CLARK FORKLIFT SM-560 WP-40 SERVICE MANUALS

SM-560 WP-40

SERV+W&NUAL

WP40

CONTENTS GROUP

PAGE

FOREWORD HOWTO USE THIS MANUAL SAFETY SIGNS AND MESSAGES USER SAFE MAINTENANCEPRACTICES

ii iii V

GROUP

PAGE

Planned Maintenance Program Battery Removal,Cleaning and Charging Direction/ Accelerator Control Electric Motor Maintenance Pump Motor Drive Motor Contactor Panel Drive Unit Wheels and Tires Brakes Lift Mechanism Machine Jacking & Blocking Truck Data, Specifications

iV

PM-1 12-01 13-01 16-01 16-03 16-04 19-01 20-01 22-01 23-01 34-01 38-02 40-01

Index - Provides help for locating informationabout various topics.

SM560 FWD i

FOREWORD

Clark Equipment Company welcomes you to the growing group of professional people who own, operate and maintainChtk lift trucks. This manualwill familiarizeyou with service maintenance and overhaul informationabout your new truck. It has been especially preparedto help you maintain your Clark lift truck in an efficient and safe operating condition.

Regular,correct maintenanceand care of your lift truck is not only importantfor full and efficienttruck life; it is essentialfor your safety. A faulty lift truck is a potential source of danger to the operator, and to other personnelworking near it. The importanceof maintainingyour lift truck in a safe operatingcondition by servicingit regularly and, when necessary, repairingit promptlycannot be emphasizedtoo strongly.

To assist you in keeping your lift truck in good operating condition, this manual includes an outline of planned maintenance(PM) proceduresthat are considered essential to the life and safe performanceof your truck. Brief proceduresfor inspections, operational checks, cleaning, lubrfcation,and adjustments are included for your reference.

Clark recommendsthat a planned maintenanceand safety Inspectionprogram(PM) be performedby a trained and authorized mechanicon a regularbasis. The PM program provides the opportunity to make thorough inspections and checks on the safe condition of your truck. Necessary adjustmentsand repairs can be done during the PM, which will increase the life of components and reduce unscheduled downtime.

The need for major adjustments,repairs,or replacementsis found and corrections made as required; not after failure has occurred.

SM56OPWD ii

HOW TO USE THIS MANUAL

This manual is intended to be used by personswho are trained and authorized to do lift truck maintenance. The recommendedproceduresfor routine servicing and adjustmentsas well as for removaland overhaulof majorcomponentsof the truck are outlined. It is written to show and describethe adjustment, removal,disassembly, inspection, repair, and assembly steps that are normally required to service these components.

The detailed procedures are arranged in sequence by numbered GROUP and Section. The GROUP numbersare the same as the component group in the Master Parts Book. Each GROUP has its own Table of Contents, so that you can find the various topics within more easily. lf you cannot find a topic in the Table of Contents, check the Index at the back of the manual.

Component specifications,information notes and safety messages are included at the proper step of each procedure. To be better prepared to do the necessary service work, please take time to read the entire procedure, including any special instructions, before doing any work.

Specificationsof selected truck componentsare included at the back of the manual for easy reference.

Also refer to the Operator’sManual, located on the truck, for additional information and instructions on the operation and maintenanceof your truck.

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

NOTICE - The descriflions and specifications included in this manual were in effect at the time of printing. Clark Equipment Company r8serves the rfght to make improvements and changes in specifications or de&n* without notice and without incumhg ob&atEon. Please check with your authorired CLARK d8af8r for information on possible updates or revisions.

0 Clark EquipmentCompany 1989

SM58OPWDiii

SAFETY

SIGNS

AND SAFETY

MESSAGES

improper or careless techniques cause accidents. Don’t take chances with incorrect or damaged equipment. READ and UNDERSTAND the procedures for safe operation and maintenance outlined in this manual.

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

DRIVE AND WORK SAFELY and follow the safety signs and their messages displayed on the truck and in this manual.

SAFETY SIGNS and MESSAGES are placed in this manual and also on the lift truck to provide instructions and to identify specific areas where potential hazards exist and special precautions should be taken. Be sure you know and understand the meaning of these instructions, signs and messages. Damageto the truck or death or serious injury to you or other persons may result if these messagesare not followed.

NOTICE This message is used when special informationis required to clarify proceduresor identify components pertaining to the truck.

IMPORTANT This message is used when additional attention is requiredfor proper operation or maintenance of the truck.

This messageis used as a reminderof safety practiceswhich can result in personal injury if proper precautions are not taken.

(A\WARNING: ] This messageis used when a hazard existswhich can result in injury or death, if proper precautions are not taken.

This messageis used when an extremehazard exists which will result in death or serious injury if proper precautions are not taken.

SM560 MID iv

USER SAFE MAINTENANCE The following instructions have been prepared from current industry and government safety standards applicableto industrial truck operations and maintenance. These recommended procedures specify conditions, methods, and accepted practicesthat aid in the safe maintenance of industrtaltrucks. They are listed here for the reference and safety of all workers during maintenanceoperations. Carefully read and understand these instructions and the specific maintenance procedures before attempting to do any repairwork. When in doubt of any maintenance procedure, please contact your local CLARK dealer.

1. Powered industrial trucks can become hazardous if maintenance is neglected.

Therefore, suitable maintenancefacilities, trained personnel, and procedures must be provided.

2. Maintenance and inspection of all powered industrial trucks shall be done In conformancewith the manufacturer’s recommendations.

9. Before Starting To Drive Truck: a) Be in operating position. b) Disengageclutch on manualtransmissions,or apply brake on trucks with powershifttransmission and electric trucks. c) Put directional control in neutral. d) Start engine or turn on power. e) Check functioning of lift and tilt systems, directional and speed controls, steering, brakes, warning devices, and any bad handling attachments.

10. Before Leaving The Truck: a) b) c) d) e)

9

3. A scheduled planned maintenance, lubrication, and inspection program shall be followed.

4. Only trained and authorized personnel shall be permittedto maintain,repair,adjust,and inspect industrial trucks, and In accordancewith the manufacturer’sspecifications.

5. Properly ventilate work area, vent exhaust fumes, and keep shop clean and floor dry.

6. Avoid fire hazards and have fire protection equipment present in the work area. Do not use an open flame to check for level, or leakage of fuel, electrolyte, or coolant. Do not use open pans of fuel or flammablecleaning fluids for cleaning parts.

PRACTICES

Stop truck.

Put directional control in neutral.

Apply the parking brake.

Stop the engine or turn off power.

Turn off the control or ignition circuit.

Put blocks at the wheels, if truck is on an incline.

11. Brakes, steering mechanisms,control mechanisms,warning devices, lights, guards and safety devices, and frame members must be carefully and regularly Inspected and maintainedin a safe operating condition.

12. Special trucks or devices designed and approvedfor hazardous area operation must receive special attention to ensure that maintenance preserves the original, approved safe operating features.

13. The truck manufacturer’scapacity, operation and maintenanceinstruction plates, tags, or decals must be maintained in legible condition.

7. Before Starting Work On Truck: a) Raise drive wheels off of floor or disconnect power source and use blocks or other positive truck-positioning devices. b) Put blocks under the bad engaging means, innermast( or chassis before working on them. c) Disconnect battery before working on the electrical system.

8. Operation of the truckto check performance must be conducted in an authorized, safe, clear area.

14. Batteries, motors, controllers, limit switches, protective devices, electrical conductors and connections must be inspected and maintained in

conformancewith good practice. Special attention must be paid to the condition of electrical insulation.

15. To avoid injury to personnel or damage to the equipment, consult the manufacturer’s procedures in replacing contacts on any battery connection.

SM546 MD-v

USER SAFE MAINTENANCE 16. Industrialtrucks must be kept in a clean condition to minfmizefire hazards and help in the detection of loose or defective parts.

17. Modifications and additions that affect capacity and safe truck operation must not be done without the manufacturer’sprior written approval. Capacity, operation and maintenance instruction plates, tags or decals must be changed accordingly.

18. Care must be taken to assure that all replacementparts, including tires, are interchangeablewith the original parts and of a quality at least equal to that provided in the original equipment. Parts, including tires, are to be installed per the manufacturer’sprocedures.

Always use genuine CLARK or CLARK-approved parts.

19. When removing tires, follow industry safety practices.

20. Use special care when removing heavy componentsfrom the truck. Be sure that lifting and handling equipment is of the correct capacity and in good condition.

NOTICE-- You should also be familiarwith additional operating and maintenance safety instructions contained in the following publications: ANSWASME858.1 - 1983: Safety Standard for Low Lift and High Lfft Trucks (Safety Code For Powered Industrial Trucks). Published by: Society of Mechanical Engineers, United Engineering Center, 345 E. 47th Street, New York, N.Y. 10017.

NFPA 505-1982: Fire Safety Standard for Powered Industrial Trucks: Type Designations, Areas of Use, Maintenance and Operation.

Availablefrom: National Fire ProtectionAssoc., Inc., BatterymarchPark, Quincy, MA 02269.

General Industry Standards, OSHA 2206: OSHA Safety and Health Standards (29 CFR 1910), Subpart N-MaterialsHandling and Storage, Section 1910.178 Powered Industrial Trucks. For sale by: Superintendent of Documents, U.S. Government Printing Cffice, Washington, DC 20402.

SM546 FWD-vl

PRACTICES

PM - PLANNED

MAINTENANCE

PROGRAM

HOW TO PERFORM THE PM PERIODIC INSPECTIONS AND MAINTENANCE

A planned maintenance program of regular, routine inspections and lubrication is important for long life and trouble-free operation of your lift truck. Make and keep records of your inspections. Use these records to help establish the correct PM intervals for your application and to indicate maintenance required to prevent major problems from occurring during operation.

Visual InspectIon

The periodic maintenance procedures outlined in this manual are intended to be used with the PM report form. They are arranged in groupings of maintenance work that are done in a logical and efficient sequence.

NAMEPLATES

A check mark or entry is made on the PM Report Form when the PM is performed.

Please note the special coding system for indicating the Importance of needed repairs and/or adjustments.

First, perform a visual inspection of the lift truck and Its components. Walk around the truck and take note of any obvious damage and maintenance problems. Check for loose fasteners and fittings.

AND DECALS

Check to be sure all capacity, safety, and warning plates or decals are attached and legible.

Do not operateor albw a lift tnrdt with damagedor missingdecals and name plates to be operated. They contain important information. Replacethem immediately.

When you have finished the PM inspections, be sure to give a copy of the report to the designated authority or the person responsiblefor lift truck maintenance.

Be sure that safety devices are in place, undamaged, and attached securely.

Do not make repalrs or adjustments unless authorized to do so.

Check the condition of the drive wheel and tire and the bad wheels. Removeobjects that are embedded in the tread. Inspect the tires for excessivewear and breaks or “chunking out”, and bond failure between the tire and rim.

For safety, It is good practice to: Remove all jewelry (watch, rings, bracelets, etc.) before working on the truck.

Always wear safety glasseswhen making repairs.

Wheels and Tires

Check all wheels for proper tightness. Adjust if necessary.

Be sure to: Make a record of all maintenanceand operating problems you find.

Write the hour meter reading on the PM report form.

SM560 PM- 1

PM - PLANNED

MAINTENANCE

Functional Tests Be sure that all controls and systems are functioning correctly.

Test horn and all other safety equipment and accessories. Be sure they are properly mounted and working correctly.

Press the horn button to check horn function. If the horn or any other part does not operate, report the failure and have it repaired before the truck is put back into operation.

Operate the brakes, directional controls, and steering system. Be sure all controls operate freely and return to neutral properly.

Test Drive The Truck Check

all around

to be sure that your

intended path of travel is clear of obstructions and pedestrians.

Test the tnrck for: General correct operation Drive train function Steering performance Brake performance By driving the truck in both the foward and reverse directions first in a straight line and then, slowly, through a series of full right and left turns.

PROGRAM

To check brake holding capability and adjustment,drive the truck on to a grade and release the handle. The brake should hold the truck on the grade that the truck can climb with a capacitybad or a 10 % grade which ever is less. , _

4

vv\ CAUTION: 1 Do

not oDerate a truck If the brakes are not op’eratlng properly.

Steerlng system Check the steering system for abnormal looseness and damage. Check for any changes in steering action. Hard steering or looseness, unusual sounds when turning or maneuveringindicates a need for inspection and setvicing.

Never operate a truck which has a steerlng system fault.

BATTERY Inspectthe battery retainment. Replace any damagedor missingparts.

Inspectthe batteries for any damage, cracks or leaking condition. If your batteries have removablevent caps, check to be sure the cells are all filled. If possible,refillwith distilled water to bottom of vent cap opening.

MECHANISMS

Listen for any unusual drive train or other running noises, such as wheel bearing noise, vibration, etc. Note any lack of smoothness in steering.

When you have completed the operatlonal tests, park and leave truck according to standard shutdown procedures

Finally, inspect all controls, handle, levers, and linkagesfor wear and smoothness of operation.

Air Cleaning

Brakes Check the brake system. The brake should be applied when the control handle is in the fully raised position or the fully lowered position.

Always maintain a lift truck in a clean condition. Do not allow dirt, dust, lint, or other contaminants to accumulate on the truck.

Keep the truck free from leaking oil and grease. Wipe up all oil spills. Keep the handle and controls clean, dry, and safe. A clean truck makes it easier to see leakage, loose, missingor damaged parts, and will help prevent fires. A clean truck will run cooler.

SM560 PM - 2

PM - PLANNED

MAINTENANCE

The environment in which a lift truck operates will determine how often and to what extent cleaning is necessary. For example, trucks operating in manufacturingplants which have a high level of dirt or lint (e.g., cotton fibers, paper dust, etc.) in the air or on the floor, will require more frequent cleaning.

LIFT TRUCKS SHOULD BE AIR CLEANED AT EVERY PM INTERVAL, AND OTHERWISE AS OFTEN AS REQUIRED. Air cleaning should be done using an air hose with special adapter or extension having a control valve and nozzle to direct the air properly. Use clean, dry, low-pressure compressed air; restrict air pressure to (207 kPa] 30 psi, maximum.

CAUTION- Wear suitable eye protection and protective clothing.

Critical Fastener Torque Checks Check torque of critical items, including: Driveuti mounting Drivewheel mounting Components.

Replace missing bolts and tightened loose bolts to the correct torque before operating the truck.

Fasteners in highly loaded (critical) components can quickly fail if they become loosened; also, loose fasteners can cause damage or failure of the component. For safety, it is important that the correct torque be maintained on all critical fasteners of components which directly support, handle or control the load, and protect the operator.

SM560 PM - 3

PROGRAM

PLANNED

SAFETY

MAINTENANCE

PROGRAM

AND OPERATIONAL

CHECKS

Notes: PM Interval: *Replace As Required A = 8 - 10 hours, or daily B = 50 - 250 hours, or every month C = 450 - 500 hours, or every 3 months D = 900 - 1000 hours, or every 6 months E = 2000 hours, or every year

DAILY

Check Check Check Check Check

MAINTENANCE

CHECKS

warning lights and hour meter. horn operation and other warning devices. steering operation. brake operation. directional and soeed controls ooeration.

SM 560 PM-4

Nominal Maintenance Interval

PLANNED

MAINTENANCE

PROGRAM

RECCOMMENDED MAINTENANCE AND LUBRICATION SCHEDULE

Notes:

PM Interval: A=& 10 hours, ordaily B = 50 - 250 hours, or every month C = 450 - 500 hours, or every 3 months D = 900 - 1000 hours, or every 6 months E = 2000 hours, or every year

MAINTENANCE .

AND

LUBRICATION .

Check truck vlsumd msoect comDonents Test drive truck -- Check functional Derformance Air clean truck

SM 560 PM-5

*Replace As Required #First PM only

Nominal Maintenance Interval

A

B

C

D

E

PLANNED

MAINTENANCE

WP40 LUBRICATION GREASE

1. LOAD

WHEEL

AXLE

PROGRAM

CHART

POINTS

( USE LUB GUN AND ADAPTOR

FOR FLUSH TYPE FITTINGS

2. PULL ROD - LOAD WHEEL END 3. LIFT CYLINDER

MOUNTING

PIN ( COLD STORAGE

TRUCKS

ONLY )

4. PULL ROD - LIFT LINK END 5. LIFT LINK ( COLD STORAGE

TRUCKS ONLY )

6. DRIVE UNIT PIVOT BEARINGS

( COLD STORAGE

SM 560 PM-6

TRUCKS

ONLY )

)

PLANNED

MAINTENANCE

WP40 LUBRICATION

PROGRAM

CHART

FILL POINTS

0 1

1. HYDRAULIC SYSTEM RESERVOIR OIL CAPACITYIN RESERVOIR FLUID TYPE FLUID TYPE FOR COLD STORAGE

1 QUART low-40 MOTOR OIL DEXTRON II ATF

2. DRIVE UNIT FLUID FLUID CAPACITY FLUID TYPE FLUID TYPE FOR COLD STORAGE

.85 QUARTS 80-9OW DEXTRON II ATF

SM 560 PM-7

GROUP G&EH&ION

01

CONTENT

NO.

HANDLINGBATTERIES BATTERY REMOVAL CLEANING PROCEDURES CHARGINGPROCEDURE

12-01-01 12-01-02 12-01-03 12-01-04

l/p\

3. Make sure the area has material handling

equipment made for the purpose of removing and installing batteries, such as an overhead hoist. Make sure the overhead hoist has safety hooks.

4. When a battery is to be removed, make sure that the battery removal hook, Clark part number 1622063, is used.

WARNING: 1

Battery

Maintenance

BATTERY ACID; FUMESAND ELECTRICAL POTENTIALCAN CAUSE iNJURY OR DEATH. READ AND UNDERSTANDTHESE PROCEDURESBEFOREWORKINGON BATTERIES. 1. DO NOT SMOKE OR ALLOW OPEN FLAMES OR SPARKS NEAR BATTERY CHARGINGAREAS.

5. When a power chain hoist is used, make sure the hoist has a chain container to hold the amount of chain used.

2. WEAR PROTECTIVECLOTHING,GLOVES AND A FACESHIELDWHENWORKINGON BATTERIES.

6. When a hand hoist is used, a battery without a cover must have a nonconductive material put over it to prevent the chain from making contact on the cell connections or terminals.

3. KEEP ALL METAL OBJECTS AWAY FROM BATTERIES. 4. BATTERIESARE VERY HEAVY. HANDLE THEM WlTH THE CORRECTLlFTlNG DEVICES.

7. Keep all tools and other objects made of metal

5. BATTERYCHARGINGAREAS MUST CONFORMTO FEDERAL REGULATIONS.

8. Because of hydrogen gas from batteries that are being charged, no smoking will be permitted in the battery area. Do not check electrolyte level with an open flame. No open flames, sparks, or electric arcs will be permitted in the battery charging area.

6. DO NOT PERFORM BATTERY SERVICE UNLESS YOU ARE TRAINED AND QUALIFIED. 12*01-01

HANDLING BATTERIES

away from the terminals.

,9. When batteries are being charged, the vent caps must be kept in position to prevent electrolyte spray. The vent holes in the caps must be open.

Change or service storage batteries only in a battery setice area.

1.

2. Make sure this area has the equipment: -to flush and neutralizeany add that may spill.

- for ventilationof fumes from batteries.

- for fire protection.

Before trying to remove, install, or charge a storage battery, the truck must be in a battery service area with the brake applied so that the truck cannot move.

10. Electrical installations must follow the National Electrical Code ( ANSI 856.2, 1974 ), NFPA 50578, Part “C” and any local ordinances.

SM 560 12-01-l

12-01-02

1A\

BATTERY

bicarbonateIn a pail of cold water and mix). Rinse with clean cold water.

REMOVAL

WARNING: 1

YOU DO SERVICE WORK OR REMOVEOR INSTALL A TRUCK BATTERY OR BATTERY PAC, READ THE FOLLOWING INSTRUCTIONS CAREFULLY. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULTIN SERIOUS PERSONALINJURY.

12-01-04 BATTERY PROCEDURE

CHARGING

BEFORE

1. Check the service and charging area for proper fire protection. Make sure there are no flames or heat in the area. Do not smoke. Make sure all necessary equipment is in the area, in good repair, and operating correctly. If service is to be done on the batteries, make sure there is equipment to flush and neutralize any acid that may spill, ventilation to carry fumes from the batteries, and equipment to handle electrolyte.

2. Put the truck in the battery area, turn the key switch to the “off” position, and disconnect the battery receptacle.

3. Attach the battery pack removal hook, Clark art number 1822063, to the battery pack.

b

WARNING: 1

BATTERY CHARGING TO AVOID PERSONALINJURY BATTERIES MUST BE CHARGEDIN AN APPROVED CHARGINGAREA AND CHARGED ACCORDINGTO APPROVED PROCEDURES. IMPORTANT DO NOT OPERATETHE CHARGERUNLESS IT IS FIRSTCONNECTEDTO THE BATTERIES. 1. Replace any missing vent caps and tighten.

Check vent caps for proper operation ( the vent hole is clean and open).

2. Open the battery charger cover. Disconnect the battery pack from the truck receptacle and turn the charger timer to the “off position.

3. Connect the A.C. cord to a 115V. A.C. outlet ( or a 220V A.C. outlet, according to the type of charger ).

4. Connect the Battery receptacle to the charger.

5. Turn the timer to the “on” position. The pilot light and the ammeter show the charger is “on” and charging. When the charger is turned to the “on” position, the charger will run for up to 12 hours maximum, or as set. See page 4 for charge rates.

4.

IMPORTANT- WEEKLY CHECK

Removethe battery pack from the truck.

12-01-03

BATTERY

AFTER CHARGING, CHECK THE HEIGHT OF ELECTROLYTE IN EACH CELL. ADD DISTILLED WATER IF NECESSARY. THEN, AFTER BATTERIES HAVE BEEN CHARGED, CONNECT THE BATTERIES TO THE CHARGERAND SET THE TIMER TO 4 ON THE DIAL. THIS ADDED CHARGING WILL EQUALIZE THE CELLS AND HELP KEEP THE BATTERIES IN GOOD CONDITION. WEEKLY CHECKS ARE TO BE MADE ONLY BY TRAINED AND AUTHORIZED BATTERY MAINTENANCEPERSONNEL.

CLEANING

1. Clean the batteries only when they are removedfrom the truck.

2. The vent caps must be in position durfng cleaning.

3. Wash the batteries with iow pressure cold water.

The batteries can also be washed with a solution of sodium bicarbonate (put a box of sodium SM 560 12-01-2

WP40 BATTERY

BATTERY

OPEN

11.80

VOLTAGE VOLTS

RATE CHART

CHARGING

VOLTAGE

CIRCUIT

BELOW

CHARGING

RATE -

AMPERS AND TIME

5 AMP

10 AMP

20 AMP

30 AMP

10 HOURS

5.5

HOURS

2.5

HOURS

1.7

HOURS

HOURS

1.5

HOURS HOURS

11.80

TO

11.90

VOLTS

9 HOURS

4.5

HOURS

2.3

11.90

TO

12.05

VOLTS

7.5

3.7

HOURS

2 HOURS

1.3

12.05

TO

12.20

VOLTS

6 HOURS

3 HOURS

1.5

1 HOUR

12.20

TO

12.35

VOLTS

4 HOURS

2 HOURS

1 HOURS

30 MINUTES

3 HOURS

1.1.

. ..m

.__I

ABOVE

12.35

VOLTS

HOURS

SM 560 12-01-3

HOURS

GROUP 13 SECTION DIRECTION / ACCELERATOR

2. Disconnectthe battery receptacle.

01

3.Remove the four (4) control handle head unit mounting screws.

CONTROL

4. D&connect the wiring harness connector.

5.Remove the two (2) screws attaching the master switch to the handle assembly. Lift out the switch.

NO.

CONTENTS CONTROL DESCRIPTION CONTROL MAINTENANCE CONTROL REMOVAL CONTROL REPAIR

13-01-01 13-01-02 13-01-03 13-01-04

G.Disconnect the wiring attached to the control switch.

13-01-01 CONTROL DESCRIPTION The accelerator / directional control is one unit located inside the control handle. This switch is actuated when either of the control handles are rotated forward or backward. Further rotation of the lever increases the speed of the,truck.

I

REFER TO PARTS MANUAL WP-2 (GROUP 13) FOR ILLUSTRATION.

.

13-01-04

CONTROL

REPAIR

NOTE: This switch has no serviceable componentsand must be replaced as a unit.

REFER TO PARTS MANUAL WP-2 .

(GROUP 13) FOR ILLUSTRATION.

13-01-02 CONTROL MAINTENANCE 1.Check for smooth operation of the rotation of the switch actuating handle and its return to neutral position.

2.With an ohm meter, check for proper opening and closing of the electrical circuits through the switch.

13-01-03

CONTROL

I

_. .

NOTE: When repairs are complete, check for proper operation and continuity, and reinstall in the control handle.

REMOVAL 1.Tunm the key switch to OFF. SM 560 13-01-I

GROUP 16 SECTION 01 ELECTRIC MOTOR GENERAL MAINTENANCE

ELECTRIC GENERAL

MOTOR MAINTENANCE PROCEDURES

A planned maintenance program of regular, routine inspections is important for long life and trouble-free operation of electric motors. Make and keep records of your inspections. Use these records to help establish correct P. M. intervals and to indicate maintenance required to prevent major problems from occurring during operation.

INSPECTION

PROCEDURES

To perform these service procedures, it is recommendedthat you first:

If a change (reduction) in truck (motor) performance has been noted, it may be due to breakdown in motor insulation causing internal grounding or a short circuit.

Failures of motor insulation are due to: (1) contamination, (2) mechanicalfactors, and (3) high temperatures.

Contamination includes dirt, moisture, oily vapors, metal chips, carbon dust from brushes, etc.

Mechanical factors include shock, vibration, overspeed, etc.

Operation at prolonged or excessively high temperature will cause insulation to become brittle and crack leading to premature failure. The insulation condition can be judged both visually and by test measurement. Regular, periodic measurements of insulation resistance can give a useful indication of the rate of insulation detertoration.

A sudden drop or consistent trend toward low values of insulation resistance give evidence that ~;;.LJI~~I is deteriorating and that failure may be

Park truck safety.

Fully towerforks.

.

Turn key switch “OFF. Disconnect battery from truck receptacle.

MOTOR

TEST FOR MOTOR INSULATION RESISTANCE TO GROUND

CLEANLINESS

(USINGA 500 VOLT MEGGER) Electric motors should be kept clean at all times, to prevent shorting, minimize wear, and for best cooling.

l.Turn the keyswitch to OFF and disconnect the battery from the truck receptacle.

Wipe off all dust, dirt, oil, water, etc., from outer surface of motor.

2. Disconnect the power cables from all motor terminals.

Remove any debris from cooling air vents and around motor frame to prevent overheating.

3. Connect one lead of a 500 volt megger to any motor terminal. Connect the other lead to the motor frame. Apply voltage.

Air clean (blow out) open motors using clean, dry (moisture-free)compressed air at [207 kPa] 30 psi. maximum air pressure. Air clean all inner areas around commutator and brushes, including cooling air vents and fan.

The presence of any oil on or near motor could indicate either bad bearings or leaking hydraulic system. Determine cause and repair problem before extensive motor damage occurs.

MOTOR

NOTE: Test all motor terminals individually.

4. The resistance should measure at least l,OOO,OOO ohms (1 megohm). If reading is less than this, the motor should be air-cleaned or dried to attempt to increase the insulation resistance.

5. If the reading is less than 1 megohm after cleaning, the motor should be removed from the truck for inspection and repair.

INSULATION SM56016 - 01 - 1

6. Brushes must be replaced when worn to approximatelyhalt of original length.

TEST FOR MOTOR INSULATION RESISTANCE TO GROUND (USINGA VOLT-OHMMETER VOM) Use a Simpson 260-6~ or equivalent VOM, calibrated on the Rx10,000 scale.

1. Turn the keyswitch to OFF and disconnect battery from truck receptacle.

2. Disconnect power cables from all motor terminals.

3. Connect the positive lead of the VOM to all terminal studs of test motor. Connect VOM negative lead to motor frame.

NOTE: Test all temu’nalsindividually.

VOM must show l,OOO,OOO ohms (1 megohm) resistanceor higher for a good motor insulation.

5. If less than 1 megohm is measured, air clean motor and repeat test of motor resistance. If air cleaning does not make an improvement, motor will have to be removed and disassembled for closer inspection and repair if needed.

BRUSH AND COMMUTATOR INSPECTION 1. Remove brush cover(s) and remove brushes from brush holders. Clean brushes and holders.

Check brush holders for damage.

2. Inspect condition of brushes. Remove each brush from brush holder and inspect brushes and commutatorfor worn condition and uneven wear.

IMPORTANT NEW BRUSHES MUST BE OF SAME SIZE AND GRADE (MATERIAL ;;;;EEFATION) AS ORIGINAL .

Observe how brushes are assembled in brush holders, and position of brush lead (brush shunt).

New brushes must be installed in same manner.

7. Check brush shunt for good contact with brush holder. Be sure shunt is not damaged or burned since this may cause brush spring to carry current and lose tension.

8. If brushes do not need to be replaced, and commutator is in good condition, install brushes and brush springs into brush holders.

IMPORTANT ALWAYS REPLACE BOTH BRUSHES AND SPRINGS. DO NOT REUSE OLD SPRINGS. Be sure brush spring is correctly placed on brush holder and that brush is free to slide in brush box.

9. Clean and check brush box and connector screws. Tighten if loose. Be sure brush box shunt connection is tight. Install brush cover on motor case.

10. Check and tighten all motor bolts. Check lower nut on each terminal post. It should be installed finger-tight, then tightened another l/4 turn with a wrench.

3. Clean commutator surface. Wipe commutator with a dry, lint-freecloth.

DO NOT USE LUBRICANT OR SOLVENT ON COMMUTATOR. 4. Check appearance of commutator surface where brushes ride. Inspect commutator bars for burned, damaged or raised areas. The best signs of good commutation are a dark brown highlypolished commutator and uniform glossy brushwearing surfaces.

5. Measure and make a record of brush length at each inspection. The record will verify amount of brush wear and indicate if there is enough brush length remaining until next scheduled inspection.

SM56016 - 01 - 2

hydraulic pump unit adaptor so that the unit can easily be realigned at assembly.

GROUP 16 SECTION LIFT PUMP MOTOR

03

CONTENTS

NO.

LIFT LIFT LIFT LIFT LIFT

16-03-01 16-03-02 16-03-03 16-03-04 16-03-05

MOTOR DESCRIPTION MOTORMAINTENANCE MOTOR DISASSEMBLY MOTORINSPECTtON MOTORASSEMBLY

2. Removethe two screws from the commutator end cap and remove the cap.

NOTICE: If the brushes have not been removed before disassemblingthe motor, the brushes must be lifted off the commutatorand held in the raised position. This is done by lifting the brush spring. ctip off the end of the brush and moving the spring clip to one side of the brush which traps or “locks” the brush in place.

3. Removethe two long screws that extend through the motor and into the pump unit.

16-03-01 LIFT MOTOR DESCRIPTION

4. Separatethe motor from the pump as a unit.

The motor is an important part of the hydraulic unit, along with the hydraulic pump, sump tank, and the solenoids. Refer to Group 29, Section 1 for components other then the motor.

5. Removethe commutatorend frame from the motor housing.

NOTE: Before the commutator end frame can be removed,the two wires from the internal circuit of the field coils must be disconnected from the brush holder.

The lift motor is a series wound motor. The exterior connections are easily accessible from side of motor, yet are protected from external damage.

The brushes are accessible and can easily be changed.

6. Removethe drive end frame and armature from the motor housing.

.

Framediameter Bnrsh

7. Separate the drive end frame from the armatureshaft.

Replace when worn to a

length of .250” or less. .

BNsh

32 to 40 ounces with new

brush.

W

(I *.

16-03-02 MAINTENANCE

6. Removethe bearing from the drive end frame.

minimumdiameter 1.5”.

9. Removethe commutator end bearing from the armatureshaft.

LIFT

MOTOR

Referto GROUP 16, SECTION 1 for electric motor general maintenance procedures.

16-03-04 COMPONENT

LIFT MOTOR INSPECTION

Refer to SM560 16-01 Electric Motor General Maintenancefor Initial inspection and testing.

1. Inspect all parts for distortion, wear or indicationsof electrical sparks.

LIFT MOTOR 16-03-03 DISASSEMBLY Refer to Group 29, section 1 for the removalof the hydraulic unit assembly from the truck.

1. Before disassemblingthe motor, put an identification match mark on the motor housing, commutatorend frame, drive end frame and the

2. Use a straightedge to check brush holders for correct alignment.

3. Inspect for indications of friction between the armature windings and the pole shoes. Some problems can be corrected by applying shellac or insulating varnish.

SM560 16-03-l

4. If a new surface must be cut on the commutator: IMPORTANT DO NOT CUT CLOSER THAN 0.187” (4.75mm) TO THE COMMUTATOR RISER BARS. MAKE SURE NO SOLDER IS REMOVED, WHICH WOULDMAKE THE COIL CONNECTIONSWEAK. THE MICA MUST BE CUT TO A DEPTH NOT TO EXCEED 0.030” (0.76mm), FULL WIDTH OF THE MICAAND FLAT AT THE BOTTOMOF THE CUT.

5. Placethe commutatorend frame on a work bench with the brush ring assemblyfacing upwards.

6. Installthe bearing spring ( end thrust ) washer into the bearing bore. Use a thin film of grease to hold the washer in place.

7. Assemblethe commutatorend frame over the bearingon the armature shaft until it joins the motor housing. Be sure the spring washer has remainedin place. Make sure that the match marksare aligned.

8. Connectthe two internal circuit field coil wires to the correct terminals.

9. Place the motor back onto the pump adaptor and install the two bolts through the motor and into the adaptor.

AICWT

WAV

WRONG WAY

.- .

10. If the brushes were not removed, set the brushes to their final position by moving the springs to the top of each brush.

1. CORRECTWAY TO CUT MICA 2. WRONGWAY TO CUT MICA A) Segments B) Mica C) Commutator

11. If the brusheswere removed, install new brushes and brush springs by:

5. Check for bad connections or broken wires.

6. Inspectall insulationfor cracks or damage.

a) Insertingthe brushes into the holders with the leads in the same position as when removedand make sure the brushes are free in the holders. b) Connect the brush leads to the correct terminals.

16-03-05 LIFT MOTOR ASSEMBLY

c) Install new springson top of each brush.

NOTE: Do not reuse old bearings. Replacewith new.

1. Install a new drive end bearing by pressingon the outer race of the beating to force it into the bore of the drive end frame until it is flush with the inside surface of the frame.

2. Install a new commrtator end bearing on the armatureshaft by pressingon the inner race of the bearing until ft is firmly seated against the shoulder on the shaft.

3. Installthe armature shaft into the drive end frame.

4. Installthe motor housing over the armatureand align the match marks on the housing with the markson the end frame.

SM560 16-03-2

4. Removethe drive wheel and tire assembly.

GROUP 16 SECTION DRIVE MOTOR

5. Removethe brake switch mounting bracket.

04

6. Disconnectelectrical cables to the drive motor noting their proper position.

NO.

CONTENTS

DRIVE MOTOR DESCRIPTION 16-04-Or DRIVE MOTOR MAINTENANCE 16-64-62 16-04-03 DRIVE MOTOR REMOVAL DRIVE MOTOR DISASSEMBLY 16-64-64 DRIVEMOTOR 16-64-05 INSPECTION 16-64-06 DRIVE MOTOR ASSEMBLY DRIVE MOTOR INSTALLATION 16-64-07

16-04-01 DRIVE DESCRIPTION

7. Disconnect the main spring from the brake linkage.

6. Move the control handle to the brake released position and disconnect the clevis from the brake lever.

9. Loosen the nut and remove the brake drum.

10. Lift one brake shoe at a time to remove the backing plate mounting bolts.

11. Removethe shoulder bolt and brake actuatingarm from gear case.

MOTOR

The drive motor is a series wound motor. The exterior connections are easily accessible from side of motor, yet are protected from external damage. The drive motor must be removed from the truck in order to replace the brushes. &ush rep- Replace when worn to a length of .250” or less. . m -32 to 40 ounces with new brush.

- minimumdiameter 1.5”. * (I. m

DRIVE MOTOR 16-04-02 MAINTENANCE

12. Loosen and remove the four (4) drive motor mounting bolts.

13. Pull motor straight out of gear case.

16-04-04 DRIVE DISASSEMBLY

MOTOR

1. Removethe locknut and pinion gear from the armatureshaft.

2. Put an identificationmatch mark on both end frames and motor housing to assure proper alignmentwhen assemblingthe motor.

3. Removethe plastic brush covers.

REMOVAL

4. Removethe brushes if they are to be replaced. If brushes are not to be replaced,the brushes must be lifted off the commutator and held in the raised position. This is done by lifting the brush spring clip off the end of the brush and movingthe spring clip to one side of the brush which traps or “locks” the brush in place.

The drive motor can be removedwithout removingthe drive unit form the truck.

5. Use an impact tool to loosen the mounting screws in the drive end frame.

1. Disconnect the battery receptacle.

6. Use the same procedure to remove the screws in the commutatorend frame.

2. Raise and block the truck with the drive tire off the floor.

7. Removethe commutator end frame.

Referto GROUP 16, SECTION 1 for electric motor general maintenance procedures.

16-04-03

DRIVE MOTOR

3. Removethe drive unit motor cover.

SM569 16-04-l

NOTE: BEFORETHE COMMUTATOREND FRAME CAN BE REMOVED, TWO WIRES FROMINTERNALClRCUlTOF THE FIELD COILS MUST BE DISCONNECTEDFROMTHE BRUSH HOLDER ASSEMBLY. 8. Removethe drive end frame and armature from the motor housing.

9. Separate the drive end frame from the armature.

4. lf a new surface must be cut on the commutator: IMPORTANT DO NOT CUT CLOSER THAN 0.187” (4.75mm) TO THE COMMUTATOR RISER BARS. MAKE SURE NO SOLDER IS REMOVED, WHICH WOULDMAKE THE COIL CONNECTIONSWEAK. THE MICA MUST BE CUT TO A DEPTH NOT TO EXCEED 0.030” (0.76mm), FULL WIDTH OF THE MICAAND FLAT ATT-HEBOTTOM OF THE CUT.

This is usually done by using a hydraulic press to force the armature out of the drive end bearing.

If a press is not available,ft can be removedby careful use of a puller. If a puller Is used, use care not to apply excessive loads to the end frame.

10. Removethe snap ring retaining the bearing into the drive end frame and press bearing out of the bore.

11. Removethe bearing from the commutator end of the armature shaft by using a bearing puller.

.

I

I

Protectthe end of the shaft with a nut or a thick flat washer. Be careful not to damage the commutatorbars.

16-04-05 COMPONENTS

DRIVE MOTOR INSPECTION

Refer to SM580 16-01 Electric Motor General Maintenance for inftial inspection and testing.

4. Inspect all parts for distortion, wear or indications of electrical sparks.

COMMUTATOR

CUMMUTATOR MICA

RIGNT WAY

WRONG WA*

1. CORRECTWAY TO CLITMICA 2. WRONGWAYTO CUT MICA A) Segments B) Mica C) Commutator 5. Check for bad connections or broken wires.

6. Inspectall insulationfor cracks or damage.

16-04-06 DRIVE MOTOR ASSEMBLY

2. Use a straightedge to check brush holders for correct alignment.

NOTE: Do not reuse old beatings. Replacewith new.

3. Inspect for indications of friction between the armature windings and the pole shoes. Some problems can be corrected by applying shellac or insulating varnish.

1. Install a new drive end bearing by pressing on the outer race of the bearing to force it into the bore until it is firmly seated against the shoulder.

Installthe snap ring to retain the bearing.

2. Install a new commutatorend bearing on the armatureshaft by pressingon the inner race of the bearing until it is firmly seated against the shoulder on the shaft.

3. Press the dtfve end frame assembly onto the armatureshaft by pressing on the inner race of the beating until it is firmly seated against the shoulder on the shaft.

SM560 16-04-2

4. Installthe annature and d&e end frame assembly into the motor body. Align the match marks on the end frame and the housing.

5. Install the drive end frame mountingscrews and tighten lightly to temporarily hold the assembly.

16-04-07 DRIVE MOTOR INSTALLATION 1. Thoroughlyclean all parts and air dry before Installation.The ‘0’ ring on the drive end of the motor should be replaced at this time.

6. Place commutatorend frame on a work bench with the brush ring assemblyfacing upwards.

2. Slide the drive motor into the gear case and work It around until the pinion gear mesheswith the intermediate gear.

7. Installthe bearing spring ( end thrust ) washer into the bearing bore. Use a thin film of grease to hold the washer in place.

3. Install the four (4) motor mountingblots and torque to 35 ft/lbs.

6. Assemblethe commutator end frame over the bearing on the armature shaft until it joins the motor housing. Be sure the spring washer has remainedin place. Make sure that the match marks are aligned.

4. Installthe brake backing plate assemblyby lifting one shoe at a time to install the mounting bolts.

NOTE: THE LOCATIONOF THE BRAKE ACTUATINGLEVER IS SHOW BELOW.

9. Installthe commutatorend frame mounting screws and tighten lightly to hold the assembly temporarfly.Tighten the screws alternatelyto assure a good mechanicalalignment.

10. Connect the two internal circuit field coil wires to the correct terminals.

60'

?

/

l *+

11. Fully tighten the drive end frame mounting screws using an impacttool.

0

12. Use the same tool to tighten the commutator end frame mounting screws.

13. If the brushes were not removed, set the brushes to their final position by moving the springs to the top of each brush.

0

0

%

5. Installthe brake drum over the armatureshaft and key and tighten the lock nut to 75 ftJ Ibs.

14. If the brushes were removed,install new brushes and brush springs by: a) Insertingthe brushes into the holders with the leads in the same positionas when removedand make sure the brushes are free in the holders.

6. Installthe brake actuating arm and shoulderbolt to the gear case. Installthe clevis pin and main brake spring. Be sure the brake actuator rod lines up correctly. Check the adjustment of the brake assembly.

b) Connect the brush leads to the correct temu’nals.

7. Connect the power cables and wiring harness to the proper terminals.

c) Install new springson top of each brush.

15. Install the pinion over the shaft and key and tighten the nut to 75 ftl fbs.

6. Install the brake switch mountingbracket.

9. Install the drive wheel and torque the nut to 250 ftllbs.

10. Install the drfve motor access cover and tighten bolts to 35 ft./ Ibs.

SM560 16-04-3

11. Remove the blocks, connect the battery receptacle and test the truck for proper operation.

SM560

16-04-4

MAINTENANCE

GROUP 17 SECTION 01 CONTACTOR PANEL

The following information is intended to assist durfng periods of normal maintenance and to provide checks to determine if the contactor is in proper operation condition.

NO.

CONTENT

CONTACTOR PANEL 17-61-61 DESCRIPTION CONTACTOR (ONE NORMALLY OPEN CONTACT) MAINTENANCE 17-01-02 CONTACTOR (ONE NORMALLY OPEN-ONE NORMALLY CLOSED 17-61-03 CONTACT)MAINTENANCE

POWER CONTACTS In normal operation, the contacts will become blackened, discolored, and roughened. This will not interfere with proper operation, and cleaning is not necessary. The contacts should be replaced before the silver-alloycontact facing is completely eroded through to the backing material.

Note:

17-01-01

CONTACTOR DESCRIPTION

PANEL

The contactor panel consists of a forward and reverse contactor assembly, a 1A contactor, 2A contactor, a time delay module for the 2A contactor, a pump solenoid and a circuit breaker.

The contactor tips can be replaced without removingthe contactors from the truck. lf a contactor assembly has to be removedfrom the truck, for any reason, the contactor panel assembly must be removedfirst.

17-01-02

AND ADJUSTMENT

DO NOT FILE CONTACTOR TIPS.

The silver-alloymay transfer from one contact and cause buildup on the mating contact. This can be expected under certain conditions and does not require contact dressing or filing. When replacing contactor tips, replace both tips, never only one contact of a matingpair.

CONTACTOR TIP REPLACEMENT 1. Disconnectthe battery receptacle and remove the compartmentcover.

2. Removeall electrical connections on the contactor.

3. Loosen and removethe two (2) cover mountingscrews attaching it to the coil frame.

Observe the position of any markings on the cover. Be careful not to lose the return spring fitted under the cover.

1A and 2A

CONTACTORS SINGLE-POLE, DOUBLE-THROW TYPE (ONE NORMALLY OPEN CONTACT)

4. Removethe nut and b&washer from the terminal studs (contacts), remove the studs from the cover and replace with new.

CONTACTORS The purpose of these instructions is to instruct proper care and maintenanceto obtain proper service from contactors.

5. Removethe armature and movablecontact assemblyand replacewith new.

6. Place new return spring over the button on the end of the armature assembly.

CONNECTIONS

The proper connections are 5/l 6-18 screws which should be tightened to 45 to 60 inch/lbs. (5.1 to 6.8 N.m). It is recommendedthat this be done with a screwdriver,spin tight, or socket on a shaft extension. lf a wrench is used, take care the head or body of wrench does not come in contact with the molded base.

7. Place the cover over the spring and install the cover mounting screws. Be sure that the return spring is in the recess in the cover.

8. Be sure that the movementof the movablecontact assembly is free of binding. Be sure that the tips are in correct orientation and tips contact correctly with matingtips.

SM560 17-01-l

INSPECTION’ POWER CONTACTS Contacts must be replaced before they have worn through contact button to the base copper material.

The spiral return spring should be replaced when the tips are replaced.

In normal operation, the contacts will become blackened, discolored, and roughened. This will not interfere with proper operation, and cleaning is not necessary. The contacts should be replaced before the silver-alloy contact fadng is completely eroded through to the backing material.

COILS Note: The coils are not a serviceable item. The completecontactor must be replaced if the coil is faulty.

If the contactor fails to operate, measurethe voltage being applied to the cot1terminals. The coils on the contactor have been designed to actuate the contactor on reduced battery voltage and with approximatelythree volts drop in the electronic circuit so that ail contactors should operate at or below 85% of rated battery voltage.

Replacethe contactor if it does not operate to the full stroke on 65% battery voltage or if the coil shows signs of being overheated.

17-01-03 FORWARD AND REVERSE CONTACTORS SINGLE-POLE, DOUBLE-THROW TYPE (ONE NORMALLY OPEN AND ONE NORMALLY CLOSED CONTACT) CONTACTORS The purpose of these instructions is to instruct proper care and maintenance to obtain proper servicefrom contactors.

CONNECTIONS The proper connections are 5116-l8 screws which should be tightened to 45 to 80 inch/lbs. (5.1 to 8.8 N.m.). lt is recommendedthat this be done with a screwdriver,spin tight, or socket on a shaft extension. If a wrench is used, take care the head or body of wrench does not come in contact with the molded base.

MAINTENANCE

AND ADJUSTMENT

The following information is intended to assist during periods of normal maintenance and to provide checks to determine tf the contactor is in proper operation condition.

NOTE: TIPS.

DO NOT FILE CONTACTOR

The silver-alloymay transfer from one contact and cause buildup on the mating contact. This can be expected under certain conditions and does not require contact dressing or filing. When replacing contactor tips, replace both tips, never only one contact of a matingpair.

CONTACTOR TIP REPLACEMENT Both the fonnrardand reverse contactor tips must be replaced at one time.

1. Disconnectthe battery receptacle and remove the compartmentcover.

2. Removeall electrical connections on the contactors.

3. Loosen and removethe two (2) cover mountingscrews, attaching it to the coil frame, from both contactors. Observe the position of any markingson the covers. Be careful not to lose the return springs fitted under the covers.

4. Removethe nut and lockwasherfrom the terminal studs (contacts), removethe studs from the covers and replacewith new.

5. Removethe armature and movable-contact assemblies.

6. Removethe stationary contact tips and replace with new. Note the proper position when replacing.

7. Installthe armatureand movablecontact assemblies.

8. Place new return springs over the button on the end of the armature assemblies.

9. Place the covers over the springs and install the cover mounting screws. Be sure that the return springs are in the recess in the covers.

SM560 17-01-2

10. Be sure that the movementof the movablecontact assemblies are free of binding and that the tips are in correct orientation and tips contact correctly with mating tips.

INSPECTION Contacts must be replaced before they have worn through contact button to the base copper material.

The spiral return spring should be replacedwhen the tips are replaced.

COILS Note: The coils are not a serviceableitem, the complete contactor assembly must be replacedif the coil is faulty.

If the contactor fails to operate, measurethe voltage being applied to the coil terminals. The coils on the contactor have been designed to actuate the contactor on reduced battery voltage and with approximatelythree volts drop in the electronic circuit so that all contactors should operate at or below 65% of rated battery voltage.

Replacethe contactor assembly if ft does not operate to the full stroke on 65% battery voltage or if the coil shows signs of being overheated.

SM560 17-01-3

GROUP 20 SECTION DRIVE UNIT

ME DRIVE UNIT ASSEMBLYMAY FALL FREE FROMMOUNTINGAT THIS TIME.

01

CONTENTS

NO.

DRIVEUNlT DESCRIPTION DRIVEUNlT REMOVAL DRIVE UNlT DISASSEMBLY DRIVEUNlT INSPECTtON DRIVE UNlT ASSEMBLY DRIVE UNIT INSTALLATION

20-01-01 20-01-02 20-01-03 20-01-04 20-01-05 20-01-06

10. Removethe drive unit by lowering it through the pivot mounting bracket.

20-01-03 DRIVE DISASSEMBLY

UNIT

After draining the gear case lubricant, thoroughly clean the outside of the drive unit and air dry. Proceedwith disassemblyas follows: 1. Removethe gear case cover.

20-01-01 DRIVE DESCRIPTION

UNIT

This is a 22:l rat& drive unit.

Note: For parts identificationrefer to the parts manualfor this truck.

20-01-02

DRIVE UNIT REMOVAL

1. Turn the keyswttch to OFF and disconnect the battery receptacle.

2. Raise and block the truck with the drive tire off the floor.

3. Removethe hydraulic compartmentcover and the plastic drive axle cover from the truck.

4. Removethe drive wheel.

5. Removethe drive motor.

6. If the drive axle is to be disassembled,the control handle will have to be removed.If not, disconnect the wiring harness from the control panel noting the wire locationsfor proper reinstallation.

7. Pull the motor cables up through the drive unit pivot mount.

2. Block the drive unit, with wooden blocks, with the gear case side down. Allow room for the gears to drop between the blocks.

3. Press the drive axle down through the collar and bearing.The axle and intermediategear will come out together.

6. Pull the wire harness down through the drive unit pivot mount.

9. Using a spanner socket, loosen the drive unit pivot retaining nut.

SM560 20-01-l

2. Position the drive unit case on work bench with the gear case side up. Place the drive axle and intermediategear in the case as a unit with the gears meshed. Because of the gear size and bearing interference, these parts cannot be assembledseparately.

20-01-04 DRIVE INSPECTION

UNIT

3. Installthe gear case cover using Locktite Gasket Eliminator#515 on the mating surfaces. Make sure that the two (2) alignmentdowel pins are in the case to position the cover. Torque the cover mounting bolts to 30 ftJ Ibs.

1. Thoroughlyclean all parts and air dry.

2. Inspect all bearings and bearing surfaces for damageand wear.

NOTE: Always replace bearing cone and race at the same time.

3. inspect all gears and pinion to be sure that the teeth have no bumps or nicks to injure the tooth surface of the mating member.

4. Replace any parts found to be defective.

5. Discard all oid seals and O-rings and replace with new.

20-01-05 DRIVE ASSEMBLY

4. Re-positionthe drive unit so that it rests on the gear case cover.

5. Temporarilyinstall the dn’vemotor into the case using two bolts to hold the motor in place.

6. Place the outer drive axle bearing cone over the axle shaft. Use a standard 1“x14 nut and bearing installation tool, shown below, to push the bearing onto the axle. At this time the bearing will not seat on the shoulder of the axle. Removethe nut and installation tool.

UNIT

Thoroughly cleanall parts with solvent or other non-corrosivecleaning fluid. Air dry parts. The transmissionshould be assembledin a dirt-free area.

1. Install new bearings and races where needed.

NOTE: HEAT BEARINGSON A BEARING HEATERTO 250 DEGREES,TO FACILITATE INSTALLATION.

SM560 20-01-2

4. Feed the cables and wiring harness back through the pivot tube.

5. Install the control handle, drive motor and brake linkage and connect all wires and cables to the proper location.

6. Install the covers and test the truck for proper operation.

BEARING INSTALLATION TOOL

1 I

7. Installthe drive axle seal into the drive unit case.

6. Installthe collar over the axle shaft and press it into place with the bearing Installationtool and the standard nut. This will also press the bearing down to seat on the shoulder of the axle. Rotate the axle shaft while toqulng the nut to 250 ft/ Ibs.; this will assure that the bearfngswill seat properly. Control the rotation of the shaft by holding the brake lever on the drive motor.

9. Removethe nut and installation tool.

20-01-06DRIVE UNIT INSTALLATION The drive motor will have to be removedbefore the drive unit installation in order to rout the cables and wiring harness through the pivot tube.

1. Pack the upper and lower pivot bearingswith grease.

NOTE: THE BOTTOM PIVOT BEARING CUP HAS A SLIP FIT INTO THE FRAMEBRACKET.BE CERTAINTHAT THIS CUP IS IN PLACEBEFORE INSTALLINGTHE DRIVEUNIT. 2. Install the lower pivot bearing on the pivot tube and slide the drive unit into place.

3. Install the upper pivot bearing over the pivot tube and, using Locktite Thread Lock on the threads, Install the pivot bearing nut. This nut should be tightened until all end play is removed from the bearings. The drive unit must be rotated back and forth while tightening the nut to insure proper seating of the bearings.

SM560 20-01-3

GROUP 22 SECTION 01 WHEELS AND TIRES NO.

CONTENTS DRIVEWHEELAND TIRE DESCRIPTION DRIVE WHEEL REMOVAL AND REPLACEMENT LOAD WHEEL DESCRIPTION LOAD WHEEL REMOVAL AND REPLACEMENT

22-01-01 22-01-02 22-01-03 22-01-04

22-01-01

TIRE

DRIVE WHEEL AND DESCRIPTION

The drive wheel on this truck also serves as a splined hub that fits onto the drive axle. The tire is pressed onto the drive wheel.

22-01-02 REMOVAL

WHEEL DRIVE AND REPLACEMENT

To remove and / or replace the drive wheel follow these steps: Note. The drive wheel can be removed and/or replaced with out disassembling the transmission.

1. Turn the keyswitch to OFF and disconnect the battery receptacle.

2. Raise and block the truck with the driie tire off the floor.

3. Remove the axle nut holding the drive wheel to the axle.

4. Remove the drive wheel by hand or, if the wheel is stubborn, thread three bolts into the wheel to push the wheel from the axle.

5. If the tire is to be replaced, the new tire will have to be pressed onto the wheel. Press tire on wheel and check that the tire fits completely over the shoulder of the wheel.

6. Reassemblethe drive wheel on the axle and torque the nut to 250 ft/ lbs.

22-01-03

LOAD WHEEL DESCRIPTION

The load wheel is a 3.25” x 5.0” single wheel type with two ball bearings per wheel.

22-01-04

REMOVAL

WHEEL LOAD AND REPLACEMENT

1. Raise the forks to the upper limit. Disconnect the battery receptacle.

2. Raise and block the forks in a safe manner with the bad wheels off the floor.

3. Drive the roll pin out of the axle shaft and removethe axle.

4. Install bearings into new load wheels by pressing on the outer race of the bearing until it is firmly seated against the shoulder. The sealed side of the bearing goes to the outside of the load wheel.

5. Install the bad wheel assembly into elevating bracket and add shims to eliminate any end play.

DO NOT prebad the bearings.

6. Install the axle and drive the roll pin into place to retain the axle shaft.

SM560 22-01-l

GROUP 23 BRAKE CONTENTS

SECTION SYSTEM

01

7. Reinstallthe spring and test the braking ability of the truck. The truck should stop within it’s own length. If braking is Inadequate, then shorten the linkage at the clevis to get adequate braking.

NO.

NOTE: The brake drum may be removedand the operating lever moved on the “spline” to compensatefor brake shoe wear.

23-01-01 BRAKE DESCRIPTION BRAKE ADJUSTMENT 23-01-02 PROCEDURE BRAKE lNTERLOCKSWITCH 23-01-03 ADJUSTMENT 23-01-01

23-01-03 BRAKE ADJUSTMENT

BRAKE DESCRIPTION

The truck brake is a spring applied, mechanically released design. The brake has a drum mounted on the drive motor armature shaft. This design gives excellent brakfng and long service life since the drum and shoes are well protected from dirt and abrasives.Brakingis accomplishedby a spring pulling a lever that will turn an internal cam that forces the brake shoes against the drum.

This action clamps the shoes against the drum and provides braking any time the control handle is in the static position (fully raised or lowered).

When the control handle is moved into the operating position, the brake is released. The brake is releasedby meansof a brake linkagearm pulling the lever, turning the brake shoe cam and allowing the shoe return springs to pull the shoes away from the drum. The drum then can rotate with the drive motor armature.

23-01-02 BRAKE ADJUSTING PROCEDURE 1. Turn the keyswitch to OFF, disconnect the battery receptacle and raise and block the drive tire off the floor.

2. Removethe drive motor compartmentaccess cover.

3. Fully raise the control handle and removethe brake applicationspring. This will allow the brakes to release.

4. Removethe clevis pin from the brake lever.

5. Lower the control handle to the operating position so that the brake linkage arm is on top of the operating cam.

6. Adjust the clevis so that the pin will just go into the brake lever.

INTERLOCK

SWITCH

The brake interlock switch is located behind the drive motor access cover. lt is activatedby the brake linkage arm. It’s purpose is to shut OFF the powerto the drive motor when the brake is applied ( control handle fully raised or lowered) by opening the control wiring. To adjust the interlock switch: 1. Turn the keyswitch to OFF, disconnect the battery receptacleand raise and block the drive tire off the floor.

2. Removethe drive motor compartmentaccess cover.

3. Leave the control handle raised (brake applied).

4. Loosen the two (2) screws attaching the interlock switch to the mounting bracket and slide the switchleft, away from the brake arm, as far as possible.

5. Slide the switch back to the right until the switch clicks, then an additional l/32 inch and tighten the screws.

6. Check that the brake arm makes solid contact with the switch lever and that the switch clicks near the middle of the cam arm movement.The brake interlock switch should operate within 10 degrees of the control handle from full up or from full down position.

7. Install the drive motor access cover and tighten the bolts to 35 ftllbs.

8. Removethe jacking blocks and test for proper operation.

23-01-04 BRAKE ASSEMBLY REMOVAL AND INSTALLATION

SM560 23-01-l

1. Turn the keyswitch to OFF and disconnect the battery receptacle.

2. Raise and block the truck with the drfve tire off the floor.

3. Removethe drive motor access cover.

4. Disconnect the main spring from the brake linkage.

5. Move the control handle to the brake released position and disconnect the clevis from the brake lever.

6. Loosen the nut and remove the brake drum.

7. Lift one brake shoe at a time to remove the backing plate mounting bolts.

To reassemble, reverse the removal procedure. Make sure that the lever is set at 60 degrees and that the brake drum lock-nut is torqued to 75 ftl tbs.

Adjust the brake linkage as described in Section 23-01-03.

SM560 23-01-2

GROUP 29 SECTION HYDRAULIC UNIT

2. All electrical connections tight.

3. Battery fully charged.

01

HYDRAULICUNlT DESCRlPTlON 29-Ol01 HYDRAULICUNIT REPAIR 29-01-02 HYDRAULIC UNIT REMOVAL 29-01-03

After the preliminarychecks are completed, install a g-300 PSI pressure gauge in the pressure line near the outlet poti in the adaptor.

Start the pump and raise the forks to the upper limit to develop maximumpressure of the hydraulic unit. The pressure gauge will reflect the pressure setting of the relief valve. The system pressure should be removed by actuating the bwer switch.

29-01-01 HYDRAULIC UNIT

The normalproblemsthat may occur with the hydraulic unit are grouped under three categories:

CONTENTS

NO.

DESCRIPTION The hydraulic unit consists of a positive displacementrotary gear pump with a reservoir mounted to an adaptor and an electrical motor mounted on the opposite side. An adjustable relief valve, a check valve and a solenoid operated dump valve are located on the adaptor.

A. Failureto raise the bad. lf the pump operates but will only develop bw pressure or slow lift: 1. Relief valve seat scored, foreign particles under ball or relief valve is out of adjustment.

2. Dirt in the solenoid operated dump valve.

3. Pumpis worn out - Replace pump.

OPERATION When the lift switch is operated it completesan electrical circuit and energizes the pump contactor coil. With the coil energized, the contactor tips close completing the electrical circuit to the pump motor. This starts the pump.

Hydraulic fluid is pumpedthrough a check valve and out the pressure port to the lift cylinder. The adjustable pressure relief valve prevents the pressure from building up beyond the pressure setting of the valve.

Opening the lift switch de-energizes the contactor coil, breaking the electrical circuit to the motor and the pump stops. The check valve prevents the fluid from leaking back through the pump. The lift cylinder is held in position by the trapped fluid.

Closing the lower switch energizes the dump valve and allows the fluid to bypass the pump and return to the resenroir.

29-01-02 HYDRAULIC

6. Failureto hold the bad in a raised position.

1. Dirt in the solenoid operated dump valve.

2. Check valve seat _ scored, foreign particles under seat or seat is scored.

C. Failureto lower.

1. No electrical circuit to the solenoid operated dump valve.

2. Solenoid coil in dump valve is open.

3. Relief valve bottomed out causing the internal pressure to raise beyond the unloading limit of the solenoid operated dump valve.

One or more of the listed trouble sources may be causing the improper operation of the hydraulic unit. Refer to the proper heading for instructions for disassembly,checks and adjustments of the components to remedy the problem.

UNIT

REPAIR

RELIEF

If the hydraulic unit does not operate correctly a few preliminarychecks should be made: 1. Proper oil level.

VALVE

Removethe hex cap from the relief valve. If the relief valve is causing the bw pressure condition, the pressure can be increased by turning the adjustment screw clockwise. Check

SM560 29-01-l

the relief valve setting to be sure it is not above the recommended setting. Be sure that the final adjustmenton the screw is at feast l/2 turn from the bottoming out position.

If the correct pressure cannot be obtained by the relief valve adjustment, remove the adjustment screw, sprfng and ball. Check the reliefvalve seat to make sure tt is free of dirt or scores. Place the ball into the cavity, insert a l/4” drive pin punch against the ball and tap lightly with a light hammerto seat the ball. Reassemble the relief valve and adjust per specifications.

SOLENOID VALVE

OPERATED

DUMP

Clean the area around the valve before disassemblyto avoid contaminationfrom falling into the cavity.

Disconnectthe wires from the terminals on the coil, loosen and remove the retaining nut and coil. Using a box end wrench, bosen the valve body from the adaptor. Remove the spool and springfrom the cavity.

29-01-03 HYDRAULIC REMOVAL

The hydraulic pump and motor assembly must be removedfrom the truck in order to separate the pump and motor.

1. Completely lowerthe forks to release any pressure in the system.

2. Turn the keyswitch to OFF and disconnect the battery receptacle. Removethe access covers and the key switch mounting bracket.

3. Disconnectthe hydraulic line to the lift cylinder.

4. Disconnectthe cables and wiring to the hydraulic unit noting the proper locations for reassembly.

5. Removethe two (2) mounting bolts and lift out the hydraulic unit.

Clean and inspect the cavity and parts to be sure they are free of any foreign material.Replaceas needed.

Make sure ‘0’ ring and Teflon seal are in place and in good condition. Install spring and spool into the cavity and screw in valve body by hand.

Tighten valve body to 35 ftJ Ibs. NOTE: DO NOT bend or apply pressureto the center stud. Handle valve body only on the flats of the hex.

Install the coil onto the valve body and tighten the nut to 5 ft./ Ibs. Connect the wires to the terminals.

CHECK

UNIT

VALVE

Loosen and remove the hex head check valve body. Removethe spring and plunger from the cavity.

Inspectthe seat in the cavity, and all other parts

to make sure they are free of dirt and scoring.

Install the plunger and spring Into the cavity.

Inspectthe seals on the check valve body and replaceas necessary. lnstaflthe check valve body and torque to 35 ft/ Ibs.

SM560 29-01-2

GROUP 34 SECTION LIFT LINKAGE CONTENTS

01

NO.

LIFT LINKAGEDESCRIPTlCN 34-01-01 LIFT LINKAGE DISASSEMBLY 34-01-02 34-01-03 LIFT LINKAGEASSEMBLY 34-01-04 LIFT CYLINDERREMOVAL LIFT CYLINDERDISASSEMBLY 34-01-05 LIFT CYLINDERASSEMBLY 34-01-06

34-01-01 LIFT LINKAGE DESCRIPTION Thelift mechanismis a welded fork assembly designed to enter pallets and lift high enough (approximately6”) to clear the floor for carrying.

Lifting is accomplishedby a hydraulic cylinder and linkage raising the forks by for&g the load wheels downward. Lowering is achieved by release of the hydraulic pressure and the force supplied by the mass of the frame.

34-01-02 LIFT LINKAGE DISASSEMBLY

LIFT LINKAGE 34-01-03 ASSEMBLY. 1. Inspectthe lower link bushings in the frame and replace as necessary.

2. Inspect and replace as needed the bushings in the pull rods.

3. Check all pins for excessivewear and replace as needed.

4. Grease all pins and bushings before installation.

To replace the pull rods and/or bushings, it is easiest to work with the truck upside down.

Disconnect the battery receptacle and remove the battery pack before turning the truck over. A small amount of hydra& oil may leak from the hydraulic unit.

1. Extend the elevating brackets and remove the pins retaining them to the pull rods.

2. Removethe lower Enkstationary pivot pin retaining bolt and remove pin.

3. With the links pivoted out of the frame channels the links can be separated and the pull rods removedfrom the truck. Each link has one shaft attached at opposite ends and the links can be pulled apart without removingany rollpins.

5. Reassemblethe pull rods on the lower links and press the links together so they will be free to pivot back between the frame members.

6. Install the pivot shaft and retaining bolt into the lower links.

7. Install the pivot pins through the elevating brackets and pull rods and install the retaining pins.

8. Place the truck in the upright position, install the battery and connect the battery receptacle.

Test for proper operation of the lift linkage.

34-01-04 LIFT CYLINDER REMOVAL 1. Raise and block the forks at their upper limit.

Release the pressure in the cylinder by activating the lower switch.Tum the keyswitch t,o OFF and disconnect the battery receptacle.

SM560 34-01-l

2. Remove the hydraulic compartmentcover, the plastic drfve axle cover and the key switch bracket from the tru&.

3. Installnew seal and wger into the barrel.

3. Removethe hydraulic line to the cylinder.

4. Install a new locking ring onto the piston rod.

4. Removethe wire retainersfrom over the cylinder hose fittings.

5. insert the piston rod into the barrel until the lock ring is visible through the pressure port.

5. Removethe four bolts holding the bottom cylinder mounting pin retainers. Removethe retaining plates.

6. Usinga screwdriver,slide the bck ring back into position. Make sure that the look ring is in place in the proper groove.

2. Liihtly oil the barrel and piston rod.

6. Removethe retaining bolt from the top cylinder mounting pin and remove pin.

7. Removethe cylinder.

34-01-05 LIFT CYLINDER DISASSEMBLY 1. Extend cylinder rod until the locking ring appears in the hydraulic port.

2. Insert a screwdrfverinto the inlet port and move the locking ring down into the deeper groove adjacent to its present position.

AVAILABLE

3. Slide cylinder rod out of barrel.

4. Removethe wiper and seal from the inside bore of the barrel.

34-01-06 LIFT CYLINDER ASSEMBLY 1. Thoroughly clean the barrel and piston rod

and inspect for nicks or burrs. Dress with emery

cloth as needed.

SM560 34-01-2

GROUP 38 SECTION 02 MACHINE JACKING AND BLOCKING

1. Disconnectand remove the battery.

2. If using a chain hoist, use a double chain devise and attach to each side of the truck.

CONTENTS

NO.

3. Block the truck with solid blocks before attempting to remove the wheels.

JACKINGAND BLOCKING DESCRIPTION DRIVE WHEEL REMOVAL LOAD WHEEL REMOVAL DRIVE UNIT REMOVAL

38-02-01 38-02-02 38-02-03 38-02-04

4. lf using a jack, raise one side of the truck and block. Then raise the other side and block it before attempting to remove the wheels.

5. Referto GROUP 22 SECTION 01 WHEELS AND TIRES for removalinstructions.

38-02-01 JACKING AND BLOCKING DESCRIPTION This section describes the recommended procedures for blocking and jacking the truck for the removaland servlclngof various parts.

38-02-02

DRIVE

WHEEL

ILLUSTRATION NOT AVAILABLE

REMOVAL

1. Disconnect and removethe battery.

2. Using a chain hoist or jack of adequate capacity, raise the drive wheel end of the truck so that the drive tire just clears the floor. Use care to insure that the lifting mechanismdoes not slip to the side allowingthe iruck to tip sideways. Block the truck with solid blocks before attempting to removethe wheel.

3. Referto GROUP 22 SECTION01 WHEELAND TIRES for removalinstructions.

ILLUSTRATIONNOT AVAILABLE

38-02-03

LOAD

WHEEL

38-02-04

DRIVE

UNIT

REMOVAL

1. Disconnectand remove the battery.

2. Usinga chain hoist or jack of adequate capacity, raise the drive wheel end of the truck so that the drive tire just clears the floor. Use care to insure that the lifting mechanismdoes not slip to the side allowlngthe truck to tip sideways. Block the truck with solid blocks.

3. Referto GROUP20 SECTlON 01 DRIVE UNIT for removal instructions.

REMOVAL SM 560 38-02-l

GROUP 40 SECTION 01 TRUCK DATA AND SPECIFICATIONS BATTERY:

FLUID

12 Volt

Lead Acid 3.52 kwh

304 Amp

24 Volt

Lead Acid 3.52 kwh

152 Amp

RECOMMENDATIONS

GREASE

& CAPACITIES:

Drive Unit Transmission Fluid:

80-9OW

0.8 quart

Hydraulic Reservoir Fluid:

1o-4ow

1.O quart

Cold Storage:

Dexron II see above Clark Part No. 879804

SPECIFICATION:

Texaco C&C #880 or equivalent

LUBRICATION

RECOMMENDATIONS

Steer Handle Bearings

Remove, Clean and Lubricate.

SAE-4OW Motor Oil

Every 150 Operating Hours

Load Wheel Bearfngs

Use Grease Gun & Adapter for Flush Type Fittings.

Texaco C&C #880 or equivalent.

Every 150 Operating Hours

Wheel Fork

Pin Bearings

Remove, Clean and Lubricate.

SAE4OW Motor Oil

Every 150 Operating Hours

Pull Rod Pin Bearings

Remove, Clean and Lubricate.

SAE-40W Motor Oil

Every 150 Operating Hours

Cylinder Rod Pin Bearings

Remove, Clean and Lubricate.

SAE40W Motor Oil

Every 150 Operating Hours

Drive Unit

Drain, Flush and Refill.

SAE-80-90W Motor Oil

Every 500 Operating Hours

Hydraulic Reservoir

Drain, Flush and Refill.

Fill to within l-Inch of the reservoir fill plug opening.

SAEl O-40W Motor Oil

Every 2000 Operating Hours

Clean screen in solvent. Air Dry.

Usea Stoddard ~o~v~;;aning

Gear Case

Hydraulic Reservoir Inlet Screen

[

Forks must be fully lowered when checking or filling the hydraulic reservoir. ]

.

SM 560 40-01-l

Every 2000 Operating Hours

TRUCK

DATA SPECIFICATIONS

-continued-

Motor lnsullation Resistance to Ground Test Datsl Using a Volt-Ohmmeter: Using a 500 Volt Megger:

1,OOO,OOO Ohms (1-Megohm) 1,OOO,OOO Ohms (1-Megohm)

.

Pump and Drive Motor Data Brush Replacement:

Replaces brushes when worn to length of 0.250” or less.

Brush Spring Tension:

32 to 40 ounces

Commutator Diameter:

1.5” Minimum

Insullation:

Class “H” Toraue

Specifications

Drive Motor Pinion Nut:

75 pound feet (Dry Thread)

Drive Motor Mounting Bolt:

35 pound feet (Dry Thread)

Drake Drum Lock Nut:

75 pound feet (Dry Thread)

Drive Wheel Nut:

250 pound feet (Dry Thread)

Drive Motor Access Cover Bolt

35 pound feet (Dry Thread)

Contactor 5/l 6-l 8 Screws:

45 to 60 inch/lbs (Dry Thread)

Drive Unit Cover Bolt:

30 pound feet (Dry Thread)

Axle Shaft Nut:

250 pound feet (Dry Thread)

Hydraulic Unit Hex Head Valve Body:

35 pound feet (Dry Thread)

Hydraulic Unit Check Valve:

35 pound feet (Dry Thread)

Wraullc

.

Relief Valve Setting:

Unit Data 2600 PSI @ 16 Volts

SM

560

40-01-2