLOTHING WHEN CLEANING OR DRYING WITH AIR PRESSURE. REDUCE PRESSURE TO [207 kPa] 30 PSI. DEBRIS REMOVED WITH AIR PRESSURE CAN CAUSE INJURY.

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CAUTION

BEARING DAMAGE

DO NOT LET THE BEARING SPIN �EN DRYING WITH AIR PRESSURE. DAMAGE TO THE BEARING WILL RESULT IF IT SPINS DRY.

Code: OH-525, MAR 82

INDUSTRIAL TRUCK DIVISION

MARKETING TRAINING DEPT.

SAFETY MESSAGES

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WARNING

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WARNING

ELECTRICAL BURNS

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

EXPLOSIVE GASES

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.

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WARNING

SULFURIC ACID

THE BATTERY CONTAINS CORROSIVE ACID WHICH CAN CAUSE INJURY. IF ACID CONTACTS YOUR EYES OR SKIN, FLUSH IMMEDIATELY WITH WATER AND GET MEDICAL ASSISTANCE.

Code: OH-525, MAR 82

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WARNING

ELECTRICAL BURNS

DISCONNECT THE BATTERY AND REMOVE All JEWELRY BEFORE WORKING ON ANY ELECTRICAL SYSTEM. SEVERE BURNS CAN RESULT FRrn1 CONT ACT WITH ELECTRICAL SYSTEMS

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WARNING

HYDRAULIC FLUD PRESSURE

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

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CAUTION

NAMEPLATES & DECALS

DO NOT OPERATE A LIFT TRUCK WITH DAMAGED OR LOST IECALS AND NAMEPLATES. REPLACE THEM IMMEDIATELY. THEY CONTAIN IMPORTANT INFORMATION.

Page iii

CLqRK

EQUIPMENT

INDUSTRIAL TRUCK DIVISION NOTES

1146-Z

REV OCT 72

INDUSTRIAL TRUCK DIVISION MARKETING TRAINING DEPl.

TABLE OF CONTENTS (By Group Number)

GROUP

Section

12

lR

Battery Pack

12

2

Battery Charger

13

1

Master Control

1

Drive Motor

1

Control Panel

12 13

1

lR

16

lR

16

2

20

1

16

19

Battery Pack

Master Control Drive Motor Pump Motor

Drive Unit

20

2R

Drive Unit Mounting

29

lR

Hydraulic Unit

34

1

Lift Cylinder

39

1

Sheet Metal

25 29

35

40

1 1

Hydraulic Unit

1

Lift Linkage

1

(See rear of manual) (See rear of manual) (See rear of manual)

Code:

Control Handle

OH-5 25, March 82 P.S. L.

Data Plates and Decals

Electric Schematic Diagram

Wiring Pictorial

Hydraulic Schematic Diagram

Page 1

INDUSTRIAL TRUCK DIVISION

MARKETING TRAINING DEPT.

TABLE OF CONTENTS

(Alphabetical Order) GROUP

Battery Pack (Removal)

12

Battery Pack (Overhaul)

12

Battery Charger (Overhaul)

Control Handle (Overhaul) Data Plates and Decals Drive Motor (Overhaul) Drive Unit

Electric Schematic Diagram

l

16

lR

1

1

16

1

20

2R

1

(See rear of manual)

Hydraulic Schematic Diagram

(See rear of manual) 29 lR

Hydraulic Unit (Removal)

Hydraulic Unit (Overhaul)

Lift Cylinder

29

1

35

1 lR

34

Lift Linkage

Master Control (Removal)

13

Master Control (Overhaul)

13

Pump Motor (Overhaul)

16

Sheet Metal

39

Wiring Pictorial

Page 2

19

20

Drive Unit Mounting

1

2

40

Drive Motor (Removal)

lR

12

25

Control Panel (Overhaul)

Section

1

l

2 1

(See rear of manual)

Code:

OH-525, March 82 P.S.L.

GROUP 12

GROUP 12 SECTION

lR BATTERY PACK REMOVAL AND INSTALLATION

Code:

OH-525, March 82 P.S.L.

Section lR, Page 1

GROUP 12

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WARNING

BATTERY SERVICE BATTERY SERVICE MUST BE DONE

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

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WARNING

SULFURIC ACID THE BATTERY CONTAINS CORROSIVE ACID WHICH CAN CAUSE INJURY. IF ACID CONTACTS YOUR EYES OR SKIN, FLUSH IMMEDIATELY WITH WATER ANO GET MEDICAL ASSISTANCE.

REMOVAL OF BATTERY PACK: 1.

Remove knob (A) and plate (B).

Fig. 23970 2.

Remove battery cover.

3.

Disconnect battery plug from lift truck.

Section lR. PaQe 2