CLARK FORKLIFT SM 538 NSNP 246 (P.M.) SERVICE MANUAL - PDF DOWNLOAD

Service & Adjustment Manual

SM 538 NS/NP 246 (P.M.)

SERVICE MANUAL SM538

NP/NS

300 C&D

CONTENTS GROUP

PAGE

FOREWORD HOW TO USE THIS MANUAL PICTORIAL INDEX SAFETY AND OPERATIONAL CHECKS RECOMMENDED PLANNED MAINTENANCE AND LUBRICATION SCHEDULE SAFETY SIGNS AND MESSAGES USER SAFE MAINTENANCE PRACTICES

ii ...

III iv V

vi vii...

VIII

GROUP

PAGE

PM 12 13 16 16 16 16 19 19 19 20 22 23 25 26 26 29 30 32 32 32 32 32 32 34 34 34 34 34 34 34 38 40

PM-l 12-01-l 13-01-l 16-01-l 16-02-o 16-03-l 16-04-l 19-02-l 19-03-l 19-04-l 20-01-l 22-01-l 23-01-l 25-01-l 26-01-l 26-02-l 29-01-l 30-01-l 32-01-l 32-02-l 32-03-l 32-04-l 32-05-l 32-06-l 34-01-l 34-02-l 34-03-l 34-04-l 34-05-l 34-06-l 34-07-l 38-02-i 40-02-l

Planned Maintenance Program Battery Handling and Care Accelerator Control Electric Motor general maintenance Drive motor Lift Pump Motor Steer Pump Motor SCR Control ,Test, Equip., Proceedures SCR, Symptom Charts Control Panel Drive Unit Wheels and Tires Brake Caster Adjustment Steering System Power Steering Pump Hydraulic Lift Pump Main Hydraulic Valve Tilt Cylinder Model C Reach Cylinder Model C Lift Cylinder Model D Tilt Cylinder NP D Tilt Cylinder NS D Reach Cylinder NP D Upright Removal Model C Upright Maintenance Model C Upright Lift Cylinder Model C Pantograph Model C Upright Removal Model D Upright Maintenance Model D Pantograph NP D Machine Jacking & Blocking Truck Data, Specifications SM538 i

FOREWORD

Clark Equipment Company welcomes you to the growing group of professional people who own, operate and maintain Clark lift trucks. This manual will familiarize you with service maintenance and overhaul information about your new truck. It has been especially prepared to help you maintain your Clark lift truck in an efficient and safe operating condition.

Regular, correct maintenance and care of your lift truck is not only important for full and efficient truck life; it is essential for your safety. A faulty lift truck is a potential source of danger to the operator, and to other personnel working near it. The importance of maintaining your lift truck in a safe operating condition by servicing it regularly and, when necessary, repairing it promptly cannot be emphasized too strongly.

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

Clark recommends that a planned maintenance and safety inspection program (PM) be performed by a trained and authorized mechanic on a regular basis. The PM program provides the opportunity to make thorough inspections and checks on the safe condition of your truck. Necessary adjustments and 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 replacements is found and corrections made as required; not after failure has occurred.

SM538 ii

HOW TO USE THIS MANUAL

This manual is intended to be used by persons who are trained and authorized to do lift truck maintenance. The recommended procedures for routine servicing and adjustments as well as for removal and overhaul of major components of the truck are outlined. It is written to show and describe the 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 numbers are 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. If 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.

Specifications of selected truck components are included at the back of the manual for easy reference.

Also refer to the Operator’s Manual, located on the truck, for additional information and instructions on the operation and maintenance of your truck.

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

NOTICE - The descriptions and specifications included in this manual were in effect at the time of printing. Clark Equipment Company reserves the right to make improvements and changes in specifications or design, without notice and without incurring obligation. Please check with your authorized CLARK dealer for information on possible updates or revisions.

0 Clark Equipment Company 1987

SM538 iii

PICTORIAL

NP/NS

30Tquf;row

INDEX

Aisle

(NP) = Pantograph (no (NS) = Straddle pantograph)

1 _ Overhead guard 2. Overhead guard rear post 3. Upri ht assembly 4. Loa 2 backrest extension 5. Fork carria 9 e 6. Load whee s (NP model shown) 7. Load forks 8. Pantograph mechanism (NP only) 9. Swivel caster 10. Battery compartment

SM538

iv

SAFETY

AND

OPERATIONAL

PM Interval: A=8 - 10 hours, or daily B = 50 - 250 hours. or everv month c=450500 ho&, or e@ry 3 months D = 900 - 1000 hours, or every 6 months E = 2000 hours, or every year

DAILY Check Check Check Check Check

MAINTENANCE

CHECKS

truck for obwous damage and leaks. / clean battery terminals electrolyte level. capacity, warning plates, decals condition of tires and wheels. Remove

SM538 v

CHECKS

RECOMMENDED PLANNED MAINTENANCE AND LUBRICATION SCHEDULE

Lubrication Standard

CHECK

OR LUBRICATE

(1-W Guide rollers (1 -A) Cable sheave &

\ (8- J)

fl>6-F ) Fork (1 -A) Pantograph 43-J)

Upr. rollers (1-K) -

Lift chain

(1-E) Batt. rollers 51&6-F)

Cont. Handle f &8-J) Pedal shaft --_( 1-A) Swivel bar. I

4 ‘:-l_~~~~s~~~r?(?J~ Trans. case ( 2 -G) 4, (‘Steer

gears (7-J) -

Trans. yoke (1 -A) / ,,I’_

Hyd.oilfilter(D)~~'~i

Eh:;'Ll

150 hours 500 hours 1000 hours

I’I

r

2000 hours

Lubricants (6) - SAE 20 Engine oil

(1) - MPl- multi urpose grease NL c?1 # 1 (2) - GL5 - transmission lubriiant APl GL5

(7) - 886785 Spray lubricant

(3) - CCa-;hgi$xicant

(8) - Dry graphite

(5) - MS68 Hydraulic oil

-Method A - Use standard lube gun B - Use lube gun and adaptor for flush type fittings (C) - Clean in solvent and re-oil D) - Change filter I E) - Remove, clean and repack

II

SM538 vi

F) - Apply light film G) - Drain, flush and refill H) - Repack bearing J) - Clean and lubricate (K) - Apply to channel of rail

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. Damage to the truck or death or serious injury to you or other persons may result if these messages are not followed.

NOTICE This message is used when special information, instructions or identification is required relating to procedures, equipment, tools, pressures, capacities and other special data.

IMPORTANT This message is used when special precautions should be taken to ensure a correct action or to avoid damage to or malfunction of the truck or a component.

CAUTION This message is used as a reminder of safety hazards which can result in personal injury if proper precautions are not taken.

WARNING This message is used when a hazard exists which can result in injury or death if proper precautions are not taken.

DANGER This message is used when an extreme hazard exists which will result in death or serious injury if proper precautions are not taken.

SM538 vii

USER

SAFE

MAINTENANCE

The following instructions have been prepared from current industry and government safety standards applicable to industrial truck operations and maintenance.

These recommended procedures specify conditions, methods, and accepted practices that aid in the safe maintenance of industrial trucks. They are listed here for the reference and safety of all workers during maintenance operations.

Carefully read and understand these instructions and the specific maintenance procedures before attempting to do any repair work. When in doubt of any maintenance procedure, please contact your local CLARK dealer.

1. Powered industrial ous if maintenance suitable maintenance and procedures must

trucks can become hazardis neglected.

Therefore, facilities, trained personnel, be provided.

2. Maintenance and inspection of all powered industrial trucks shall be done in conformance with the manufacturer’s recommendations.

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

9. Before working on engine fuel system of LPgas powered trucks, close LP-gas cylinder valve and run engine until there is no more fuel in the system and engine stops running. If engine will not run, close LP-tank valve and vent fuel slowly in a safe area.

10. Operation of the truck to check performance must be conducted in an authorized, safe, clear area.

11. Before Starting To Drive Truck: a) Be in operating position. b) Disengage clutch on manual transmissions, or apply brake on trucks with powershift transmission 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 load handling attachments.

12. Before Leaving The Truck: a) Stop truck. b) Fully lower the load engaging nii . upright, carriage, forks, or attachments. c) Put directional control in neutral. d) Apply the parking brake. e) Stop the engine or turn off power. f) Turn off the control or ignition circuit. g) Put blocks at the wheels, if truck is on an incline.

4. Only trained and authorized personnel shall be permitted to maintain, repair, adjust, and inspect industrial trucks, and in accordance with the manufacturer’s specifications.

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 flammable cleaning fluids for cleaning parts.

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

PRACTICES

13. Handle LP-gas cylinders with care. Damage such as dents, scrapes, or gouges may dangerously weaken the tank and make it unsafe for use.

14. Brakes, steering mechanisms, control mechanisms, warning devices, lights, governors, lift overload devices, guards and safety devices, lift and tilt mechanisms, articulating axle stops, and frame members must be carefully and regularly inspected and maintained in a safe operating condition.

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

SM538 viii

USER

SAFE

MAINTENANCE

15.

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

16. Fuel systems must be checked for leaks and condition of parts. Extra special consideration must be given in the case of a leak in the fuel system. Action must be taken to prevent the use of the truck until the leak has been corrected.

17.

All hydraulic sytems must be regularly inspected and maintained in conformance with good practice. Tilt and lift cylinders, valves, and other similar parts must be checked to assure that “drift” or leakage has not developed to the extent that it would create a hazard.

18. When working on hydraulic system, be sure the engine is turned off or battery disconnected on electric trucks, upright is in its fully-lowered position, and hydraulic pressure relieved in hoses and tubing. WARNING -- Always put blocks under the carriage and upright rails when necessary to work with upright in an elevated position.

19. The truck manufacturer’s capacity, operation and maintenance instruction plates, tags, or decals must be maintained in legible condition.

20. Batteries, motors, controllers, limit switches, protective devices, electrical conductors and connections must be inspected and maintained in conformance with good practice. Special attention must be paid to the condition of electrical insulation.

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

22.

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

Modifications and additions that affect 23. capacity and safe truck operation must not be done without the manufacturer’s prior written approval. Capacity, operation and maintenance instruction plates, tags or decals must be changed accordingly.

PRACTICES

24.

Care must be taken to assure that all replacement parts, including tires, are interchangeable with the original parts and of a quality at least equal to that provided in the original Parts, including tires, are to be equipment. installed per the manufacturer’s procedures.

Always use genuine CLARK or CLARK-approved parts.

25. When removing tires, follow industry safety practices. Most important, deflate pneumatic tires completely prior to removal. Following assembly of tires on multi-piece rims, use a safety cage or restraining device while inflating.

26. Use special care when removing heavy components from the truck, such as counterweight, upright, etc. Be sure that lifting and handling equipment is of the correct capacity and in good condition.

NOTICE -- You should also be familiar with additional operating and maintenance safety instructions contained in the following publications: ANSVASME B56.1 - 1983: Safety Standard for Low Lift and High Lift 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-l 982: Fire Safety Standard for Powered Industrial Trucks: Type Designations, Areas of Use, ,Maintenance and Operation.

Available from: National Fire Protection Assoc., Inc., Batterymarch Park, Quincy, MA 02269.

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

SM538 ix

PM - PLANNED MAINTENANCE PROGRAM CONTENTS

PG

General Visual Inspection Functional Tests Test Drive The Truck Air Cleaning Critical Fastener Torque Check Lubrication, Fluids and Filters

: 5 8 11 11 11

Disconnect battery from truck receptacle working on electrical components.

before

Always wear safety glasses.

Wear a safety (hard) hat in industrial plants and in special work areas where protection is necessary or required.

HOW TO PERFORM INSPECTIONS AND

VISUAL

THE

PM

PERIODIC

MAINTENANCE

INSPECTION

First, perform a visual inspection of lift truck and its components.

Walk around truck and take note of any obvious damage and maintenance problems. Check for loose fasteners and fittings.

GENERAL A planned maintenance program of regular, routine inspections and lubrication is important for long l,ife 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.

PM Report Form As an aid in performing and documenting your PM inspections, Clark has prepared an “ELECTRIC TRUCK PLANNED MAINTENANCE REPORT” form. Copies of this form may be obtained from your authorized CLARK dealer.

We recommend that you use this form as a checklist and to make a record of your inspection and truck condition.

The periodic maintenance procedures outlined in this manual are intended to be used with PM report form.

They are arranged in groupings of maintenance work that are done in a logical and efficient sequence.

A check mark when PM is coding system repairs and/or

L

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

NOTICE NAMEPLATES & DECALS Do not operate a lift truck with damaged or missing decals and nameplates.

Replace them immediately.

They contain important information.

or entry is made on PM Report Form performed.

Please note special for indicating importance of needed adjustments.

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

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

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

SM538

PM - 1

Inspect truck for any signs of external leakage: transmission fluid, etc. Check for hydraulic oil leaks and loose fittings. DO NOT USE BARE HANDS TO CHECK. Oil may be hot or under pressure.

SAFETY

NOTE

HYDRAULIC FLUID PRESSURE Do not use your hands to check for hydraulic leakage. Fluid under pressure can penetrate your skin and cause serious injury.

Be sure that driver’s overhead guard, load backrest extension, finger guards, shields, padding, and any other safety devices are in place, undamaged, and attached securely.

NOTICE - For trucks equipped with sparkenclosed construction (EE), or with polyurethane tires: Check ground strap for security of attachment and wear damage.

Then, check all of the critical components that handle or carry the load.

1

Overhead Guard

Upright Load Backrest Extension

XI r

SAFETY

NOTE

Uprights can drop suddenly. Look at upright, but keep hands out.

Inspect upright assembly: rails, carriage rollers, lift chains, lift and tilt cylinders, reach mechanism and Look for obvious wear and reach cylinder. maintenance problems, damaged or missing parts.

Check for any loose parts or fittings. Check for leaks, any damaged or loose rollers. and rail wear (metal flaking). Carefully check lift chains fcr ‘qr. rust and corrosion, cracked or broken 11~11 stretching, etc. Check that lift and carriage chains are correctly adjusted to have equal tension.

Check that lift chain anchor fasteners and locking means are in place and tight.

Be sure all safety guards and chain retainers are in place and not damaged. Inspect carriage stops and cylinder retainers.

Check all welded connections.

Carriage -_ Forks Load Wheel I Outrigger I

Check overhead guard for damage. Be sure that it is properly positioned and all mounting fasteners are in place and tight.

Check load backrest for damage. Inspect welds on carriage and load backrest for cracks. Be sure that mounting fasteners are all in place and tight.

NOTE - If load backrest has been removed, a bolt and washer must be in place on each end of top fork bar to act as a fork stop.

Inspect all lift line hydraulic connections for leaks.

Check lift cylinder rod, tilt cylinder rod and reach cylinder rod for wear marks, grooves, and scratches. Check cylinder seals for leaks.

IMPORTANT Uprights and lift chains require special attention and maintenance to maintain them in safe operating condition. Refer to Lift Chain Maintenance section for additional information.

SM538 PM - 2

Forks Inspect load forks for cracks, breaks, bending and wear. The fork top surfaces should be level and even with each other.

The height difference between both fork tips should be no more than 3% of fork length.

blade of fork with 4” surface against blade. Put a 24” carpenters square on top of block and against shank. Check fork 20” above blade to be sure it is not bent more than 1 inch maximum.

If fork blades are obviously bent or damaged, have them inspected by a trained maintenance person.

Inspect fork latches. Be sure they are not damaged or broken and operate freely and lock correctly. Check fork stop pins (or bolt and washer) for secure condition.

FORK LENGTH X .03 = HEIGHT DIFFERENCE

10% of ‘A’ max. wear

Check amount of wear at heel of fork.

WARNING If fork blade at the heel is worn down by more than lo%, load capacity is reduced and the fork must be replaced. (IE. 1.75 X .9 = 1.575 MINIMUM THICKNESS PERMITTED FOR AN ORIGINAL FORK THICKNESS OF 1.75 INCHES).

Sh lank

Inspect forks for twists and bends. To check, put a 2” thick metal block, at least 4” wide by 24” long on

SM538

PM - 3

Wheels

and

FUNCTIONAL

Tires

Check condition of drive wheel and tire, of stabilizing caster wheel, and of load wheels.

Remove objects that are embedded in treads.

Inspect tires for excessive wear and breaks or “chunking out”, and bond failure between tire and rim.

Check all wheel lug nuts or mounting fasteners be sure none are loose or missing.

to

Have missing fasteners replaced and loose fasteners tightened to correct torque before operating truck.

SAFETY

TESTS

Be sure that all controls and systems are functioning correctly.

Test all warning devices, horn, lights, and other safety equipment and accessories.

Be sure they are properly mounted and working correctly.

Press horn button to check horn function.

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

Operate brake pedal, all hydraulic controls: Ii’ reach, and auxiliary (if installed), operator hacd control accelerator and directional control, an? steering system.

Be sure all controls operate freely and return to neutral properly.

\I v+l

NOTE

Personnel working on wheels and tires must be trained and qualified to do wheel and tire maintenance.

I

I

Fully rotate operators control handle release, to check for free movement.

SM538

I

\I I Check function of foot brake mechanism.

Apply, then release foot-operated pedal. When correctly adjusted, foot pedal should move to brake-applied position by spring action when released.

If foot pedal binds or does not operate freely, apply lubricant to linkage at pivot points.

PM - 4

and then

Check directional control by rotating control handle both ways, then releasing handle, for correct function.

Report any malfunction.

Do not attempt to operate truck until repair has been made.

Be sure lift and tilt contol feature of control handle moves freely and returns to center or neutral position when released.

Before starting a lift truck, safe condition.

Check to see that:

begin

from

a

Brake is applied (foot is not on brake pedal).

Forks are fully lowered to floor.

You are familiar with how all controls function.

All controls are in neutral or other correct position.

Check battery discharge indicator.

The indicator should register in green area when key switch is ON. Also, check function of battery discharge indicator when making a battery load test, below.

Turn key switch ON. Battery

Load

Test

Check battery condition by holding operator hand control in full back-tilt position, allowing pump to run against loading of bypass relief pressure for a few seconds.

Watch battery discharge indicator.

The needle should stay in green area. If needle falls into red area, battery is faulty or charge level is low and battery must be recharged before completing other electrical tests and performance parts of PM.

BEFORE DO

Check hour meter operation.

With key switch ON, release brake (step on brake pedal).

The steer pump and hourmeter should begin operating.

Watch for movement of indicator in the dial opening. Report any malfunction or damage.

Turn key switch off and remove foot from brake.

Power steer motor should stop running after an eight (8) second delay.

Write form.

hourmeter

reading

on

THESE

DRIVING THE TESTS:

TRUCK,

Test for correct function of lift pump motor switch on LIFT portion of operator control handle.

Turn key switch ON. Slowly pull back on operator control handle (RAISE position). The pump motor should start to run as handle moves from neutral position.

Push handle forward (LOWER position) Pump will stop until upright starts to lower. running.

Pump motor should not operate when handle is moved to “lower” position.

PM report If operator control handle movement is excessive before pump starts, or if pump does not stop running when handle returns to neutral, spool position switch needs repair or adjustment.

Test for correct function of motor switch for TILT, REACH, and AUX function control.

Slowly move tilt control portion of operator handle forward and then backwards,

SM538

PM - 5

control while

pressing on blue side of toggle switch (showing picture of TILT on switch).

(Pressing this blue switch prevents LIFT motor from turning ON).

This movement

should activate tilt cylinder.

Repeat test for reach control, if installed, by depressing yellow side of toggle switch (showing picture of REACH on switch) and pulling back or pushing forward on control handle at same time.

Refer to discussion above if handle movement or switch action is not correct.

Check function of parking brake microswitch.

With key switch ON and parking brake applied (foot off brake pedal), move operator control handle to Rotate operator control FORWARD position. handle for FWD direction slowly _ The drive motor should not operate.

If it does, microswitch on the parking brake linkage is not adjusted correctly.

Also, check REVERSE direction rotation of handle.

Check brake switch and braking action. Release brake by stepping on brake pedal.

Rotate operators control handle to move truck slowly forward. Then, apply brake by taking foot off brake pedal. The brake should turn drive motor off and stop and hold truck from further movement.

Turn key switch OFF and apply brake. Steer pump should stop after an eight (8) second delay.

NOTICE - The steering system, steer wheel and steering linkage should be inspected periodically for abnormal looseness and damage.

Check for any changes in steering action.

Hard steering, excessive freeplay (looseness) or unusual sounds when turning or maneuvering indicates a need for inspection and servicing.

Never operate a truck which steering system fault.

To check brake holding capability and adjustment, park truck on a grade and apply brake. The brake should hold a lift truck with rated load on a 15% When brake pedal is released, brake grade. should not drag.

CAUTION if brake

- Do not operate a lift truck is not operating properly.

Test for correct function of power steering pump switch and system. Turn key switch ON, and release brake. The steer pump should begin operating.

With truck not moving, check steering system by moving steering handwheel in a full right turn, and then in a full left turn.

Return handwheel (steer wheel) to straight-ahead position.

The steering components should operate smoothly when steering wheel is turned.

Listen for steering pressure relief valve to by-pass when steer wheel hits stops. The steer pump and motor should not stall or exhibit excessive loading. If it does, power steering system relief pressure valve may be malfunctioning.

SM538

PM - 6

has a

TEST

DRIVE

THE TRUCK

NOTE - It is recommended that these tests be conducted with a rated capacity load, if possible.

Test truck for general correct operation and drive train function, by driving truck in both forward and reverse directions first in a straight line and then, slowly, through a series of full right and left turns.

Check all around to be sure that your intended path of travel is clear of obstructions and pedestrians.

Test for correct function Check CREEP PLUGGING.

of SCR traction control.

SPEED,

1A

RANGE,

and

1. Check CREEP SPEED and 1A RANGE while driving truck in a straight line in both FORWARD and REVERSE directions.

CREEP SPEED should be obtained at beginning of SCR RANGE after rotating operator control handle a slight amount.

1A RANGE - When operator control handle is rotated farther , truck should accelerate in SCR RANGE and make a smooth transition into 1A RANGE for maximum travel speed.

As 1A contactor closes, there should be very little surge as truck goes out of SCR RANGE and into 1A. All speed changes should be smooth while increasing and decreasing speed. Listen for any unusual drive train noises or actions of controls and drive train components.

Stop truck with brake. Note any unusual reactions in driving or braking performance, and need for adjustment.

2. PLUGGING is an SCR control function which provides for reversing direction of travel under A correctly-adjusted controlled conditions. plugging control should result in a smooth deceleration, or gradual stop of travel from any speed in one direction, and acceleration in opposite direction.

Plugging speed and distance is determined by amount operator control handle is rotated .

Check PLUGGING function first at a slow speed. If operating correctly, then test at full speed.

First, drive truck in FORWARD direction.

Rotate operator control handle and allow truck to accelerate to desired travel speed. Then, reverse rotation of operator control handle to REVERSE

SM538

position.

The truck should slow to a smooth, controlled stop and accelerate in opposite direction.

Repeat test by rotating operator control handle backward to FORWARD position.

Check acceleration control of operator control handle while conducting speed ‘range tests.

It must move easily and smoothly throughout acceleration stroke, and return without binding.

There should be no restriction to movement on either acceleration or deceleration.

Test brake (drive motor cut-off) switch. Drive truck FORWARD (or in REVERSE) at creep speed.

While holding operator control handle steady in creep-speed position, remove foot from brake pedal. The braking action should interrupt power to drive motor and stop truck. Depress brake pedal and move control handle to NEUTRAL and then to FORWARD (or REVERSE).

The drive motor should start again moving truck.

Retest brake operation by applying and releasing brakes several times while driving truck. 1) Check for quick pedal return,and for full stopping without pulling to one side 2) Listen for brake squeal and other abnormal noise.

Check steering control operation.

First, drive truck in a straight line. Then, drive SLOWLY (creep speed) through a series of full right and left turns.

The truck must drive in a straight line without Check steering drifting toward either side. response and smoothness of operation.

Turning effort must be same in either direction.

NOTICE - It is recommended that following tests also be conducted with a rated capacity load, if available.

Test for general drive train operation and noises.

Drive truck at various speed and operating conditions, in both FORWARD and REVERSE Test shifting from NEUTRAL to directions.

PM - 7

WARNING

FORWARD, then back to “N”. Next, test shift from “N” to REVERSE, then back to “N”. Check for positive control action when changing directions.

Listen for clunking, squealing, grinding, scraping or other unusual noise. Check for vibration. Listen for wheel bearing or other specific running noise.

Lift mechanism

and controls

NOTE - It is recommended that these tests be conducted with a rated capacity load (RATED LOAD is shown on nameplate), if possible.

Test operation of hydraulic system and upright.

SAFETY

NOTE

FALLING FORKS

Do not walk or stand under raised forks. The forks can fall and cause injury or death.

Observe upright assembly: rails, roilers, carriage, lift chains and cylinder as they move. Check for binding or excessive freeplay (looseness) between carriage and upright rails and rollers.

Listen for abnormal noises. If there is excessive clearance between rails and channels,a need for upright roller adjustment is indicated. If rails or carriage bind or hesitate when lowering, this indicates either damaged rollers or incorrect roller adjustment.

Check upright for excessive downdrift. Stop the fork carriage in an intermediate position. Check that it holds its position and raises or lowers smoothly from any height position.

If the fork carriage does not hold its position when stopped , upright may have too much downdrift due to wear of cylinder seals. Conduct an upright cylinder downdrift test, with rated load, as needed.

BE SURE THERE IS ADEQUATE OVERHEAD CLEARANCE BEFORE RAISING UPRIGHT.

Test tilt control. Check for excessive tilt cylinder drift. Stop carriage at a position near vertical.

Check that carriage holds its position without moving forward. If you observe forward movemer,. (drift), or have a report of a tilt drift problem, check tilt cylinder for too much drift.

Check correct fork height adjustment (also carriage chain adjustment). Tilt forks to vertical position and fully lower carriage. The forks should stop and be held approximately [13 mm] .50 inch above floor. If forks hit floor, carriage lift chains should be adjusted.

Cycle (raise to full height and then lower) upright at both slow and fast speed, with forks tilted slightly backwards. Watch upright assembly as it rises. All movements of upright, fork carriage, and lift chains must be even and smooth, without binding or Watch for chain wobble or jerking motion. looseness; chains should have equal tension and move smoothly without noticeable wobble.

Check for correct function of lift control portion of operator control handle and main hydraulic valve.

Listen for abnormal noise in hydraulic valve, main hydraulic pump, and system components.

If maximum fork height is not reached, this indicates there is an inadequate (low) oil level in hydraulic sump tank, or severe binding within upright.

Auxiliary

function

control

If truck is equipped with an attachment, check control for correct function by briefly operating attachment.

When you have completed operational tests, park and leave truck according to standard shutdown procedures.

Be sure to make a record of all maintenance and operating problems you find.

Battery

SM538 PM - 8

Compartment

Inspection

Turn key switch OFF. Disconnect battery from truck receptacle by pulling on red emergency battery disconnect lever. Make sure lower arm of lever is spaced correctly to engage battery cable end of quick disconnect connector and that lever moves freely without binding and returns to rest position.

Inspect condition of battery connector.

Check spring-loaded terminal and retaining tab for poor connection due to burning, bad crimp, or loose or broken retainer. Check molded body for damage from overheating, burning and chips or cracks.

Clean all corrosion from contacts, as necessary.

Inspect spring-loaded connectors in truck battery receptacle. Look for looseness, burned pans and other damaged areas due to excessive heat.

Refer to checks noted above. If any of above conditions are evident, replace connectors.

Inspect condition of battery and cables. Check battery cables for wear or other damage, and routing clear of interference (rubbing) with other components. Be sure that cable terminals are tight and clean. Clean off minor deposits of corrosion that you find on battery.

IMPORTANT is in truck.

- Never wash battery when it

Check battery post terminals for corrosion and damage. Clean all corrosion from cable end and battery post. Check tightness of cable and post terminals.

If necessary, check state-of-charge condition of battery. Take a specific gravity test of electrolyte with a hydrometer. Be sure to check a minimum of six battery cells.

Degreaser (or equivalent to MS-l 80 Freon TF Degreaser and Cleaner).

Turn key switch OFF. Disconnect battery from Remove lower control panel truck receptacle. cover.

Discharge capacitor. Use an insulated tool, such as a screwdriver with plastic or wood handle, to short between terminals.

Inspect SCR controls for clean condition. Check for oily dirt buildup on contactors, SCR control card, capacitor, etc. Inspect all controls wiring and terminals for any obvious damage. Look for cracks or worn areas in wiring insulation. Check for loose connections at controls terminals. Air clean, as necessary.

AIR

CLEANING

Always maintain a lift truck in a clean condition. Do not allow dirt, dust, lint, or other contaminants to accumulate on truck. Keep truck free from leaking oil and grease. Wipe up all oil spills. Keep controls and floorboards clean, dry, and safe. A clean truck makes it easier to see leakage, loose, missing or damaged pans, and will help prevent fires. A clean truck will run cooler.

The environment in which a lift truck operates will determine how often and to what extent cleaning is necessary. For example, trucks operating in manufacturing plants which have a high level of din or lint (e.g., cotton fibers, paper dust, etc.) in air or on floor, will require more frequent cleaning. If air pressure does not remove heavy deposits of grease, oil, etc., it may be necessary to use steam or liquid spray cleaner.

LIFT TRUCKS

Check electrolyte level of battery. Add distilled water, as required, to fill each cell to correct level.

Check to be sure vent holes in all battery cell caps are open. If cap vents are plugged with corrosion, remove them and wash in a solution of baking soda and water.

Motor

SCR Controls

Inspection

EVERY OFTEN

SHOULD PM INTERVAL, AS REQUIRED.

BE AIR CLEANED AND OTHERWISE

AT AS

Air cleaning should be done using an air hose with special adapter or extension having a control valve and nozzle to direct air properly. Use clean, dry, low-pressure compressed air; restrict air pressure to [207 kPa] 30 psi, maximum. CAUTIONWear suitable eye protection and protective clothing.

IMPORTANT CLEANING AND INSPECTION OF ELECTRICAL COMPONENTS

Do not clean electrical components with steam. Only approved solvents should be used to clean controls and SCR Use Clark #1801146 components.

Upright assembly; drive unit; battery, Air clean cables, switches and wiring harness; SCR controls and wiring; drive, lift, and steer motors; and steer linkage.

CRITICAL CHECK SM538 PM - 9

FASTENER

TORQUE

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

Check torque of critical items, including: Overhead guard; drive unit mounting; drive wheel mounting; stabilizing caster mounting: load wheel mounting; load backrest extension; tilt cylinder mounting and yoke; reach mechanism and mounting; upright mounting & components.

LUBRICATION, FILTERS HYDRAULIC

FLUIDS

B - Pumping fluid out by using truck hydraulic system. This method may be used most easily and satisfactorily for routine changes of fluid.

Hydraulic

Oil Filter

Remove and replace hydraulic system fluid filter per recommended PM schedule, or as may be required by truck operating conditions and usage.

Install a new oil filter. Be sure to follow installation instructions printed on filter. Check for leaks after installation of filter. Also, check that hydraulic line connections at filter adapter are tightened correctly.

AND

IMPORTANT Always use genuine CLARK parts.

Sump Tank

SUMP

Breather

Maintenance

Check hydraulic sump tank fluid level. Correct fluid level is important for proper hydraulic system operation.

Low fluid level can cause pump damage. Overfill can cause loss of fluid or lift system malfunction.

Remove sump tank fill cap/breather and inspect for excessive (obvious) contamination and damage.

Clean or replace fill cap/breather, per recommended PM schedule or as required by operating conditions.

Hydraulic fluid expands as its temperature rises.

Therefore, it is preferable to check fluid level at operating temperature (after approximately 30 minutes of truck operation). To check fluid level, first park truck on a level surface and apply brake.

Retract reach mechanism and lower fork carriage fully down. Pull dipstick out, wipe it with a clean wiper and reinsert it fully into dipstick tube.

Remove dipstick and check oil level. Keep oil level above LOW mark on dipstick by adding recommended hydraulic fluid only, as required.

DO NOT OVERFILL.

ACCESS

To reach drive unit check points (oil level/fiQr plugs and drain plugs) , it is ncessary to elevate rear of truck.

Refer to Machine Jacking and Blocking section for additional information on raising rear of truck safely.

Check condition of hydraulic fluid (age, color or clarity, contamination, etc.). Change (replace) oil, as necessary.

Hydraulic

TO THE DRIVE UNIT

Fluid and Filter Change

Drain and replace hydraulic sump fluid every 2000 operating hours, or sooner, as required. Replace hydraulic oil filter at every oil change. Replace sump tank breather/fill cap every 1000 operating hours.

There is no drain plug in hydraulic sump tank. The hydraulic fluid can be changed by one of following methods: A - Removal of hydraulic sump tank cover assembly and pumping fluid out by suction using a separate pump and hose.

SM538 PM - 10

DRIVE

AXLE

FLUID

The drive unit inspection and service openings are shown in following illustration.

plug

1

Inspect and clean drive unit breather (air vent) located on upper side of drive unit housing rear surface (almost directly in line with drive wheel).

TRUCK CHASSIS LUBRICATION

INSPECTION

AND

Lubrication and inspection of truck chassis components, including steer wheel, steering linkage, wheel bearings, and stabilizer caster assembly, will be easier if rear of truck is raised and blocked up under frame. Refer to Machine Jacking and Blocking section for additional information.

WARNING DO NOT RAISE TRUCK

BY LIFTING BE OR HOISTING ON UPRIGHT. SURE TO PUT BLOCKING UNDER FRAME TO KEEP TRUCK SAFE.

1.

2.

3.

4.

5.

Upper Upper Lower Lower Lower

Case Case Case Case case

Breather Drain Plug Breather Fill Plug Drain Plug

Inspect steering universal joints and shaft, gears and gear shaft and torque generator for looseness or for leaks.

Lubricate

miscellaneous

AND LUBRICATION UPRIGHT

Check driveunit fluid level with truck on a level surface and oil at operating temperature.

Remove housing section reaches

fill plug located on upper left of drive unit rear vertical surface.

Oil level for upper of drive unit is correct (FULL) when oil lower edge of this plug opening.

Remove fill plug located in bottom sump at rear of sump housing. Oil level is correct (FULL) when oil reaches lower edge of fill plug opening.

Clean fittings mechanisms.

reach

Lubricate entire length of lift and carriage with Clark Chain and Cable Lube.

NOTE - Do not lubricate carriage roller rails.

chains

LIFT

Replace, as needed.

NOTICE - Check PM interval (operating hours), or condition of oil to determine if drive unit fluid needs to be changed.

Drive

Unit

Fluid

Change

Drain and replace drive unit fluid every 1000 operating hours. Oil should be drained when it is warmed to operating temperature.

Put truck in a level position.

Apply brake and block wheels to prevent truck from moving.

SM538

PM - 11

and

CYLINDER

and

Add recommended fluid only, as required.

Refer to Specifications for drive unit recommended oil specification.

Inspect fill plugs for damage.

Install and tighten plugs.

TILT

linkage, as needed.

lubricate

tilt

CHAINS

GROUP 12 SECTION 01 BATTERY HANDLING AND CARE CONTENTS

NO.

BATTERY HANDLING BATTERY REMOVAL PROCEDURE BATTERY MAINTENANCE BATTERY RECORDS FOR MAXlNMUM BATTERY LIFE BATTERY INSTALLATION

12-01 12-02 12-03 12-04 12-05 12-06

12-01

BATTERY

HANDLING

1. Change or service storage batteries only in an area designated for this purpose.

OVERHEAD HOIST I

7

8 CONVEYER

SAFE-f-Y HOOK

4. Area should contain correct material handling equipment designed for purpose of removing and replacing batteries (such as an overhead hoist or a conveyor). Overhead hoist should be equipped with safety hooks. _

LIFTING

2. Area should have provisions for: a). Flushing and neutralizing any spillage. b). ventilation of fumes from gassing. c). Fire protection.

3. Before attempting to service a storage battery, truck should be correctly positioned in designated battery service area and braked with key switch OFF.

5. When using overhead battery hoist, be sure an insulated spreader bar (or simmilar lifting device) is’ used, which puts lifting stresses vertical. Neither outward nor inward force must be applied to battery. Lifting eyes on lift member shall be of same width as battery lifting handles, making lift stresses vertical. Be sure lifting hooks are of correct size to fit lifting holes or handles of battery and not oversize to cause additional side stress on battery lifting members.

SM538 12 - 01 - 1

NON-CONDUCTIVE MATERIAL

6. If battery is not equipped with a cover, cover battery with a piece of durable non-conductive material (such as a correctly sized piece of plywood) before attaching lifting device to battery. This prevents any accidental material shorting across battery terminals.

8. Keep all tools away from battery to prevent accidental shorting of terminals.

9. All persons servicing batteries should wear protective clothing including face shield, long sleeved clothing and gauntlet gloves to protect person in case of accidental explosions, etc.

CHAIN CONTAINER

7. When using a powered hoist, be sure hoist is equipped with a chain container to accumulate excess lifting chain.

SM538 12-01-2

CAUTION

smoking should be permitted in battery service area.

The charging process generates hydrogen gasses which are explosive.

Never check electrolyte level with an open flame.

Do not permit open flames, sparks, or electric arcs in area.

No

10. When handling electrolyte, a carboy tilter or siphon shall be used.

11. When mixing electrolyte, ACID SHALL ALWAYS BE POURED INTO WATER. CAUTION NEVER POUR WATER INTO THIS WILL ELECTROLYTE. DANGEROUS CAUSE CHEMICAL &TI~N.

VENT

CAP

2. Battery can be removed from either side of truck. Remove battery retainers by pushing up on one side of retainer, then pulling one end free.

HOLE

12. When charging batteries, vent caps shall be kept in place to avoid electrolyte spray. Care should be taken to assure that vent caps are functioning.

Vent cap holes must be open to allow gasses to escape. The battery must have air space around it to allow dissapation of heat.

13. Electrical installations shall conform to THE NATIONAL ELECTRICAL CODE (ANSICI-1971), NFPA505-1973, Part “C” and all local ordinances.

14.

Reinstalled batteries shall be properly positioned and secured in truck prior to releasing truck for use.

12-02 BATTERY PROCEDURE

REMOVAL

1. Position truck in designated area. Turn key switch OFF. Disconnect battery.

3. A recommended method of handling battery is to use a platform equipped with rollers.

If battery does not have a cover, use a nonconductive material to cover it to prevent accidental shorting across terminals.

4. Once battery is out of truck, a lifting device equipped with an insulated spreader bar and safety hooks can be used to transport this style of battery.

IMPORTANT

IF BATTERIES DISCHARGE RAPIDLY DURING NORMAL OPERATION OR DO TO CORRECT NOT CHARGE CONTACT A SPECIFICATIONS, QUALIFIED BATTERY SERVICE TECHNICIAN TO CHECK BATTERY. DO NOT ADD ELECTROLYTE A-f-TEMPT TO SERVICE BATTERY.

SM538 12-01 -3

OR

BATTERY CLEANING 1. The easiest and most satisfactory way of cleaning a battery is to wash it occasionally with a low pressure water spray.

electrolyte. The level should be slightly below lower lip of filling vent hole.

4. Keep battery clean and dry. Wash down as needed.

5. Do not overcharge.

6. Keep battery records as indicated above.

7. Keep metal objects and tools away from top of battery to prevent short circuits.

8 Keep open flames away from top of battery to prevent explosions.

12-06

BATTERY

INSTALLATION

1. Use correct equipment to lift or move battery.

2. Recommended equipment is a roller conveyor for moving battery into truck.

3. When battery has been properly inserted into battery compartment, secure with battery retainer.

4. Connect battery and check for proper truck operation. Turn key switch on and check that controls function.

2. The top can also be washed off with a solution of baking soda (one box baking soda in a pail of water and stir until completely disolved).

3. Then rinse with clear water.

It is good practice to have a container containing a baking soda solution in the area at all times, to be used to neutralize acid spills.

4. Be sure all vent caps are in place and screwed tight when cleaning battery in this manner.

12-03

BATTERY

MAINTENANCE

Refer to battery vendor for recommended procedures.

12-04

BATTERY

RECORDS

Records shall be kept to get the best service out of battery. Select a pilot cell, take readings of specific gravity and temperature before and after charging, and record with date and battery identification.

It is best to change pilot cell occasionally to distribute electrolyte loss over battery in taking readings.

Every two or three months, take complete battery readings. Check specific gravity, temperature and voltage and record values.

12-05 LIFE

FOR

MAXIMUM

BATTERY

1. Do not add acid to a battery. Only a qualified battery representative should determine if this is necessary.

2. Lift only with a correctly constructed lifting device which will not put undue forces on battery lifting tray.

3. Battery must be checked before each charge for electrolyte level. Add water before charge but do not overfill.

Over-filling causes loss of

5. Be sure battery disconnect lever functions correctly by pulling on lever and noting if lever action causes quick disconnect plug to be disconnected.

NOTE: There are two sizes of battery plugs and quick disconnect mechanism is assembled with a spacer on pivot shaft.

Changing position of spacer on shaft will move lever inboard or outboard from truck depending on where spacer is psotioned. Spacer is placed ito accomadate size of plug used. Check that lever contacts plug fully for quick-disconnect. If it does not, then shift spacer on pivot shaft and recheck.

SM538 12-01-4

13-02

ACCELERATOR

TROUBLE-SHOOTING

1. HANDLE IS FREE AND DOES NOT RETURN TO CENTER (NEUTRAL). a. Probable due to broken return spring Replace module.

2. DEVICE OPERATES OFF CENTER AND DOES NOT HAVE EQUAL TRAVEL ON EITHER SIDE OF NEUTRAL. a. Stop cam assembled incorrectly to detent mode.

Remove detent module assembly and reassemble making sure space is equal on either side of center.

3. DEVICE BINDS WHEN OPERATED IN FORWARD OR REVERSE DIRECTION. a. Assembly screws too tight.

Loosen two assembly screws one half turn and check for binding Repeat if necessary.

4. VISIBLE ARCING ON CONTACTS WHICH HAVE A CAPACITOR CONNECTED ACROSS CONTACT TERMINALS. THIS COULD BE A MALFUNCTION OF SCR CONTROL. a. Capacitor may be faulty.

Leads broken. b. Open internally. Can be checked by using a multimeter on 1OOKohms scale. Connect meter leads to capacitor leads and observe that needle deflects quickly toward zero, then back to maximum.

Reverse meter connections and repeat. If meter fails to indicate in this manner, capacitor is faulty.

Replace capacitor.

5. LACK OF SPEED CONTROL a. Full OFF voltage -- measured between S and N terminals of transducer, voltage is to be not less than 3.5 VDC when control shaft is rotated to position where F or R switch contacts just close.(approximately 1O” from neutral position). A voltage in excess of 4.0 VDC is undesirable.

If voltages are incorrect, check for loose connections. Then check SCR control for problem. b. Full On voltage -- measured as above is to be not more than 0.3 VDC when control shaft is rotated to maximum position. A voltage as low as 0 VDC is acceptable.

Replace module.

6. SWITCH CONTACTS DO NOT MAKE, BREAK, OR CARRY THE LOAD PROPERLY. a. Contacts may be worn or welded.

Replace contact module. b. Cam may be deformed.

Replace cam(s).

13-03 CONTROL REMOVAL 1. Park truck on level surface. Block wheels to prevent truck moving. Disconnect battery.

2. Remove three (3) screws attaching top cover front edge to frame of truck. Remove fastener just below control handle and another fastener mounting cover to angle bracket near sump tank. Remove screw attaching bottom of DOG rear LH leg to frame and loosen top fastener. Swing leg inward toward center line of truck. This will allow clearance for top cover to be moved rearward. Unfasten two (2) quick disconnect couplings in wire harness. Position steer wheel toward rear to allow top cover to slip over it as it is pulled away from upright. Remove top cover from truck.

SM538 13-01 -2

SPEED,DIRECTIONAL SELECTORAND LIFT LINKAGE

3. Remove three (3) bolts mounting control bracket to top frame of truck (two bolts are thru battery compartment and third is inside operators compartment). This will allow control to be moved to permit better access to components.

4. Remove the fasteners (either snap rings or cotter pins) securing cross shaft through upper casting of handle assembly and base bracket. Pull out cross shaft.

5. Lit upper casting assembly off L-shaped shaft.

6. Loosen setscrew locking shaft of handle assembly to lever. This will allow handle to begin being moved away from casting.

7. Press push-button switch out of handle and disconnect wires from switch. Push toggle switch out of handle and remove wires from it. Pull handle shaft out of casting.

8. Remove screws fastening accelerator control assembly to upper casting. Note that one fastener also secures a wire harness clip. Removal of fastener will free wire harness.

9. Remove wire harness from accelerator control by removing seven (7) spade terminals (two on side and five on front). Remove accelerator control.

10. Remove upper casting. Note that bushings in casting are retained by seals. Remove and discard seals.

11. Pull L- shaped shaft out of lower lever (casting).

12. Remove snap ring and washer from shoulder pin serving as pivot for lower lever. Remove cotter pins locking plate of link assembly at lever-to-main-valve link. Pry off plate with screwdriver and lift out link. Lift lever off bracket.

13. Lift out bracket.

14. Remove setscrew attaching lever to accelerator control. and remove lever. Disassemble lever and balljoint assemblies only if they require replacement.

SM538 13 - 01 - 3

13-04

HAND

MASTER

SWITCH

(HMS)

DISASSEMBLY.

NOTE: Disassemble only as far as necessary to replace suspected component.

POTENTlOMElER

ASSEMBLY NTlOMETER SHAFT

SPACER

SWITCH

QUARE LOCATING TABS

PlASTlC SWITC

/ I

SHAFTCOVER

CAM METAL HOUSING

,?_

/

SHADING DISC (FlATSIDE) F.,-

BO$a’SH>Dl, LED

\;y LEFI-

RESISTOR SIDE

SPRING TAB

DISC _ ~~ FLAT SIDE (ALIGN VERTICAL TO RESISTOR SIDE)

HAND MASTER

SWITCH

1. Use a felt pen to scribe a line across the major assembly which will serve to help assemble parts in correct order. When viewed from square shaft end, exposed resistors are on RH side of switch along with contact markings of ‘F’ and ‘2’. Markings ‘R’ and ‘3’ are on LH side. Also, RH side has two cam operated switches, and LH side has one plus spacer.

2. Remove TWO (2) frame mounting screws. Remove housing exposing return spring assembly. Note that boss inside housing fits between legs of spring.

NOTE: For normal repair procedure, disassembly of switch.

it is not necessary to remove snap ring from shaft for

3. Grasp assembly across ends to keep assembly from separating and pull outward on square shaft and spring assembly. Shaft will pull out of square bore in cam.

4. Remove thin plastic cover. Note that square screw hole bosses are on exterior of cover and match slots in metal outside cover.

5. Plastic cam is exposed and can be pulled off potentiometer shaft. Use pliers to pull cam off potentiometer.

6. Remove three (3) switches from plastic shell housing. Note that switches are identical and two are on RH side. Remove spacer.

7. Remove plastic housing from potentiometer assembly.

8. Do not remove any other parts. Potentiometer assembly is serviced as a unit. Do not remove two (2) plastic fiber spacers on side of housing.

SM538 13-01 -4

13-05

MASTER

SWITCH

ASSEMBLY

1. Install plastic switchhousing to potentiometer assembly, aligning screw slots. Potentiometer shading disk must be positioned with flat facing towards right side (resistor side). Line must be centered inside of LED. Install cam on potentiometer shaft with long arc pointing towards bottom of plastic comer and square bore of cam square with plastic switch cover. Do not push cam fully on shaft, stop about [l mm] l/32 inch short to prevent shaft from binding of housing.

2. Install switches in slots in housing.

F side (RH side) has two switches, R side has spacer.and switch Switches have three (3) push-on spade connection posts, the middle post being off center.

Position switches so that off center is toward top, making center post closer to top terminal post.

3. Install thin plastic cover, making sure square bosses are to outside surface of this cover (these bosses mate into slots on adjoining cover).

4. Insert shaft and spring assembly into square bore in cam. Note that legs of spring are on same side of assembly as external resistors.

5. Install shaft assembly (with springs in place) and thin plastic cover onto assembly.

6. Put housing in place over spring assembly.

Be sure that boss on inner surface goes between spring legs.

7. Install fasteners and tighten to a torque of[l,4-2,7 N.m] 6-12 Ibf.in.

8. Install mounting bracket on face of master switch and tighten screws.

9. Adjust potentiometer shading disk to intersect LED. Remove square shaft comer, insert screw driver down square shaft and into potentiometer shaft slot. View from potentiometer end, align potentiometer shading disk (flat side marked top) vertical to resistor side of housing. This will assure that switch travel is equal in each direction . Insert square shaft cover.

13-07

CONTROL

INSTALLATION

1. Install master switch on bracket.

2. install lever to square shaft on master switch and tighten setscrew.

3. Install ball joint and shaft connecting lever ends.

4. Position valve operating lever on stud on bracket and apply washer and snap ring to retain lever. Be sure snap ring is fully seated in groove. Insert L shaped shaft into lever.

5. Position cast bracket assembly on control bracket. Insert L-shaped shaft into vertical bore of casting.

Make sure bearings are in place in casting and are retained by seals. Insert shaft and lock in place with cotter pin. Spread legs of cotter pin.

6. Connect lever to main valve with link and plate. Put plate on bottom and insert cotter keys to lock plate.

Spread legs on cotter pins.

7. Attach mounting bracket to base of truck.

8. Install wire harness on master switch. Make sure all terminals are correctly connected.

9. Install screws attaching accelerator control to upper casting assembly. Install wire harness clip under one screw and clip harness to switch.

10. Push handle into cast bracket and tighten setscrew in lever which will lock handle in place.

11. Install wires on push button switch. Press push button switch into handle.

12. Install wires on toggle switch. Push toggle switch into handle.

13. Position cover on truck and connect two quick-disconnect wire harness fasteners.

Thread cover over steering wheel and over control handle and then move into position on truck.

Install and tighten all fasteners.

14. Install lower fastener on DOG leg and tighten both fasteners to a torque of [21-23 N.m] 180-200 Ibf.in.

15. Connect battery.

SM538

13 - 01 - 5

GROUP 16 SECTION 01 ELECTRIC MOTOR GENERAL MAINTENANCE

MOTOR INSULATION 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

ELECTRIC MOTOR MAINTENANCE GENERAL 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 recommended that you first:

procedures,

it is

Park truck safely.

are due to:

(1) contamination, (2) mechanical factors, 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 Regular, periodic and by test measurement. measurements of insulation resistance can give a useful indication of the rate of insulation deterioration.

Fully lower upright.

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

Apply parking brake.

Turn key switch OFF. Disconnect

batteri

Discharge

capacitor

from truck receptacle

TEST FOR MOTOR INSULATION TO GROUND (USING A 500 VOLT MEGGER)

on control panel.

MOTOR CLEANLINESS

1. Disconnect

Electric motors should be kept clean at all times, to prevent shorting, minimize wear, and for best cooling.

2.

Disconnect terminals.

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

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

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.

SM538

battery from truck receptacle. power

cables

3. Connect one lead of a 500-volt motor terminal.

from

all

motor

megger to any

NOTE: Test ALL terminals individually or by interconnecting with jumper wires.

Connect other lead to motor frame. Apply voltage.

and

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.

RESISTANCE

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

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

16-01

-1

TEST FOR MOTOR INSULATION RESISTANCE TO GROUND (USING A VOLT-OHMETER VOM) Use a Simpson 260-6~ or equivalent calibrated on the Rx10,OOOscale.

VOM,

1. Disconnect battery from truck receptacle.

2. Disconnect terminals.

power cables

from all motor

3. Connect the positive lead of the VOM to all terminal studs of test motor. Use jumper wires to connect between motor terminals. Connect VOM negative lead to motor frame.

NOTE: Test all terminals individually, or joined together, as noted.

VOM must show l,OOO,OOOohms (1 megohm) resistance or 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 from truck for closer inspection and repair if needed.

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

IMPORTANT NEW BRUSHES MUST BE OF SAME SIZE AND GRADE (MATERIAL SPECIFICATION) AS REPLACED BRUSHES. 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.

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 commutator for worn condition and uneven wear.

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-free cloth.

DO NOT USE LUBRICANT OF 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.

SM538 16-01 -2

GROUP 16 DRIVE

MOTOR MOTOR MOTOR MOTOR MOTOR MOTOR MOTOR

16-01

SECTION MOTOR

02

16-01 16-02 16-03 16-04 16-05 16-06 16-07

DESCRlPTlON MAINTENANCE REMOVAL DISASSEMBLY INSPECTION ASSEMBLY INSTALLATION

MOTOR

DESCRIPTION

The drive motor is a series wound motor with an integral cooling fan. The exterior connections are easily accesible from side of motor, yet are protected from external damage. The brushes are accesible and can easily be changed.

The motor has Class H insulation.

16-02 DRIVE MAINTENANCE

MOTOR

Refer to GROUP 16,SECTION motor maintenance procedure.

16-03

DRIVE

3. Remove all hoses from sump tank and remove sump tank.

4. Remove two wires from brake switch.

5. Remove lower sump tank retaining bracket

MOTOR

01 for correct

REMOVAL

1. Fully lower upright.

2. Drain oil from sump tank into a CLEAN container.

This can be accomplished by disconnecting the outlet hose from steer section of steer pump at priority valve and inserting it into storage container for oil, then activating steer pump.

NOTE: DO NOT ALLOW PUMP TO RUN AFTER ALL OIL HAS BEEN DRAINED FROM SUMP. PUMP WILL CAVITATE AND DAMAGE PARTS.

arm by 6. Remove brake cable from . . brake . removing cotter pin from clevrs pm and tnen removing clevis pin.

7. Remove brake cable from bracket by loosening retaining nut on cable, then sliding cable toward truck until smaller cable control wires reach bracket slot and can be slid off bracket.

SM538 16 - 02 - 1

2. Clean all dirt and grease from motor. Inspect motor for any damage.

3. After removal of brake assembly( as described in Brake Section) put motor on clean work surface.

8. Remove four main power cables from drive motor. Be sure to identify cables for location before removal.

REMOVE PARTS

4. Remove nut and lockwasher

attaching drive gear to motor. Remove gear and key. Remove slinger between gear and motor. Remove and discard O-ring.

5. Remove brush cover.

9. Remove six (6) fasteners attaching motor to drive unit. Carefully lift motor and brake assembly off of gear case. Motor should be lifted vertically until drive gear on motor is clear of drive unit.

NOTE: Motor weighs about [25 kg.] 55 Ibs. 10. Refer to Brake Section for removal of brake parts.

16-04 DRIVE DISASSEMBLY

MOTOR

6. Loosen and remove brush terminals. Remove brush springs and lift out brushes. Both springs and brushes will be replaced with new.

7. Remove fasteners retaining commutator end frame to motor housing.

1. Use a scribe to make a locating mark on each end bell and extend this mark onto main frame (yoke) of motor. This will assure endbells are correctly positioned on frame in same location at assembly as when removed.

SM538 16 - 02 - 2

8. Remove commutator end frame. Remove the thrust washer between bearing and commutator end frame bearing.

NOTE: Brush holder is not removed from end frame. If brush holder is damaged, replace entire assembly.

13. If drive end bearing requires replacement, remove snap ring and press bearing out of end frame using an appropriate size tool on bearing to prevent damaging it.

14. Unless fan is damaged, it normally is not removed from armature assembly. If it must be removed, use heat very carefully to expand it and allow it to be pulled off without damage.

9. Remove fasteners attaching drive end frame to motor housing.

15. If field coils need repair, loosen fasteners attaching them to housing and remove field coil assembly.

10. Use a soft faced hammer to tap end frame loose from motor housing at same time. Remove end frame and armature assembly as a unit.

11. Use a press or a puller to remove end frame from armature assembly.

12. If commutator bearing requires replacement, use a puller to remove it. If bearing appears satisfactory after inspecting it, do not remove and replace it.

DRIVE 16-05 INSPECTION

MOTOR

1. Carefully inspect all components of motor for wear, evidence of damage from overheating, damage from rust or corrosion, excessive build up of dirt or contaminents or for any other damage that would impair its operation.

2. Discard all removed bearings and replace with new.

3. Examine brush boxes for evidence of wear, Make sure damage. arcing or external connections are solid and tight.

SM538 16-02-3

4. Examine commutator for evidence of excessive wear, eroded surfaces, raised commutator bars, excessive heat build-up or any visible damage that would impair its operation.

5. Discard brushes and replace with new.

Examine field windings making sure that insulation is in place and not damaged (no exposed surfaces). Look for any evidence of arcing or of excessive heat build-up.

6. Examine ventilating fan for any evidence of damage. If dirty, carefully clean surfaces.

16-06 DRIVE ASSEMBLY

MOTOR

1. If field coils were removed, position coil assembly in housing and insert and tighten fasteners mounting coil to housing.

2. If fan was removed, press fan onto armature making sure it is fully seated.

3. If required, install new bearing in drive end frame. Use new snap ring to lock it in place. Make sure snap ring is fully seated in groove.

4. If required, press new bearing onto armature assembly. Make sure it is firmly seated against shoulder.

5. Press armature assembly into drive end frame.

6. Insert armature assembly into motor housing and press end frame onto housing. Make sure match marks on frame and housing are aligned.

Insert fasteners and tighten to a torque of [l l-15 N.m] 100-l 30 Ibf.in.

7. Put commutator end frame on motor housing and press end frame onto housing. Make sure match marks are in alignment. Insert fasteners and tighten to a torque of [11-l!? N.m] loo-130 Ibf.in.

8. Install new brushes by connecting leads to brush terminals. Make sure brushes are free to move up and down in brush boxes. Insert new springs and make sure springs bear on brush ends correctly.

9. Install brush cover.

10. Install key in keyway on drive end of shaft, then install slinger and gear on motor shaft and tighten to a torque of [55-68 N.m] 40-50 Ibf. ft.

Position washer and nut on shaft and tighten.

11. Make sure motor shaft turns freely.

12. Install new O-ring on motor end frame.

16-07 DRIVE INSTALLATION

NOTE: Drive motor weighs about [25 kg.]

55 Ibs. 3. Insert six (6) fasteners attaching motor to drive. unit. Tighten fasteners to a torque of [55-68 N.m] 40-50 Ibf.ft.

4. Install power cables on motor terminals. Be sure cables are identified and are positioned on correct terminals. Tighten terminal nuts.

5. Insert small section of brake cable end into,slot in bracket, then slide cable forward and secure end with retaining nut.

6. Connect cable end to brake arm with clevis pin.

Use a new cotter pin to secure clevis pin and spread legs of cotter.

7. Install lower sump retaining bracket.

8. Install two (2) wires on brake switch.

9. Install sump tank. Attach all hoses to sump tank.

10. Fill sump tank to correct level with CLEAN fluid.

11. Test truck operation by first slowly raising and lowering upright, then checking travel, steer and brake actions.

MOTOR

1. Refer to Brake Section for installation of brake parts.

2. Lift motor and position it in place on drive unit.

Use care when inserting gear into drive unit to be sure gear meshes with drive unit gear and that pinion gear is not damaged.

SM538 16-02-4

GROUP 16 SECTION 03 LIFT PUMP MOTOR CONTENTS

NO.

MOTOR MOTOR MOTOR MOTOR MOTOR MOTOR MOTOR

16-01 16-02 16-03 16-04 16-05 16-06 16-07

DESCRIPTION MAINTENANCE REMOVAL DISASSEMBLY INSPECTION ASSEMBLY INSTALLATION

16-01 LIFT PUMP DESCRIPTION

MOTOR

The lift pump motor is a series wound type with Class H insulation and integral cooling fan. It has provisions on its driving end bell for mounting lift pump.

16-02 LIFT PUMP MAINTENANCE

PUMP

Disconnect two quick-disconnect plugs from wire harness. Lift off cover and store in a safe place.

MOTOR

Refer to GROUP 16, SECTION 01 for electric motor general maintenance procedures.

16-03 LIFT REMOVAL

To remove top cover, remove lower fastener from LH DOG leg, loosen upper fastener and swing leg outward from center of machine. This will permit cover to be pulled rearward, clearing control handle and steer handle.

,/‘. ,,“ i. i ii. : il. : ; ‘.I : ; :: :

MOTOR

1. Disconnect battery.

2. Apply parking brake.

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I’

/“

/’

‘.. /I ,“ : \ 1 1

i

4. Place a drain pan under truck to catch any oil spill. Remove hose clamp on inlet line to pump, cap end, and pull free. Remove line to check and dump valve, cap end and push to one side.

5. Remove power leads to motor. Put nuts and washers back on motor for safe keeping.

Remove top cover by removing three 3. fasteners at forward edge of cover, one fastener below control handle and one fastener mounted near sump tank.

SM538 16-03-l

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6. Remove four (4) fasteners mounting pump and motor asembly to frame.

(Screws are accessible thriough battery compartment).

10. Remove fasteners attaching pump to motor and remove pump. Make sure to note how pump is mounted to motor with respect to inlet and outlet ports.

16-04 LIFT PUMP DISASSEMBLY

MOTOR

1. Remove plastic brush hole cover band.

7. Remove bolt, holding check and dump valve (to give room for removing pump and motor assembly).

8. Remove power leads from motor.

9. Lift pump and motor from truck and place on work bench.

2. Liit brush springs and pull brushes out of holders. Unscrew brush terminal binding screws and remove and discard brushes and springs.

SM538 16-03-2

COMMUTiTOR

END

3. Use a scribe to make a mark on each end frame

7. If pole shoes or coils are damaged and need to

and extend mark onto motor housing (yoke) to make sure end frames are installed in same location at assembly.

be repaired or replaced, it will be necessary to remove them for repair.

4. Remove commutator end frame mounting screws. Tap gently on end frame with a soft hammer while pulling end frame off motor assembly.

This can best be done with a pole shoe screwdriver. Use a spreader bar under each shoe to prevent damage to parts when using this type of screwdriver.

5. Remove bolts mounting drive end frame to main frame and pull drive end frame off motor assembly.

6. Remove armature and fan assembly.

8. If commutator bearing requires replacement, use a puller to remove it. If bearing appears satisfactory after inspecting it, do not remove and replace it.

9. If drive end bearing requires replacement, remove snap ring and press bearing out of end frame using an appropriate size tool on bearing to prevent damaging it.

SM538 16 - 03 - 3

undercuts between bars, and excessive runout.

Refinish commutator surface if pitted or excessively worn. Check shaft bearing journals and internal spline for wear.

6. Check insulation of field coils.

Inspect for burned, blackened or charred areas. Check coil connections and terminal ends for damage.

7. Check blades and hub of cooling fan for broken or damaged areas. Carefully remove all din and smooth rough surfaces with very fine emery cloth.

TO REMOVE FAN HEAT CAREFULLY

MOTOR RECONDITIONING

10. Unless fan is damaged, it normally is not removed from armature assembly.

If it must be removed, use heat very carefully to expand it and allow it to be pulled off without damage.

16-05 LIFT INSPECTION

PUMP

MOTOR

1.

After motor has been disassembled, ali components should be cleaned and inspected for wear and damage.

1. Check commutator condition for carbon buildup in undercuts between commutator bars and for excessive runout, before proceeding further with disassembly.

If necessary, commutator should be removed, turned and re-undercut.

2 If new bearing is required for drive end frame, press into place in bore by pressing on outer race of bearing until it is firmly seated and snap ring groove is fully exposed.

Then install snap ring and make sure it is fully seated.

Thoroughly clean all parts, except bearings and armature, with a good grade petroleum-base cleaning solvent, and then dry using compressed air.

NOTE: Do not reuse have been removed.

bearings

which

The armature should be blown off with compressed air to remove brush dust and din from around commutator and windings.

Bearings should be wiped with a clean cloth.

3.

If necessary to remove bearing from commutator end, remove by using a puller.

Protect end of armature shaft with a nut or thick flat washer.

Also, use care not to damage commutator bars.

2. Check brush holder insulation cracks or any sign of burning. holders for wear.

4.

Install new bearing on armature shaft by pressing on inner race of bearing until it is firmly against shoulder on shaft.

and wiring for Check brush

Replacement NOTE: packed with lubricant further lubrication.

3. Check drive end frame for cracks or other damage.

Check bearing recess and snap ring groove (if bearing is removed) for evidence of wear.

4. Check bearings for looseness or damage by rotating them and noting if any evidence of binding, gritty effects, excessive looseness, wobble, or if it turns exceedingly free. If any faulty condition is found, it should be discarded and replaced.

5. Check armature assembly for damage. Check windings, commutator bars and commutator connections for any signs of burning or Check commutator for worn looseness. condition, excessive carbon build-up in

SM538

16-06

MOTOR

bearings are and need no

ASSEMBLY

1. Press drive end frame and bearing assembly onto armature shaft until bearing inner race is firmly seated against shoulder on shaft.

Install bearing on shaft by NOTE: pressing on bearing inner race. DO NOT PRESS ON DRIVE END FRAME. 2. Install armature and drive end frame assembly into motor body. Align match marks on end frame and motor body.

16-03-4

5. Attach power leads to motor.

3. Install drive end frame mounting screws and tighten lightly to temporarily hold assembly. Then tighten screws alternately to be sure of good mechanical alignment.

4. Put commutator end frame on work bench with brush ring assembly facing upward.

5. Install bearing spring (end thrust washer) into bearing bore in commutator end frame. Use a thin film of grease to hold in place.

NOTE: If brushes are installed, raise all brushes to locked position.

6. Assemble commutator end frame over bearing on armature and to motor body. Be sure bearing spring washer is correctly in place. Align match

6. Install fastener holding check and dump valve (removed to give room for removing pump and motor assembly) and tighten to a torque of [l l-l 5 N.m] 8-l 1 Ibf.ft.

7. Operate pump and check for leaks.

8. Position cover on truck and connect two quickdisconnect wire harness fasteners. Thread cover over steering wheel and over control handle and then move into position on truck. Install and tighten all fasteners.

8. Install lower fastener on DOG leg and tighten both fasteners to a torque of [21-23 N.m] 180200 Ibf.in.

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9. Connect battery.

7. Install commutator end covering mounting screws and tighten lightly to hold assembly temporarily. Then tighten screws alternately to make sure of good mechanical alignment.

10. Check operation of truck, making trial test for pump in no-load condition, then in by-pass condition.

Listen for any unusual noise in hydraulic system.

Tighten fasteners to a torque of [ll-15 130 Ibf.in.

RECONNECT THE TWO ELECTRICAL CIRCUIT WIRES.

N.m] 100-

INTERNAL

8. Fully tighten all end frame screws to a torque of [ll-15 N.m] loo-130 Ibf.in.

9. Install new brushes by putting brushes in holders, making sure all brushes are free to move in holder. Connect brush lead assemblies and Install new brush spring tighten screws. assemblies, putting clip on top of each brush.

10. Install plastic brush cover over opening.

16-07 PUMP INSTALLATION

MOTOR

1. Position pump on motor making sure ports are in correct position. Tighten fasteners to a torque of [32,5-365 N.m] 24-27 Ibf.ft.

2. Install hose on inlet port and tighten clamp.

3. Install line going to check and dump valve.

4. Put assembly in place on truck and insert and tighten fasteners to a torque of [20-25 N.m] 177221 Ibf.in.

SM538 16-03-5

GROUP 16 SECTION 04 STEER PUMP MOTOR NO

CONTENTS MOTOR MOTOR MOTOR MOTOR MOTOR MOTOR MOTOR

16-01 16-02 16-03 16-04 16-05 16-06 16-07

DESCRIPTION MAINTENANCE REMOVAL DISASSEMBLY INSPECTION ASSEMBLY INSTALLATION

16-01 STEER DESCRIPTION

PUMP

MOTOR ITEM

The steer pump motor is a permanent magnet motor with provisions for mounting steer pump directly on it. Insulation is Class H.

1

16-02 STEER MAINTENANCE

: 4 5 6

PUMP

MOTOR

Refer to GROUP 16, SECTION 01 for ELECTRIC MOTOR GENERAL MAINTENANCE procedure.

1. The permanent magnet motor differs from coventional D.C. motors in that field winding has been replaced with ceramic magnet pole pieces.

NOTE: USE FOLLOWING ADDITIONAL PROCEDURES FOR MAINTENANCE FOR SPECIAL CONSTRUCTION OF THIS PERMANENT MAGNET MOTOR.

Armature assembly Stator assembly Drive end cover Hole plug Brush inspection cover Bearing spring washer Bearing-Commutator end Bearing-Drive end Commutator cover Brush ring assembly Brush Terminal bolt and lead assembly

MOTOR TROUBLESHOOTING 1. Try to turn shaft by hand. If motor leads have not been removed, keep them separated while doing this. If shaft won’t turn, proceed to item 2. If shaft turns freely, go to item 3.

IMPORTANT DO NOT IMPACT MOTOR HOUSING OR COMPONENTS (STRIKE WITH HAMMER, ETC.), DROP, OR SQUEEZE MOTOR AS THIS CAN CAUSE DAMAGE TO CERAMIC POLE PIECES AND WILL AFFECT WARRANTY CONSIDERATIONS. 2. Care must be taken when permanent magnet motor is disassembled, since magnet pole pieces will attract ferrous metals (iron and steel).

IMPORTANT PERMANENT - MAGNET MOTORS SHOULD BE DISASSEMBLED ONLY IN AREA FREE OF FERROUS METAL CHIPS.

SM538

; 9 10 11 12

DESCRIPTION

16-04-l

2. The shaft could be tight for several reasons.

This check is to determine if tightness is of a temporary nature only.

Step 1: You will need a power source equal to name plate voltage (24 volt), e.g., use truck battery with cable adapter.

Step 2: Provide power cable leads between motor and power source. Secure motor to workbench to prevent it from moving.

DO NOT MAKE CONNECTION.

A PERMANENT

Step 3: First, touch motor leads quickly to power supply just long enough to observe if shaft turns. If it does turn, hold motor leads on power supply for a longer time. If motor sounds normal, go to item 3. If motor sounds noisy, it should be disassembled (described later).

3. If motor turned circuit as shown.

freely,

connect

an ammeter

u

in

4. Brushes should be removed, as follows: a) Remove brush spring clip from its mounting on top of brush assembly. Use a brush hook to reach into motor and lift brush springs. b) Disconnect brush assembly lead c) Lift brush assembly from brush holder.

5. Remove any carbon dust or dirt from brush ring assembly.

6. Inspect condition of brushes.

Remove each brush from brush holder and inspect brushes and commutator for worn condition and uneven wear, arcing, etc.

7. When reassembling motor, replace brushes and brush springs (complete set), as needed, by reversal of above procedure NOTE: If brushes have not been removed before disassembling motor, brushes must be raised off commutator and held in “locked position.” This is done by moving brush spring clip from top of brush and placing it against side of brush to hold (lock) brushes in a raised position in brush holders.

HOTOR

With rated voltage applied and shaft running free, ammeter should read less than 20% of name plate full load current. If motor meets above conditions, then it can be assumed original problem is external to motor.

A higher current reading indicates a faulty armature.

BRUSH REMOVAL AND INSPECTION 1. Loosen and remove clamping screw in brush cover band.

16-03 STEER PUMP REMOVAL 1. Disconnect battery.

MOTOR

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2. Remove brush cover band segments by prying cover pins out of engagement in motor housing.

3. Air clean inside of motor around brushes and commutator, using dry (moisture-free) compressed air.

NOTE: Observe how brushes are assembled in brush holders and position of brush lead (shunt). New brushes must be installed in same manner.

SM538

16-04-2

2. Remove the top cover by removing the three fasteners at the forward edge of cover, one fastener below control handle and one fastener mounted near sump tank.

5. It is normal to remove pump and motor as an Remove power leads to motor. assembly.

Remove four (4) fasteners mounting pump and motor assembly to frame. Note that filter bracket will be left free and that motor rests on four (4) cushions under mounting flange. Move assembly to worktable.

6. Remove four (4) capscrews attaching pump to motor.

Separate pump from motor and discard gasket.

16-04

STEER DISASSEMBLY

To remove top cover, remove lower fastener from LH DOG leg, loosen upper fastener and swing leg out from center of machine. This will permit cover to be pulled rearward, clearing control handle and steer handle.

Disconnect two quick-disconnect fasteners from wire harness.

Lift off cover and store in a safe place.

PUMP

MOTOR

IMPORTANT Do not place stator ring (motor housing) in any mechanical holding device (e.g., vise) during disassembly or assembly operation.

Permanent distortion or other damage will result.

With motor disassembled, care must also be taken not to drop stator ring assembly, since it can be distorted. Motor may be held by clamping on mounting bracket. disassembling NOTE: Before motor, note if there are match marks on stator assembly housing and commutator cover. If marks are not visible, use a scribe tool to make match marks. These marks will be used at assembly.

IMPORTANT PERMANENT MAGNET MOTORS SHOULD BE DISASSEMBLED ONLY IN A CLEAN AREA FREE OF FERROUS (IRON, STEEL) METAL CHIPS.

3. Remove hose clamp on inlet line to pump, cap end, and pull free.

Remove lines to steering torque generator and to check and dump valve, cap ends and push to one side.

1. Remove brush cover band.

2. Remove brushes and brush springs.

IMPORTANT If brushes are left installed, raise all brushes to locked position.

3. Remove pump drive coupling segment from motor shaft end.

Loosen motor assembly thru-bolts at 4. commutator-end cover.

5. Remove thru bolts from assembly.

6. Scribe a match mark on cover and housing, then remove drive end (pump mounting) cover.

Carefully pry on cover to loosen. Tap lightly on pry bar, if necessary.

7. The drive end bearing may now be inspected.

NOTE: Be sure parts have match marks before disassembly.

SM538

16-04-3

8. Remove commutator end cover for inspection of commutator and commutator end bearing.

Remove and save bearing spring washer from cover bore.

9. Carefully inspect commutator-end bearing and commutator surface for wear, burning, or other damage that will require repair or repiacement of parts.

ARMATURE AND BEARING REPAIR 1. Check commutator condition for carbon buildup in undercuts between bars and excessive wear and runout, prior to reassembly.

If necessary, commutator should be turned and re-undercut.

2. Remove bearings with a standard ball bearing puller. Use extreme care not to damage armature with bearing puller.

NOTE: It may not be necessary to remove armature, unless other inspection and tests show requirement for repair or servicing of stator assembly, armature or bearings.

See discussion of procedure below.

ARMATURE REMOVAL - RECOMMENDED PROCEDURE To avoid damage to either armature or permanent magnets, it is recommended that armature be removed only with motor housing and armature shaft positioned VERTICALLY. 1. Reassemble either commutator-end cover or drive end cover to armature shaft and stator housing.

2. Support and hold stator housing firmly on end cover (a second person is suggested).

3. Pull armature out of assembly in one quick motion.

NOTE: IT IS IMPORTANT THAT PULLING MOTION ON THE ARMATURE BE CONTINUOUS. DO NOT PULL PART WAY OUT AND RELEASE. If pulling motion is not continuous it will allow magnets to pull armature back into stator and cause severe damage.

4. Remove end cover from stator housing.

16-05 STEER INSPECTION

PUMP

With motor disassembled, checklist to locate problem:

MOTOR go through

following

A. Bearings - Should spin smoothly and easily, have ample lubrication and be free of corrosion.

Replace bearings if they are worn out, damaged, or have been removed from armature shaft.

B. Armature.

Check for grounds and shorted turns. Check commutator for worn condition, excessive carbon build-up in undercuts between bars, and excessive runout. Refinish commutator surface if pitted or excessively worn.

SM538

C. Stator. Check magnets to be sure they are securely mounted.

D. Inspect wire harness and all connections on brush ring assembly for signs of damage due to overheating.

E. Brushes. Remove any carbon dust or dirt from brush ring assembly. Check brushes for wear and that they are free in brush holders.

16-04-4

NOTE: Do not reuse bearings which have been removed from armature shaft.

2. Install new bearings on armature shaft. New bearings should be installed by pressing inner race of bearing into correct position against shoulder on armature shaft.

BEARING LUBRICATION Replacement bearings are packed with lubricant during manufacture and require no further lubrication during life of bearing.

16-06 STEER ASSEMBLY

PUMP

1. Place commutator

cover on a work bench with

MOTOR

4. Put complete stator assembly over vertical armature, and into position on commutator cover.

brush ring assembly facing upward.

NOTE; brushes

If brushes are installed, to locked position.

2. Place bearing spring washer in commutator cover.

raise all

into bearing

armature assembly, 3. Take a complete bearings installed, and insert comutator bearing into bearing bore of cover.

CAUTION Care must be exercised at this point.

There is a strong magnetic attraction between stator assembly and armature, which tends to pull stator assembly rapidly downward.

It is important to have a firm grasp on stator assembly and be sure fingers are free from space between stator assembly and commutator cover.

bore

with end

Keep armature assembly in a vertical position.

SM538

5. The stator assembly must be placed in a definite relationship with commutator cover in order to obtain a neutral brush setting. There should be match-marks on both items.

6.

Assemble drive end cover in correct relationship.

Install mounting thru bolts and tighten alternately to ensure a good mechanical alignment. Do not use hammer or excessive force.

7. If brushes were not removed (replaced), set brushes to final (lowered) position, by moving brush springs to top of each brush.

8.

Install new brushes by reversing removal procedure: a) Install brush with lead wires positioned as when removed. b) Install brush assembly into brush holder.

Be sure all brushes are free in holder. c) Connect brush lead assembly. d) Install brush spring clip on top of brush.

9. Install brush cover.

10. Install pump drive coupling segment.

11. Spin shaft by hand to check if it is free. Be sure motor leads (if attached) are not touching together.

If leads are touching, a generator action will give effect of friction in motor.

12. A no-load test can be performed. At rated voltage, observe no-load current. It should be less than 20% of name plate full-load current. A higher reading indicates: Brushes are not on neutral setting (check match-marks for exact alignment); Fautty armature.

16 - 04 -5

16-07 STEER INSTALLATION

PUMP

MOTOR

1. It is normal practice to install pump and motor as an assembly.

Position pump on motor and tighten fasteners to a torque of 121-23 N.m] 180-200 Ibf.in.

2. Position pump and motor assembly on truck frame with cushions and hydraulic oil filter bracket under motor flange.

Insert four (4) fasteners and tighten to a torque of [21-23 N.m] 180-200 Ibf.in.

3. Attach hydraulic lines to pump.

4. Attach power leads to motor making sure they are connected to correct terminals and are tightended.

Operate pump and check for oil leaks.

5. Install top cover. Attach two quick disconnect couplings to wire harness.

Install fasteners to cover. Install fastener to lower end of DOG leg and tighten to a torque of 121-23 N.m] 180-200 Ibf.in.

6. Connect battery.

SM538

16-04-6

GROUP 19 SECTION 02 RECOMMENDED TEST, TEST EQUIPMENT AND PROCEDURES I.

RECOMMENDED 1.

2.

3.

4.

5.

6.

7.

TESTS:

Ground Fault Condition.

Power Steer Idle Current.

SCR Current Limit 1A Free-Wheeling Current.

1A Time Delay.

Creep Speed Motor Volts.

Plugging Function.

TEST

II.

volts, and battery type number on test sheet.

Open circuit battery voltage is measured as follows: STEP #l: Turn Digital Multimeter ON Select 200 volts, DC scale.

STEP #2: Connect RED lead to POSITIVE (+) terminal on battery.

Connect BLACK lead to NEGATIVE (-) terminal on battery.

STEP #3: Read and record voltage reading displayed.

This is OPEN CIRCUIT BATTERY VOLTAGE. 6. Always have key switch turned OFF before connecting battery to truck .

7. The test for parameter #3 (SCR Current Limit) requires truck’s compartments (e.g., cables, controls, axles, brakes, etc.) be in cold condition, i.e., compartments are at approximately same temperature as normal, not to be operated / driven for any significant period of time (more than 10 minutes) before conducting test.

If required, provide sufficient cool down period for truck.

EQUIPMENT:

1. Current Monitoring Shunt, 500 Amps, 50 mV. (Qty: 2 Req.).

2.

Digital Multi-Meter (Qty: 1 Req.) Recommend “Simpson D.M.M. Model #461” or equivalent.

3. Digital Stop Watch, 0.01 second resolution (Qty: 1 Req.).

Ill

TEST

PROCEDURES:

PRELIMINARY PRECAUTIONS: The A. following precautions must be adhered to while preparing for and / or conducting above tests: 1. Tests #l through #6 require drive wheels be raised off floor.

2. Always inspect condition of battery cables and connector of battery being used for test. If battery cables are worn out, cable ends at terminations cracked, or cable insulation broken / cracked, battery should not be used for test but should be sent for repair or maintenance.

3. No extension cables should be used to connect battery to truck for test.

It is recommended to install battery in truck for test whenever possible.

When such installation is not practical, battery should be set on floor close to truck battery receptacle, to eliminate need for extension cable.

8. Before connecting battery to truck, visually inspect to be sure contactor tips are not welded. any 9. The preferred method of disabling function / component (e.g., preventing 1 A contactor from closing) is to disconnect appropriate control wire, in order to break electrical circuit. Use of cardboard and / or any other mechanical device is not advised.

These methods should only be used if breaking electrical connections is not practical. SUCH METHODS SHOULD BE USED WITH CAUTION! B.

NOTE: DO NOT LIFT LOAD WITHOUT BATTERY INSTALLED IN TRUCK. WITH BATTERY REMOVED, TRUCK IS LACKING NECESSARY WEIGHT TO MAINTAIN LOW C.G. AND CAN OVERTURN. 4. Always inspect condition of battery cells for proper water level.

5. Before conducting any test, measure open circuit voltage of battery.

Record measured value, nominal rating of battery

SM538

19-02-l

PROCEDURES: 1 GROUND FAULT CONDITION: “STEP #l: Disconnect battery from truck receptacle and turn key switch OFF. STEP #2: Turn ON Digital Multimeter; select resistance measurement function, 200,000 Ohm scale.

STEP #3: Connect Red positive lead of Multimeter to POSITIVE (+) terminal of truck receptacle and connect BLACK negative lead of Multimeter to an unpainted surface (e.g., bolt, etc.) of truck frame. Record resistance.

STEP #4: Connect RED positive lead of Multimeter to negative (-) lead of truck receptacle and leave BLACK negative lead of Multimeter connected as in Step #3. Record resistance.

STEP #5: Compare values obtained Steps #3 and #4 against specification determine PRESENCE / ABSENCE GROUND FAULT.

in to of

NOTE: It is recommended that if ground fault is detected on truck, tests for other parameters should be conducted ONLY AFTER ELIMINATING CAUSE OF AND THEREBY GROUND FAULT. 2. POWER STEER IDLE CURRENT: STEP #1 : Raise drive wheel off floor.

STEP #2: Connect current monitoring shunt to measure battery current. Shunt sensor wires are connected to Digital Multimeter.

The voltage reading across these two sensor wires gives Direct Current reading.

Turn ON the Digital Multimeter; select DC VOLTS. STEP #3: Connect battery to truck Turn key switch ON, receptacle. depress foot brake pedal.

The power steer motor noise should be heard.

STEP #4: Measure and record voltage across shunt sensor wires (or terminals).

STEP #5: The voltage reading obtained in Step #4 is a direct reading of POWER STEER IDLE CURRENT using conversion of 1 mV equal 10 Amps for 500 Amp, 50 mV shunt.

NOTE: Precaution should be taken not to touch steering handwheel while taking measurements / readings in Step #4.

3. SCR CURRENT LIMIT STEP #l: Raise drive wheel off floor. Make sure truck is in cold condition.

STEP #2: Connect shunt to measure battery current.

STEP #3: Install jumper wire on foot brake switch to defeat its operation.

STEP #4: Disconnect control wire #41 from 1A / 3A contactor coil negative terminal and tape up.

STEP #5: Connect battery to truck receptacle, turn key switch ON. STEP #6: Move truck to position outriggers against a solid immovable surface (like a brick wall). Select FORWARD direction.

Rotate hand control gradually to FULL SPEED position.

Measure and record highest current reading (voltage across shunt) obtained.

STEP #7: Subtract power steer idle current from reading obtained in Step #6 to

SM538

obtain SCR CURRENT LIMIT FOR DRIVE SYSTEM. STEP #8: Repeat Steps #6 and #7. Take average of two (2) readings and compare average value to specifications.

NOTES: 1. Precautions should be taken not to stall traction motor more than 20 seconds during Step #6.

2.

There should be wait (idle) period minimum of two (2) minutes between Steps #6 and #8.

3. Drive wheels should be allowed to turn between Step #6 and #8.

4. 1A / 3A FREE WHEELING CURRENT: STEP #l : Raise drive wheel off floor.

STEP #2: Install jumper wire on foot brake switch to defeat its operation.

STEP #3: Connect control wire #41 to 1A /3A contactor coil negative terminal.

STEP #4: Connect shunt to measure battery current.

STEP #5: Connect battery to truck receptacle, turn key switch ON and depress brake foot pedal.

STEP #6: Select FORWARD direction, rotate accelerator control fully to full speed and hold.

STEP #7: Gradually release brake foot peda! until battery current reading is between 100-200 Amps.

Hold brake pedal and accelerator hand control in these positions for minimum of ten (10) minutes.

STEP #8: After ten (10) minutes, release brake by fully depressing pedal while still holding accelerator hand control fully rotated for full speed.

After current reading has stabilized, measure and record it.

STEP #9: Release hand control completely.

After current reading has stabilized, measure and record it as POWER STEER IDLE CURRENT. STEP #lo: The difference of current readings obtained in Steps #8 and ##9 is 1A / 3A FREE-WHEELING CURRENT and must be used to compare against specifications.

5. 1A TIME DELAY: STEP #l : Raise drive wheel off floor.

STEP #2: Install jumper wire on foot brake switch to defeat its operation.

19 - 02 - 2

STEP #3: Connect battery to truck receptacle, push foot brake pedal down, turn key switch ON. STEP #4: Select FORWARD direction; release brake pedal fully to maintain HARD STALL condition of traction motor.

STEP #5: rotate hand control accelerator to full speed as fast as possible and start Digital Stop Watch the moment hand control is moved.

STEP #6: Stop the stop watch the moment any motion or movement of !A (bypass) contactor tip is detected.

STEP #7: Stop Watch reading is 1A TIME DELAY. Repeat Steps #5 through #7 at least four (4) times. Take average of all readings as 1A TIME DELAY to compare against specifications.

STEP #3:Select FORWARD direction, rotate hand control accelerator to full speed, and hold . After top speed contactor has picked up (closed) and truck has travelled in top speed mode at least [23 m] 75 feet, quickly change direction of travel to REVERSE at full speed.

STEP #4: If truck continues to travel forward with continuously decreasing speed until truck stops and smoothly accelerates in reverse direction, PLUGGING function is correct.

STEP #5: Repeat Steps #3 and #4 starting out with reverse travel, then changing to forward travel. The PLUGGING function should operate same way.

STEP #6: Measure distance from point on travel path where direction change was initiated to point where truck actually started moving in reverse direction. This measurement is PLUGGING DISTANCE.

6. CREEP SPEED MOTOR VOLTS. STEP #l: Raise drive wheel off floor.

STEP #2: Connect RED positive lead of Multimeter to pig-tail of commutating diode (#3 REC) and BLACK negative lead of Multimeter to negative (-) terminal on control panel.

STEP #3: Turn Digital Multimeter ON; select DC Volt measurement function, 20 Volt scale.

STEP #4: Install jumper wire on foot brake switch to defeat its operation.

STEP #5: Connect battery to truck receptacle, turn key switch ON, select FORWARD direction.

STEP #6: Rotate hand control accelerator pedal until drive wheel begins to rotate.

Record voltage reading of meter.

STEP #7:Repeat step #6. Average of two reading is CREEP SPEED MOTOR VOLTS and should be compared against specifications.

NOTES: Measurements made in Step #6 should only be compared to specifications, if test was conducted after truck was operated for a minimum of 50 hours.

7. PLUGGING: STEP #l :Lower drive wheels to floor, remove jumper wire from foot brake switch.

STEP #2: Connect battery to truck receptacle, turn key switch ON, drive truck to open space or aisle where at least [76 m] 250 feet of running space is available.

SM538

19-02-3

SYMPTOM

1

PL_UGTHEEl*TrERY. TURNKEY SWrrCH ‘ON’. MEASURE VOLTAGE ON 72.

CHECK IF IA CcNrAcTORTlFs AREWELDED.

SM538 19-03-l

SYMPTOM

YES

*

2

TURN KEY SwrCH ON AND OPERATE TRUCK IN ANY DlREcrION. MEASUPE VOLTAGE ON TERMINALP.5 (WIPE 1129) OF Xl CAR0 TO BATTERY NEGATIVE As HMS IS ROTATED FROM NEUTPALTO MAXIMUM.

OF CONTACTOR TIP TO LOWTE OPEN.

CARD.

DEFECTIVE 1C CAPACITOR. REPLACE.

REPLACE.

SM538

19-03-2

SYMPTOM

3

UNPLUG s*l-rERY. DlSCHARGE IC CAP. CHECK 113REC FOR OPEN.

ABNORMAL

IS t3 REC. OPEN?

YES DEFECTIVE113 REC. REPLACE

8 57 NO

ABNORMAL

DISCONNECT M REC CHECK 114REC FOR SHORT.

8--

NO

ASNORMAL

L14 RECSHORT?

YES

DEFECTlVE P4 REC. REPLACE

I

OisCONNEC CHECK P2 l-4

DEFECTIVEPZ REC. REPLACE

DlSCONNECT lt5 REC. CHECK #S REC. FOR SHORT.

DEFECTIVE “5 REC. REPLACE

1NO

t

CGCONNECTTHERMAL PROTECTOR. CHECK W,TH OHMMETER

DEFECTIVE THERMAL PROTECTOR. REPLACE.

SM538 19-03-3

SYMPTOM

4

DlRECTlONAL CONT.4CTORS CLOSE. F”LLsJxHUMANDPoWERWrrn HMS IN CREEP SPEED POSITION.

1

TURN KNSWm2.H ‘ON’.

MEASURE VOLTS ON TERMINAL R50F#, CARD TO SATTERY NEGATM

CHECK x.5 REC. FOR SHORT.

a

CHECK IF x5 PEC WLL OATE’ON’.

TURN KM SWITCH OFF. DISCONNECT WIRE1129 FROM TERM PSOFI), CARD. TURN KEY SWITCH ON. MEASURE “OLTAGEONWlRE*29WrrH HMS AT CREEP SPEED.

SYMPTOM

5

NO

EdI INSTALLa? FIX. CHECK ,c. CAPKTOR FOR OPEN OR LOOSE CONNECTIONS.

TRANSFORMER MODULE REPLACE.

SM538 19-03-

4

SYMPTOM

SYMPTOM

6

7

UNPLUG BATTERY. IA CONTACTOR

CHECK FOR FREE

SWITCH ‘ON’. PUSH BRAKE PEDAL DOWN. MEASURE VOLTAGE ON

CHECK SHORT FROM WlRES#z.l2.10, 815 TO TERMINALS I.9 AND uo ON “1 CPIRD AND OPERATWN OF FwWRE”SWrrCHEs REPAIWREPLGE.

ROTATE HMS TO CLOSE DlRECTlONAL SW,TCnOFCONT~CTORTH*TWI~ NOT CLOSE. MEASURE VOLTS AT OTHERDlRECTloNALlNPUTTERMlNAL CL9 OR LIO, OF #I CARD.

CHECKCONTIN”I-WANDFOR PROPER CONNECTIONS OF WIRES #SMS To SWITCH. CAPI, AND COIL AND OPERATION OF DIRECTIONAL SWITCH (FWD/RE”,.

REPAIWREPUCE.

CHECK VOLTAGE BETWEEN TERMINALS )tryltS OF PMTD AND SAITERY NEGATIVE. MEASURE VOLTAGE ON TERMINALPS(WIREP41) OF IA DRIVERTO BATTERY NEGATIVE.

CHECK DlRECTloNAL CONTACTOR COIL FOR OPEN REPAIWREPUCE

CHECKVOLTAGE S”WEEN TERMlNALS 111AND X2 OF PMTD

REPLACE.

DEFECTIVE REPLACE.

11 CARD. REPLACE.

SM538 19- 03 - 5

DEFECTIVE REPLACE.

,A DRl”ER

SYMPTOM

8

SYMPTOM

1A CONTACTORWIU_NOT CLOSE WHEN IN SCR STALL ORGOING UP A RAMP.

ISTIFFPLUSANCVDR PLUGGING DISTANCEWlLL NOT ADJUST.

9 I I

c UNPLUGBATTERY. CHECK I A CONTACTOR FOR FREE MOVEMENT.

DEFECTIVE

IA

CHECK IF GREEN AND YELLOW WIRES FROM CURRENT SENSOR ARECONNECTEDTO PINX13 AND PIN 1114 RESPECTIVELY OF X1 CARDCONNECTOR. NOTETHAT YELLOW WIRE SHOULD SE CLOSER TO SATERY NEGATlYE AND NOT REVERSED.

lNsTALLAJUMPERFROMW,W XIOTOWIREI11IONBRAKE PEDALSWITCH. PLUG SAlTERY. Do NOT PUSH BRAKE PEDAL DOWN. TURN KEY SWITCH ‘ON’ AND ROTATE I-MS ?wI-rcn TO MAXIMUM. MEASURE VOLTS ON ‘OR0 LEAD OF THERMAL PROTECTORTO SATTERY

1

CHECK GREEN AND YELLOW WIRES FROM CURRENT SENSOR FOR OPEN. CONTROL IN THERMAL CUTBACK. ALLOW TRUCK TO COOL. THEN RECHECK ,A CONTACTOR OPERPiTION.

I

DISCONNECT AND NO

* TURN ‘IA TIME’ TRIMPOT FULLY CCW. RECHECK ,A THERM. CUTBACK.

READJUST ‘1 A TIME TRJMPOT PERSPEC

DISCONNECT

L

WIRE R9 FRO,., TERMINAL RS OF X1 CARD. PLUG BATTERY. CLOSE KEY SW~CH SLIT Do NOT PUSH DOWN BRAKE PEDAL. ROTATE HMTO MAXIMUM. MEASURE VOLTAGE ON WIRE “29

1 UNPLUG BATTERY. RECONNECT WIRE 869 ON TERMINAL RS OF XI CARD. PLUG BATTERY. TURN KEYSWITCH ‘ON’, DO NOT PUSH BRAKE PEDAL DOWN. ROTATE “MS TO MAXIMUM. MEASURE VOLTAGEONTERMINALRSOF

I

NO

1

DEFECTIVE

#I CARD

SM538 19-03-6

I NO

SYMPTOM

1.

2.

3.

4.

CONTROL NOT ADJUSTED PROPERLY. TEST EQUIPMENT OUT OF CALIBRATION. ABUSE OF TRUCK. POSSIBLE BAD DRIVE MOTOR OR BIND IN DRIVE TRAIN. 5. USE OF INCORRECT REPLACEMENT PARTS.

1. EXCESSIVE SCR COMPONENT FAILURES.

2. SHORT BATTERY OR LIFE.

10

USAGE

1. BATTERY(S) NOT FULLY CHARGED. 2. BATTERY(S) DOES NOT HAVE ENOUGH CAPACIT? fOR DUN CYCLE. 3. POSSIBLE POOR MAINTENANCE. 4. POSSIBLE DEFECTIVE BATTERY. 5. POSSIBLE DEFECTIVE DRIVE OR PUMP MOTOR. 6. POSSIBLE DEFECTIVE DRIVE SYSTEM HlGH WHEEL UP CURRENT.

3. TRUCK TRIPS THE PMT OCCASIONALLY.

1. CHECK CONTROL ADJUSTMENTS. 2. CHECK FOR WEAK bl. X2. OR 114 REC USING OHM METER. 3. CHECK FOR STICKING 1A CONTACTS. 4. CHECK FOR LOOSE CONNECTION IN SCR PANEL. 5. CHECK FOR BOUNCING DIRECTIONAL CONTACTS. 6. REPLACE PMT CARD. 7. REPLACE #22 AND 1125 FILTERS.

4. TRUCK FREQUENTLY SLOWS DOWNDURING NORMAL WORK CYCLE.

1. THERMAL PROTECTOR IS CUTTING POWER BACK. CHECK CONTROL ADJUSTMENTS AND OPERATION TRUCK IS DOING. CHECK BATTERY STATE OF CHARGE. CHECK CONTACTOR 1AOPERATION. 2. CHECK FOR POOR POWER CABLE CONNECTION.

5. MAIN HYDRAULIC WILL NOT WORK.

1. LOW BATTERY OR DEFECTIVE EATERY CONTROLLER (IF SO EQUIPPED).

2. CHECK DRIVE MODULE (IF SO EQUIPPED).

3. BAD VALVE SWITCH. 4. BROKEN WIRE TOCOIL. 5. BAD CONTACTS. 6. IF MOTOR WILL NOT RUN WHEN CONTACTS ARE MANUALLY CLOSED, MOTOR OR CABLE IS BAD. BE SURE TO CHECK FUSE.

PUMP

6. MAIN PUMP MOTOR ALL THE TIME.

RUNS

1. STUCK CONTACTS. 2. STUCK OR SHORTED VALVE SWITCH. 3. SHORT IN WIRE FROM POSITIVE SIDE OF PUMP CONTACTOR COIL.

6. STEERING DROPS OUT WHEN CHANGING DIRECTION.

1. CHECK TIME DELAY MODULE STEERING COIL CIRCUIT.

9. 1A CONTACTOR CLOSES WHEN KEY SWITCH IS ON.

1. CHECK

NOTE:

FOR SHORTED

BEFORE REPLACING dl CONTROL CARD, ALWAYS CHECK CONNECTOR PLUG PINS.

SM538 19-03-07

DRIVER

IN POWER

1AD MODULE.

GROUP 19 SECTION CONTROL PANEL

04

CONTENTS

NO.

CONTROL PANEL DESCRIPTION CONTROL PANEL MAINTENANCE CONTROL TROUBLE-SHOOTING CONTROL PANEL REMOVAL CONTROL PANEL DISASSEMBLY CONTACTOR INSPECTION CONTROL PANEL ASSEMBLY CONTROL PANEL INSTALLATION

19-01 19-02 19-03 19-04 19-05 19-06 19-07 19-08

19-01 CONTROL DESCRIPTION

The control card then supplies a gate pulse to #2 REC, turning it ON to a conducting state.

This allows current to flow from battery through lC, 1X, #2 REC, motor field, motor armature, sensor, and back to battery.

After 1C charges, #2 REC turns OFF, due to lack of holding current.

The control card checks that 1C is charged and unlocks gate to #1 REC and #5 REC. The control card then supplies a gate pulse to #l REC, turning it ON to a conducting state.

This allows current to flow from battery through #l REC, motor field, motor armature, sensor, and back to battery. #5 REC turns ON and allows current to flow through T4-T3,1C, #l REC, #5 REC back to T4T3.

PANEL

The EVl W CONTROL is an electronic device that controls electrical power supplied to vehicle traction motor to provide smooth power to move truck and to minimize power drain from battery.

This current charges bottom of 1C positive with respect to battery positive.

Then #5 REC shuts OFF. This charge is now stored on capacitor until it is time to turn OFF #l REC.

The electrical system of the truck is composed of the contactor control panel, the relay panel, the speed control (master switch), drive motor and source (battery).

Current continues to flow through #l REC until control card fires #2 REC. When #2 REC conducts, capacitor 1 C discharges around circuit composed of lC, #2 REC, 1X, and #l REC.

The electrical control circuit utilizes electric valves and electrical electrical section of the

This discharge current opposes battery current through #1 REC so that resultant current is zero.

Due to lack of holding current, #1 REC is turned OFF.

system for the hydraulic relays to energize solenoid interlocks to control the hydraulic control circuit.

The relays interlock hydraulic functions to prevent more than one hydraulic circuit operating at any given time.

Interlocks operate whenever spool valve is not in neutral position.

The contactor control consists of a SCR unit and a contactor assembly unit. The SCR monitors power demand of truck and then responds by controlling power circuit applied to traction components.

The contactor panel contains switching devices to direct heavy power loads to drive motor and its components.

Current continues to flow in #2 REC, lC, motor and battery loop until capacitor (card terminal 7) is fully charged negative.

This charge exceeds battery voltage by an amount which is a function of peak motor current, and #2 REC turns OFF. FIG. 1 illustrates

c

in!

AVERAGE ‘CURRENT

The control circuit is energized by closing key switch, depressing brake pedal to close brake switch, and rotating forward / reverse operator hand control to desired position.

This applies power to control card which will close selected directional contactor and complete circuits to Further rotation gives desired traction motor. speed.

FIG.

SM538

I battery.

PEAK CURRENT

19-04-l

Battery current illustration.

During off time, energy stored in motor, by virtue of motor’s inductance, will cause current to circulate through motor around loop formed by #3 REC. This current is called FLYBACK CURRENT. 100 %

AVERAGE CURRENT

The % ON-TIME. 95%.

has a range of approximately

5-

The center ( or mid) operating condition of oscillator is at 50% ON-TIME with a nominal 1.8 milliseconds ON-TIME and 1.8 milliseconds OFFTIME. This corresponds to a maximum operating frequency of about 300 Hertz.

50%

ON ON ON OFF OFF OFF

TIME

I ;

FIG. 2. Motor current illustration. shows average motor current.

5

The dotted line

cs

I I

50 SCR RANGE

I I

95 TS

% ON TIME

FIG. 2 shows nature of motor current which is composed of both battery current and inductive (or flyback) current.

FIG. 3. Oscillator frequency

It should be noted that measured average motor current will be greater than average battery current.

At CREEP, ON-TIME will decrease to approximately 0.8 milliseconds while OFF-TIME will rise to about 20 milliseconds.

At full SCR operation, this condition will be reversed (short OFF-TIME and long ON-TIME).

The SCR control converts battery current at battery volts into a higher motor current but at a lower motor voltage.

The time for next ON / OFF cycle to start is determined by time that control card takes to oscillate. This frequency of oscillation is controlled by position of operators hand control and oscillator control circuitry in card.

Slow speed is obtained by having maximum input volts from hand master switch.

As input volts decrease, speed of motor increases.

The SCR circuit is capable of delivering approximately 95% of maximum speed. For full speed operation, 1A contactor is closed to apply full battery voltage across motor.

CONTROL FEATURES OSCILLATOR. The oscillator two adjustable features and With hand master switch maximum volts, creep speed CREEP trimpot on card.

section of card has one fixed feature. output voltage at can be adjusted by

Top speed is fixed by card design and is obtained with hand master switch output voltage at minimum.

SM538

curve.

This variation of ON/OFF TIME of oscillator produces optimum frequencies through SCR range. The frequency curve of oscillator is shown in Fig. 3.

The rate at which oscillator may increase its percent ON-TIME is limited by “CONTROLLED ACCELERATION”.

The minimum time required to go from creep speed to 80-85 % ON-TIME point This is may be varied by trimpot (C / A) on card. adjustable from approximately 0.5 seconds to 3.5 4.5 seconds.

CURRENT LIMIT. This circuit monitors motor current by utilizing a sensor in series with armature.

The information detected across sensor is fed back to card so current may be limited to a preset value.

If heavy load currents are detected, this circuit over-rides oscillator and limits average current to a value set by C / L adjustment pot. The C/L setting is based on maximum thermal rating of #l REC and peak voltage on capacitor.

19 - 04 - 2

Because of flyback current through #3 REC, motor current usually runs 2 to 3 times that of battery current. The current limit is set with C / L trimpot on card.

2). If motor current is reduced during cutback to a point where 1A pickup would cause a severe torque increase, 1A timed pickup function will be disabled.

or slowing down of truck is PLUGGING. accomplished when reversing by providing a small amount of retarding torque for deceleration.

THERMAL PROTECTOR (TP). This temperature sensitive device is mounted on 1 REC heatsink. If 1 REC temperature begins to exceed design limits, thermal protector will lower maximum current limit and not allow 1REC to exceed its temperature limits.

If truck is moving and operator hand control is rotated from that direction selection to opposite direction selection, motor field is reversed.

The plug signal is initiated by fact that directional switch has been rotated from one direction of selection to opposite direction.

The motor armature, driven by inertia of vehicle, acts as a generator.

This generated current passes through #4 REC and sensor. The oscillator circuit regulates at a plug current limit level as set

by PLUG trimpot on control card.

This controls pulse rate of #l REC to regulate generated motor current and bring truck to a smooth controlled stop and then reversal.

The hand master switch input will modulate plugging current.

With hand master switch at maximum rotation, plugging trimpot will enable adjustment of plugging current limit from maximum to minimum current limit level. With hand master switch at minimum rotation, plugging current limit will be reduced to minimum.

FULL POWER TRANSITION. This built-in feature provides smooth transition from SCR to 1A bypass. This is accomplished

by SCR continuing to pulse until 1A contactor power tips close.

1A CONTROL. of control:

1).

The contactor

has two modes

TIMED PICKUP. This feature works with hand master switch. When hand master switch is activated so that hand master switch voltage is reduced to 0.4 volts or less, then 1A time is enabled.

The time delay pickup of 1A is provided by a circuit in card. This allows truck to accelerate through SCR range until 1A picks up, even if hand master switch is fully rotated immediately.

This time delay is adjustable by means of a 1A TIME trimpot on card.

SM538

Even at reduced current limit, truck will normally be able to reach sufficient speed for full 1A operation, thereby allowing panel to cool.

As panel cools, thermal protector will automatically return control to full power status.

1A THERMAL HOLD-OFF. This feature prevents 1A contactor from closing when truck is in severe thermal cutback to avoid torque “jumps”.

When control goes into severe cutback, “MUST PULSE TO TIME” will disable 1A timer.

MUST PULSE TO TIME. This feature prevents 1A timer from timing if oscillation pulse rate has not reached a particular level of operation.

LOW VOLTAGE. Batteries under load, particularly if undersized or more than 80 percent discharged, will produce low voltages at SCR control terminals.

Low battery volts may cause control not to operate correctly but PMT should open F or R contactor in event of a commutation failure.

19-02 CONTROL MAINTENANCE

PANEL

The SCR control, like all electrical apparatus, does have thermal losses. The semiconductor junctions have finite temperature limits, above which these devices may be damaged.

For these reasons, normal maintenance should guard against any action which will expose components to excessive heat, (such as steam cleaning).

The following DO’S and DONT’S should be observed: Any controls that will be used in ambience of [50° C] 120° F or over should be brought to attention of Clark Equipment Co. All external components having inductive coils must be filtered l

l

19 - 04 - 3

* The control should not be steam cleaned. In dusty areas, use low-pressure air to blow off control. In oily or greasy areas, a mild solution of detergent or denatured alcohol can be used to wash off control.

Then use low pressure air to blow unit completely dry. The control can also be cleaned with a Freon TF degreaser. * Terminal boards and other exposed SCR control parts should be kept free from dirt and paint that might change effective resistance between points.

THE TRUCK SHOULD NOT BE PLUGGED WHEN THE TRUCK IS JACKED UP AND THE DRIVE WHEEL IS IN A FREE-WHEELING POSITION. THE HIGH MOTOR SPEEDS CAN CREATE EXCESSIVE VOLTAGES THAT CAN BE HARMFUL TO THE

CONTROL. * Do not HIPOT (or MEGGER) control. Unless terminals of each semiconductor and card are connected together, control may be damaged. Refer to control manufacturer before hipotting.

Use a lead-acid battery with voltage and ampere hour rating as specified for vehicle.

Follow normal battery maintenance procedures, recharging before 80 percent discharged and with periodic equalizing charges. l

19-03 CONTROL TROUBLESHOOTING

Useless work can be avoided by diagnosing trouble accurately on basis of preliminary investigation and correct use of information in trouble-shooting guide. Take necessary time for sufficient preliminary investigation.

Use symptoms indicated by trouble to locate proper diagnosis chart in trouble-shooting section. You may also want to use sequence of operation manual as a diagnostic tool.

Proceed to find problem by using flow chart in trouble-shooting guide which defines symptom and its possible cause(s) and solution.

Locate trouble by a process of elimination. The cause is usually simple, rather than mysterious and complicated. * MOST IMPORTANT, USE THE ELECTRICAL SCHEMATIC DIAGRAM FOR THE TRUCK YOU ARE WORKING ON. YOU MUST BE ABLE TO TRACE THE: o POWER CIRCUITS which consist of heavy cables and main power components of truck. o CONTROL CIRCUITS which control speed, time delay, and controlled plugging. o DIRECTIONAL CIRCUITS which control forward and reverse contactors. o ACCESSORY CIRCUITS which control components, including horn, battery indicator and hourmeter.

ALL TESTING

SHOULD

DONE WITH DRIVE RAISED OFF THE

BE

WHEELS

FLOOR.

TROUBLE-SHOOTING NOTES

When diagnosing and correcting cause of trouble with a SCR control, do not begin by disassembling components.

Trouble-shooting is based on using a digital voltmeter to determine if correct voltages are available to permit control to operate correctly.

Stan by analyzing complaint of symptoms. Make a preliminary investigation of trouble.

Then systematically determine probable cause.

The pulsing of main SCR is too fast for canventional instruments to measure.

When control is functioning properly, a low hum can be heard.

The following points are fundamental to troubleshooting a SCR system. * Never start your troubleshooting until you get facts. Talk with truck operator and review work order. * Operate truck to observe fault and then determine what corrective action should be.

Determine where to start. * Perform basic checks. Check battery and test for grounds and shorts. Do not take short cuts by assuming these checks do not have to be made.

Before proceeding with any testing, visually check for loose wiring, signs of overheating of components, condition of battery and battery receptacle, etc.

Discharge capacitor by using an insulated screwdriver or similar device that is insulated to short across terminals of capacitor.

SM538 19-94-4

Check resistance(s) from frame to SCR power and control terminals.

A resistance of less than 20,000 ohms can cause misleading symptoms.

If less than 20,000 ohms resistance is measured, conduct further tests to eliminate short circuit / ground fault conditions.

An index of most common symptoms for EV-1W SCR control troubles is: 1. Directional contactors will not close 2. Directional contactors close. No power. No audible SCR hum. Truck inoperative with accelerator in SCR range. contactors close.

No power.

3. Directional Truck inoperative with Audible SCR hum. accelerator in SCR range.

4. Directional contactors close. Full SCR hum and power with accelerator in creep speed position.

5. Directional contactors close once or twice and then remain open. PMT trips.

6. One directional contactor close with normal operation but other contactor will not close.

7. 1A contactor will not close.

8. 1A contactor will not close when in SCR stall or going up a ramp.

9. Stiff plug and/or plugging distance will not adjust.

10. Miscellaneous.

1. Make sure truck has been parked in a safe position with upright fully lowered.

Return all controls to neutral and turn key switch to off.

2. Disconnect battery (if not already removed from truck).

3. Loosen and remove two bottom fasteners and two top fasteners attaching control panel cover to frame on RH side of operators compartment.

Remove panel cover.

Removal of the two panel control cover top fasteners also loosens the relay panel cover and compartment rest pad. Lift off this cover and pad (cover has two top pins that lift out of holes in frame). This exposes the relay panel control.

Refer to Systems Diagnostic area for detailed information on sequence of operation and troubleshooting of control.

Tools and test equipment required are: 6 volt lamp 6 volt battery Two Al4 diodes (1 amp 400 v) Clip leads Volt-ohm meter (VOM) + (20,000 ohms) General hand tools l l

l l l l

NOTE: A digital VOM (such as Simpson Digital Multi-meter Model 461, or equivalent) is recommended for all electrical and control testing.

19-04 SCR AND RELAY

CONTACTOR PANEL PANEL REMOVAL

This will expose control panel compartment which is mounted RH lower side of operators compartment.

The SCR panel and contactor panel are considered an assembly and are removed as a unit.

4.

Discharge capacitor by using an insulated screwdriver or similar device to short across terminals of capacitor.

WARNING ELECTRICAL

SHOCK

DISCONNECT THE BATTERY AND DISCHARGE THE CAPACITOR(S) BEFORE HANDLING THE CONTROL PANEL

BREAKING SERIOUS

THIS RULE CAN CAUSE INJURY TO YOURSELF

SM538

19 - 04 - 5

19-05 CONTROL DISASSEMBLY

PANEL

1. Put control assembly on a clean work surface with contactors away from technician and SCR panel nearest technician.

(Directio,ls will be noted with this orientation of panel, ie. right, left, front, rear, etc.).

2. Note position of all wires on panel, placement of all components, and locations of all mounting fasteners.

5. Remove all power cables (located on RH side of panel at rear of compartment).

Make sure terminals of all cables have identification labels to assure correct assembly.

6. Remove all control wires attached by screws to Make the terminal block (normally eleven wires). sure these wires all have identification tags on them.

LEFT

RIGHT

REAR

7.

Loosen and remove three attaching control panel to frame.

(3)

fasteners

8. Remove all control leads at relay panels.

9. Remove two nuts securing large panel to truck and remove panel and spacers 10. Remove two (2) nuts and spacers attaching smaller relay/timer panel to frame and remove panel and spacers.

3. Make sure capacitor is discharged.

4. PUMP CONTACTOR REMOVAL. Remove power lead from top LH upper surface of contactor to terminal NEG . Remove lead from top RH upper surface of contactor to power steering contactor.

Other lead from top RH upper surface gee- to terminal N on battery connector.

Lead from bottorr RH upper surface of contactor goes to S terminal on lift pump motor.

5. Remove two (2) control wires (#lo and #28) from lower LH side of contactor (on coil). Remove two (2) fasteners attaching contactor to panel base plate and remove contactor.

6. 1A CONTACTOR REMOVAL. Remove lead from top LH upper surface of contactor to terminal POS. Remove bus bar from top surface of contactor to 400 amp fuse. Remove flat twisted wire lead on LH side of contactor going downward to F contactor.

7. Remove lead from bottom LH upper surface of contactor to T2 terminal.

8. Remove two (2) control wires #lO and #41 from lower LH side of contactor (on coil). Remove two (2) fasteners attaching contactor to panel and remove contactor.

FORWARD CONTACTOR REMOVAL. 9.

Remove lead from top LH upper surface of contactor to lower LH upper surface of R contactor.

._-

SM538

19 - 04 - 6

Remove bus bar on top lower LH side of F contactor and extending down to bottom lower LH side of R contactor. (Power cable leads Al and Sl attached to upper surface top and bottom terminals respectively on RH side). Remove two (2) control wires #6 and #50 from lower LH side of contactor (on coil). Remove two (2) fasteners attaching contactor ro panel and remove contactor.

REVERSE CONTACTOR REMOVAL. 10.

Remove power lead from bottom LH upper surface of contactor to Al on terminal block and second lead from same terminal to T2 on terminal block.

(Power lead S2 is attached to top LH terminal on upper surface of contactor).

Remove two (2) control wires #8 and #62 from LH side of contactor (on coil). Remove two (2) fasteners attaching contactor to panel and remove contactor.

11. POWER STEER CONTACTOR REMOVAL. Remove two (2) control wires to solenoid, #71 to top small terminal and #lO to bottom small terminal.

(Power lead to pump contactor removed earlier).

(Power lead at large bottom terminal goes to terminal A on power steer motor). Remove two (2) fasteners attaching contactor to panel and remove contactor.

Loosen 12.

400 AMP FUSE REMOVAL. fasteners attaching fuses to bus bar and to standoff. With fasteners loosened, fuse ends will swing free of fasteners, and fuse then can be removed.

13. Remove all control wires to SCR panel card.

(Five wires on LH side and six wires on RH side).

Make sure all wires are correctly identified with markers. Swing retainer clips away from card.

Remove junction box at rear of card and remove card.

14. Disconnect all power cables now exposed, and carefully note positions of each.

15. Remove screws from bracket securing capacitor. Remove nuts and wires from capacitor terminals and remove capacitor.

16. Disconnect lead wires from thermal protector and remove thermal protector.

17. Loosen a nd remove wires and gate lead from #l REC. Remove screws securing #l REC and remove #l REC. 18. Disconnect wires going to transformer.

Disconnect wires leading to terminal board.

Remove transformer and #2 REC and #5 REC. 19. Remove filters.

20. Remove #3 REC and #4 REC. 21. If necessary, remove terminal board and heatsink.

This completes disassembly of SCR panel.

19-06

CONTACTOR

1. Check armature and movable contacts for freedom of movement by depressing movable arm with a screwdriver or small rod.

Check for any restrictions to movement and for return of parts by action of spring.

2. Inspect contact tips. Look for any worn or eroded surfaces. Look for evidence of tip welding.

Inspect for evidence of any contaminants on tips (paint, dirt, paper or cloth material, etc.) which would impair operation. Do not use sandpaper or file tips. Any damage must be corrected by tip replacement. Tips must be replaced before they wear through and damage copper base. To remove and replace contact tips, use following procedure: 1. Loosen and remove retaining lock nut, lockwasher flat washer, spring seatand spring from armature bolt of center movable contact tip set.

2. Remove movable contact tip set.

3. Loosen four long bolts holding fixed contact and insulators to assembly. Observe position of short and long contact tip bus bar terminals.

4. Remove bolts, lockwashers, insulators and two contact tips.

5. Install new contact tips by reversing above procedure. Check for correct positioning of long and short fixed contact bus bars.

INSPECTION

1A and LIFT PUMP CONTACTORS

SM538 19 - 04 - I

6. Tighten four long bolts of fixed contact set gradually and by even torque increments until firmly seated. (Tighten each fastener in a sequential manner and use torque increments to avoid overstressing and damaging insulator bars.

DO NOT OVER TORQUE! 7.

Tighten armature and movable contact assembly retaining nut. Tighten firmly but DO NOT OVER TORQUE. 8. Check armature and movable contact set for free movement.

FORWARD / REVERSE CONTACTORS 1. Check contactor for correct operation in same manner described for 1A and pump contactors. ,

6. Install all control wires on card. Make sure they are in correct position.

7. Install 400 amp fuse to stand-off.

8.

Install power steer contactor and tighten fasteners to a torque of 19-l 1 N.m] 83-94 Ibf.in. .

Attach control wires #71 to top small terminal and #71 to bottom small terminal.

9. Install Reverse contactor.

10. Install forward contactor.

11. Install 1A contactor.

12. Install pump contactor.

13. Install bus bars between contactors.

19-08 CONTROL INSTALLATION

1. Install small relay panel and tighten fasteners.

Be sure spacers are correctly positioned behind panel and fasteners are tightened to a torque of [l O-l 1 N.m]\ 90-l 00 Ibf.in.

2. Install large panel on frame making sure three (3) fasteners are tightened to a torque of [l O-l 1 N.m] 90-l 00 Ibf.in.

3. Connect all control wires to panels making sure they are in correct locations. Install all power cables to correct terminals.

4. Install the top cover by putting the two pins on cover in correct holes. Install bottom panel cover and install and tighten fasteners.

5. Install and connect battery.

2. Loose: and remove top contact retainer and four (4) long bolts.

3. Remove two (2) stationary normally closed contacts.

4. Remove two (2) contact spacers.

5. Remove two (2) bottom stationary contacts.

6. Loosen and remove retaining nut for armature and movable contact assembly.

7. Remove movable contact tip assembly.

8. Install new contact tip sets in reverse order.

9. Torque four long bolts t0 [1.5-2.0 N.m] 14-18 Ibf.in. using a diagonal tightening sequence.

19-07 CONTROL ASSEMBLY

PANEL

1. #3 REC / #4 REC INSTALLATION. Install rectifiers in rectifier heatsink using an open end wrench.

2. Install filters.

3. Install transformer and #2 REC and #5 REC Connect wires to transformer.

4. Install thermal protector and install lead wires on protector.

5. Put capacitor in position on panel base plate, position clamps and fasteners correctly to retain capacitor.

Connect junction box on rear of card and then install card. Swing retainer clips inward to lock card.

SM538

PANEL

19-04-8

GROUP

20 SECTION DRIVE UNIT

01

Make sure all fasteners are in place and are secure when making routine inspection of truck.

20-03 CONTENTS

NO

GENERAL DESCRIPTION DRIVE UNIT MAINTENANCE DRIVE UNIT REMOVAL DRIVE UNIT DISASSEMBLY DRIVE UNIT INSPECTION DRIVE UNIT ASSEMBLY DRIVE UNIT INSTALLATION

20-O 1 20-02 20-03 20-04 20-05 20-06 20-07

20-01

GENERAL

DESCRIPTION

The drive unit has two gear sets consisting of a helical spur gear input set driving a ring and pinion gear set to give a total 19.82:1 gear ratio.

All gears are ground and matched for optimum efficiency and minimum noise. Lubrication of all parts are enhanced by separate oil reservoirs for each gear set. A large external spur gear on top surface of drive unit provides a positive means of steering vehicle.

20-02 DRIVE MAINTENANCE

UNIT

When troubleshooting a drive axle problem, it should be kept in mind that drive unit is only a central unit in a group of related powertrain components.

Proper operation of drive unit depends on condition and correct function of other Therefore, to properly components of group. diagnose a suspected problem, it is necessary to consider transmission fluid, assembly and motor connection, and tire condition, as a complete system.

By analyzing principles of operation together with information in this section, it should be possible to identify and correct any malfunction that might occur in this system.

OIL LEVEL CHECK Check oil level in both sections (upper and lower).

It must be at correct level Refer to PM section for correct method of checking and replenishing gear case oil.

Grease upper support with specified grease.

bearing

UNIT

REMOVAL

NOTE: Drive motor weighs kg] 55 Ibs.

about 125

15. Remove three (3) retaining fasteners which hold drive unit to frame. Drive unit is now free of truck. Carefully raise truck upward off drive unit and remove drive unit.

N,OLFbsDrive unit weighs about [72 kg.]

at proper interval

SM538

DRIVE

1. Park truck on a level surface, fully lower upright and retract forks.

2. Disconnect and remove battery.

3. Open rear door and lift to remove it. Store it in a safe place.

Use a chain hoist to lift the truck up 4. approximately [lo0 mm] 4. in. and block securely (Refer to GROUP 38, MACHINE JACKING AND BLOCKING).

5. Remove drive wheel assembly by loosening and removing seven (7) wheel nuts.

6. Remove two wires from brake switch.

7. Remove lower sump tank retaining bracket 8. Remove brake cable from brake arm by removing cotter pin from clevis pin and then removing clevis pin.

9.

Remove brake cable from bracket by loosening retaining nut on cable, then sliding cable toward truck until smaller cable control wires reach bracket slot and can be slid off bracket.

10. Remove four main power cables from drive motor.

Be sure to identify cables for location before removal.

11. Remove brake cable mounting bracket by removing fasteners attaching it to motor end frame.

12. Remove steering stop (which is mounted to frame) and spacer from underside by one fastener through frame.

The other end of steering stop is trapped to frame by passing through a slot in battery compartment rear wall.

13. Use blocking under drive unit to support it and prevent it dropping when fasteners are removed 14. Fasten a lift sling to drive motor to support it Remove six (6) fasteners from dropping. attaching drive motor to drive unit. Raise drive motor upward and use two flat bars placed over opening to support motor above truck floor plate.

20 - 01 - 1

16. Raise drive motor slightly to remove bars.

Lower motor into opening until it can be tipped to clear truck parts and lifted out of truck. Store in a safe place.

20-04 DRIVE DISASSEMBLY

UNIT

1. Before removal from truck, remove fill and drain plugs from upper and lower chambers and fully drain all oil.

2. Remove fasteners attaching steering ring gear to drive unit cover and lift off gear. Store in a safe place.

Remove three fasteners securing large 3. mounting ring to top cover and remove ring.

4. Remove six (6) capscrews which lock large ball bearing to top cover. Remove cap and bearing and store in a safe place.

5. Remove seven (7) fasteners from underside of the top cover, two fasteners from topside, and lift off top cover and gasket. Discard gasket and store cover in a safe location.

6. Use a drift or chisel to bend taps of tab washer from pinion shaft nut to allow nut to be turned.

Use gear locking tool (V9375) to lock gear to case and remove nut and tab washer. Lift drive gear off pinion shaft spline.

7. Remove six (6) capscrews locking bearing cap to gear case and remove bearing cap assembly (with seal). Use a screwdriver or cape chisel to remove seal from cap. Discard seal.

8. Invert gearcase and remove four (4) fasteners holding bottom cover on case (two large capscrews and two smaller capscrews plus lockwashers).

9. Lii axle shaft assembly out of case.

If necessary, carefully use a pry to work parts free from case. Apply prying pressure carefully and evenly to all parts to avoid damaging case and parts.

10. Bend tabs of tabbed washer from nut to allow nut to be turned. Remove nut and tab washer.

11. Remove bearing and then snap ring from axle shaft.

12. Use a gear puller to remove spacer.

13. Pull gear off axle shaft.

14. Remove bearing outer race and snap ring.

15. Use a gear puller to remove inner bearing race.

16. Lift off snap ring. Pull off and discard seal.

17. Use a brass drift and a soft-faced hammer to tap on end of pinion shaft and drive it upward through bore. When pinion shaft upper ball bearing has been moved out of bore in gearcase, entire pinion gear assembly can be lifted out of case. Turn gear case right side up and lift out pinion gear assembly

18. Use a gear puller to remove top bearing.

Make sure fingers of gear puller bear on inner race of bearing.

19. Remove shim and spacer.

20. Use a gear puller to remove inner race of pinion shaft needle bearing.

21. Remove snap ring holding needle bearing position.

22. Lift out needle bearing.

23. Remove bleeder from gear case. Remove relief valve from top cover.

20-05

DRIVE

UNIT

INSPECTION

1. Carefully clean all parts.

2. Inspect gear assemblies for mechanical damage to gear teeth or for evidence of badly worn, broken or pitted contact surfaces. Inspect web area of all gears for evidence of cracks.

Inspect hub areas for for cracks, corrosion, erosion, worn contact faces, or spline damage.

3. Carefully clean all gasket or mating surfaces to remove all traces of gasket material or sealants.

4. Inspect gear case and cover for any evidence of cracks or of mechanical damage that would impair operation.

5. Inspect pinion gear shaft and axle shaft for any evidence of damage to parts.

6. Inspect all bearings for any evidence of damage including pitting or corrosion. Make sure bearings are free in their cages but are not wb,? to permit rollers or balls to shift or bind in cages c. retainers.

7. Inspect all threaded holes for evidence of thread damage.

8. Inspect wheel studs to be sure they are fully retained in hub and are solidly retained. Make sure threads are not damaged.

9. Apply a thin layer of oil to all parts. If left exposed for some time or for overnight, cover all parts to protect them from contaminates 10. Replace all seals. Damaged or faulty parts must be repaired or replaced with new before assembly.

20-06

DRIVE

UNIT

ASSEMBLY

INPUT GEAR ASSEMBLY 1. Position housing in normal upright manner and Press insert needle bearing into housing. bearing into bore until it is seated on counterbore (Use special tool V9371 as shown in rear of this section for this operation).

SM538 20 - 01 - 2

SNAP

5. Fill ball bearing with lithium grease ( FAG ARCANAL L 71 or equivalent).

Place bearing onto pinion gear shaft.

6. Push this assembly into bore of gear housing from top side of gear case.

7. Lay bearing cap upside down on a flat surface and push seal into the groove on underside of bearing cap with sealing surface pointing out..

Insert this assembly (with seal downward to rest against the ball bearing) into bore to secure bearing in place Make sure cap rests against bearing.

8. Insert fasteners and lock washers in bearing cap and tighten to a torque of [25 N.m] 18.5 Ibf.ft.

2. Insert snap ring into bore and make sure it is firmly seated in snap ring groove to retain needle bearing.

3. Inner raceway and spacer sleeve are installed on shaft, then pressed into place using a tool made from tubular stock. Tool must have an I. D. providing clearance to shaft and also must have sufficient bearing surface for spacer sleeve Heat inner raceway of needle bearing to about [100-l 20°C] 210-25OOF. (For ease of assembly, pinion shaft should be kept refrigerated for at least 12 hours).

Quickly slide heated inner raceway onto pinion gear shaft, and immediately follow with spacer sleeve. Next, force parts onto shaft until free end of spacer is beyond bottom of shoulder on pinion gear (clearance must exist between bearing and sleeve). This will permit bearing to fully seat against shoulder of pinion gear shaft.

9. Position upper driving helical gear of spline of pinion gear shaft.

NOTE: Force parts onto shaft making sure sleeve is pressed beyond shoulder on shaft (bearing must have clearance with sleeve).

10. Put tabbed washer and nut on assembly and tighten nut to a torque of [280 N.m] 206 Ibf.ft.

(Use tool V9374 to lock gear case when tightening nut).

After tightening, bend one tab downward and two tabs upward to lock nut in place.

4. Put adjusting shim (with chamfer side facing down) on shaft of bevel pinion.

SM538 20 - 01 - 3

OUTPUT SHAFT GEAR ASSEMBLY 1. Coat outside diameter of seal with sealing compound Fluid-Terolan 3030 (or equivalent).

Position seal on axle shaft with lips of seal pointing inward (away from axle hub).

2. Place first snap ring over axle shaft.

3. Heat inner raceway of roller bearing to about (100-l 25O C] 21 0-250° F and quickly slide it onto axle shaft until it is seated tightly against shoulder of shaft. Then slide remainder (outer race) of bearing onto shaft.

4. Next, put a second snap ring over shaft against bearing.

5. Insert any replacement studs in axle hub making sure they are fully seated. Slide ring gear over axle shaft (hub end first) until it rests against bearing. Make sure snap rings are not trapped by these parts and are free to move.

6. Position spacer on shaft and then slide snap ring over shaft.

7. Slide last bearing onto shaft and press into place (this is an interference fit and must be pressed onto shaft).

NOTE: Use a sleeve that has an inside diameter that just clears shaft diameter for pressing this part in place.

Again, make sure snap between these parts.

ring is not trapped

8. Slide tabbed washer over shaft and insert nut.

Tighten to a torque of [450 N.m] 332 Ibfft. After tightening, bend one tab of washer downward into shaft keyway and bend at least two tabs upward to lock nut.

9. Position this assembly into recess in lower portion of gearcase, making sure teeth of gears are in mesh and snap rings are fully seated in snap ring grooves of case.

10. Apply joint sealer Teroson ATMOSIT 158-89 W (or equivalent) on mating surfaces of lower cover and case. Put lower cover in position on case and make sure snap rings seat in grooves of this lower cover. Insert fasteners and tigl-‘en smaller [12 mm] capscrews to a torque of [l>?

N.m] 88 Ibf.ft and tighten larger [16 mm] capscrews to a torque of [295 N.m] 217 Ibf.ft.

FREEPLAY MEASUREMENT PROCEDURE 1. Put indicator tool on wheel flange of axle and tighten fasteners. Use a dial indicator, positioned at right angles to centerline of indicator mark, to measure free movement of gears (gear backlash).

2. Measure backlash by moving output shaft without movement of input shaft.

Measure movement in each direction (forward rotation and backward rotation).

3. Remove and index indicator tool on wheel studs at least three times to get a minimum of three different measurements (to allow for gear variations).

4. If averages of readings for gear freeplay movement exceeds [ 0,25 mm] 0.010 inches, it indicates excessive freeplay and output shaft gears must be moved together by replacing shim with next thinner shim. Shims are [0,30 mm] 0.012 in., [0,35 mm] 0.014 in., [0,040 mm] 0.016 in., [0,45 mm] 0.018 in., [0,50 mm] 0.020 in., and [9,55 mm] 0.022 in. thick. If backlash is less than [ 0,20 mm] 0.008 in., it indicates insufficient freeplay and shim must be replaced with next larger shim

SM538 20 - 01 - 4

5. Remove lower cover and remove axle shaft assembly. Disassemble parts and replace spacer with correct spacer.

6. Replace all parts following same procedure.

After assembly, again check for correct freeplay tolerance.

TOOTH CONTACT CHECK If bevel gear set has been replaced, use following method of checking gear tooth contact wear and (Not correction to achieve full tooth contact. necessary if gear set has not been replaced).

1. Apply a thin layer of gear marking compound to both sides of bevel gear teeth.

2. Install axle shaft assembly and lower cover as noted above.

3. Rotate axle shaft one revolution in each direction.

4. Remove lower cover and examine gear teeth for distribution of marking compound and compare pattern to that shown at rear of this section.

5. If necessary to correct gear contact pattern, disassemble necessary parts and apply correct parts which will move gears as shown in sketches.

UPPER GEARCASE ASSEMBLY 1. Put a new gasket on top surface of case. Coat surfaces with Hylomar SQ32M (or equivalent).

Put top cover in position on upper surface of case. Be sure bleeder valve is in correct position on top cover.

2. Insert case fasteners and tighten them to a torque of [49 N.m] 36 Ibfft.

5. Put upper ring gear on top cover and insert fasteners attaching it to top cover.

Tighten fasteners to a torque of [35 N.m] 26 Ibf.ft.

6. Make sure assembly is free to turn by rotating gear on pinion shaft. Insert upper case and lower case drain plugs and tighten them. Make sure breather relief plug is inserted correctly in undersurface of upper portion of gear case. Fill lower section of gear case with correct fluid to fill point level. Insert fill plug in lower case and insert breather in upper case.

This completes assembly of case.

20-07 DRIVE UNIT INSTALLATION 1. Position drive motor into approximate area and support it above gear case opening on two flat bars placed across floorboard.

NOTE: Be sure to leave sufficient room to install gearcase attaching fasteners.

y

1

..A

3. Put upper trunnion ball bearing assembly on top cover. Make sure grease fitting is in position on side of bearing assembly and is pointing upward.

4. Put bearing cap in place to lock bearing assembly between cap and top cover. Insert fasteners and tighten to a torque of [49 N.m] 36 Ibf.ft.

2. Raise truck and move gearcase into position Align holes in gearcase with under truck. mounting holes in truck using a drift or sections of small rods to assist. Install all three fasteners and tighten to a torque of [ 70-80 N.m] 52-59 Ibfft.

3. Raise motor and remove bars, then lower motor onto drive unit and install six (6) motor Tighten fasteners to a mounting fasteners. torque of [20-25 N.m] 117-221 Ibf.in.

4. Install steering stop and spacer in frame and tighten fastener to a torque of 120-25 N.m] 177221 Ibf.in.

5. Install brake cable mounting bracket on end frame of motor. Tighten fasteners to a torque of [19-22 N.m] 170-191 Ibf.in.

6. Attach power cables to motor. Make sure connections are on correct terminals.

SM538 20 - 01 - 5

7. InstaIl brake cable in bracket by inserting small section of cable in the slot, then moving the larger section into place and finally tightening retaining nut.

8. Install clevis pin thru cable end and insert a new cotter pin and spread legs to lock it in place.

9. Install lower sump tank retaining bracket.

10. Install two wire leads on brake switch.

11. Install drive wheel assembly. Tighten seven (7) wheel mounting nuts to a torque of [447-610 N.m] 30-450 Ibf.ft.

12. Install rear door on frame.

13. Install and connect battery.

14. Remove all blocking from truck. (Refer to GROUP 38, MACHINE JACKING AND BLOCKING).

V9374

GEAR CASE LOCK TOOL

V9375 SPBTH TOOL

SM538 20’- 01 - 6

SPIRAL

BEVEL AND

HYPOID

TOOTH

BEARING

CONTACT

CHART

MOVE PINION TOWARD GEAR IN THIS DlRECTlON MOVE

PINION

GEAR IN THIS

AWAY

FROM

DIRECTION

GEAR

V

MOVE GEAR AWAY PINION IN THIS

FROM

MOVE GEAR TOWARD

DIRECTION

PINION IN THIS

DlRECTlON

A

L

LARGE

END

-

ALL CONTACT

BEARINGS

RING

THE

GEAR -

SHOWN

BELOW

DRIVE IS ON THE

FIG. TYPICAL

ARE ON

CONVEX

RIGHT

SPIRAL

1

PREFERRED BEARING ON BOTH SIDES WHILE UNDER A LIGHT LOAD

FIG.

HAND

SIDE OF THE TOOTH.

OF TOOTH

2

TOE BEARING ON BOTH SIDES OF TOOTH - GEAR SET NOISY. TO MOVE BEARING TOWARD HEEL INCREASE BACKLASH WITHIN LIMITS BY MOVING GEAR AWAY FROM PINION.

FIG.

HEEL BEARING COULD RESULT TOE DECREASE PINION.

3

ON BOTH SIDES OF TOOTH -GEARSET NOISY AND IN EARLY GEAR FAILURE. TO MOVE BEARING TOWARD BACKLASH WITHIN LIMITS BY MOVING GEAR TOWARD

FIG.

4

LOW BEARING ON GEAR AND HIGH BEARING ON PINION. CORRECT

BY PULLING PINION AWAY FROM GEAR (INCREASE MOUNTING DISTANCE.

FIG.

5

HIGH BEARING ON GEAR AND LOW BEARING ON PINION. CORRECT

BY MOVING PINION IN TOWARD GEAR (DECREASE MOUNTING DISTANCE. BACKLASH BACKLASH SHOULD LAR TO THE TOOTH

BE MEASURED WITH A DIAL INDICATOR SURFACE AT THE EXTREME HEEL.

SM538

RIGIDLY

20 - 01 - 7

MOUNTED

WITH

THE STEM

PERPENDICU-

SPIRAL

BEVEL AND

HYPOID

TOOTH

BEARING

CONTACT

CHART

MOVE PINION TOWARD GEAR IN THIS PIRECTION MOVE

PINION

GEAR IN THIS

V LARGE END

ALL RING

CONTACT GEAR -

BEARINGS THE

SHOWN

DRIVE IS ON TtlE

FIG. TYPICAL

BELOW

MOVE GEAR AWAY PINION

ARE

CONVEX

IN THIS

ON

LEFT

FIG.

PINION IN THIS

HAND

DIRECTION

A

SPIRAL

TOOTH.

1

“*\

OF TOOTH

‘_

c

2

TOE BEARING ON BOTH SIDES OF TOOTH - GEAR SET NOISY. BEARING TOWARD HEEL INCREASE BACKLASH WITHIN LIMITS ING GEAR AWAY FROM PINION.

HEEL BEARING COULD RESULT TOE DECREASE PINION.

FROM

MOVE GEAR TOWARD

DIRECTION

SIDE OF THE

PREFERRED BEARING ON BOTH SIDES WHILE UNDER A LIGHT LOAD

FIG.

FROM

AWAY

DIRECTION

TO MOVE

BY MOV-

3

ON BOTH SIDES OF TOOTH - GEARSET NOISY AND IN EARLY GEAR FAILURE. TO MOVE BEARING TOWARD BACKLASH WITHIN LIMITS BY MOVING GEAR TOWARD

FIG.

4

F

LOW BEARING ON GEAR AND HIGH BEARING ON PINION. CORRECT

BY PULLING PINION AWAY FROM GEAR (INCREASE MOUNTING DISTANCE.

FIG.

5

HIGH BEARING ON GEAR AND LOW BEARING ON PINION. CORRECT

BY MOVING PINION IN TOWARD GEAR (DECREASE MOUNTING DISTANCE.

‘,\,

BACKLASH BACKLASH SHOULD LAR TO THE TOOTH

BE MEASURED WITH A DIAL INDICATOR SURFACE AT THE EXTREME HEEL.

SM538

20 - 01 - 8

RIGIDLY

MOUNTED

WITH

THE STEM

PERPENDICU-

GROUP

22 WHEELS TIRES

AND 2. Remove the lug nuts from the wheel.

CONTENTS

NO.

DRIVE TIRE SPECIFICATIONS DRIVE TIRE REPLACEMENT

22-01 22-02

a.

22-01 DRIVE TIRE SPECIFICATIONS NOTICE The drive tire specified for the NP/NS 300C Series fork lift trucks was chosen after extensive testing as the best combination of tread and shape design and material compounding, including hardness, to provide the required wear and handling characteristics.

Std Cushion Drive Tire Size: Caster wheel size (dual) : Front Wheel Size NS 300 30: Front Wheel Size all others:

13.5 x 5.5 7 x 2.5 4 X 2.62 Poly.

5 x 2.62 Poly.

IMPORTANT The use? is advised that replacement of the original equipment tires with tires other than those recommended by CLARK may result in decreased operating performance and stability.

22-02 DRIVE REPLACEMENT

1. Remove the tire and wheel assembly from the drive axle hub.

2. Remove objects (nails, metal fragments, etc.) embedded in the tread of the tire. Be careful not to further damage the tire when removing these objects.

3. Check the tire for separation from the base band. If a thin steel rule or similar tool can be inserted more than [12 mm] .5 inch into the separation area from the side of the tire, the tire should be replaced.

TIRE

SAFETY

NOTE

To perform this service procedure, it is recommended that you first: Park truck on a level surface.

Return all controls to neutral Turn key switch OFF. Apply parking brake.

1. Use a portable jack of correct capacity placed under the frame of the truck to raise the drive wheel off the ground. (Refer to Group 38 Machine Jacking and Blocking for correct method).

4. Check the tire tread. If the tread is worn down to [6 mm] .25 in. or less in height, the tire should be replaced.

5. Check the tire for damage from chunking This is a judgment or heat damage.

SM538 22 - 01 - 1

requirement for replacement. In general, if the damage is greater than [12 mm] 5 in. deep and involves more than [650 mm*] 4 in* , it will usually affect the tire performance and the tire should be replaced.

6. Look for bulges or other evidence of internal damage. Replace all tires that show evidence of internal damage.

SM538 22-01-2

GROUP

23 SECTION BRAKE

01

NO

CONTENT BRAKE BRAKE BRAKE BRAKE BRAKE BRAKE

23-01

23-01 23-02 23-03 23-04 23-05 23-06

DESCRIPTION ADJUSTMENT PROCEDURE REMOVAL DISASSEMBLY ASSEMBLY INSTALLATION

BRAKE

DESCRIPTION

The truck brake is a shoe type brake that is spring applied when operators foot is taken off brake pedal (deadman type).

If pedal height is not correct, loosen jam nuts on cable end at bracket (mounted to truck frame) and adjust pedal height by moving nuts. When height is correct, tighten jam nuts.

Brake is mounted on end of drive motor and is attached to brake pedal by cable.

23-02 BRAKE ADJUSTING PROCEDURE 1. Turn handwheel to full right turn.

2. Disconnect battery from truck.

3. Open motor compartment access door.

4. Check operation of brake and brake pedal.

BRAKE PEDAL AND LINKAGE MUST OPERATE FREELY AND RETURN TO BRAKE APPLIED POSITION WHEN RELEASED. If brake action is not correct, adjust and lubricate brake system. DO NOT oil brake shoes or brake lining.

rMOlOR

BRAKE

6. Brake lever release spring length (on brake bracket mounted to motor) must be [46-51 mm] 1.90-2.00 inches with brake pedal released.

Adjust by turning adjusting nut on threaded shaft.

ON

LQA clG -.-

4 -00 [101,61

5. Check pedal released position height. It should be [lo0 mm] 4 inches measured from top surface of floor board frame to top rear surface of pedal.

SM538 23 - 01 - 1

7. Center cable jam nuts on brake mounting bracket at brake end of cable.

Then adjust cable end position by moving same jam nuts until brake releases with pedal approximately [51 mm] 2.00 inches from pedal stop. Tighten jam nuts.

8. Adjust microswitch by positioning it on its mounting bracket to make switch disconnect when pedal is (25 mm] 1.OOinch from pedal stop.

2. Loosen cable jam juts until will slide out of cable bracket, -end from bracket.

3. Remove hose connections tube assembly to allow sump away from drive motor exposing

small end of cable and remove cable from sump tank tank to be pulled brake parts.

4. Remove cover over brake drum.

5. Remove nut and washer from motor shaft. Lift off brake drum and remove key from shaft keyway.

BRAKE REMOVAL 23-03 1. Remove brake cable cotter pin and clevis pin at cable end connection to brake arm at motor.

6. Remove two wire leads from brake switch.

SM538 23 - 01 - 2

7. Remove brake bracket from motor et-d frame.

8. Remove cotter pin and clevis pin from brake arm. Remove push rod and spring.

9. Remove brake assembly from end frame of motor by removing four (4) capscrews.

Lift off brake assembly.

23-04

BRAKE

DISASSEMBLY

1. Remove fastener from cam assembly and lift off cam assembly.

2. Remove fasteners from actuator arms (cam followers) and remove actuator arms.

3. Remove brake shoe fasteners and lift off brake shoes. Remove spring. Remove drive blocks from shoes.

4. Remove fasteners and lift off cam actuating lever.

23-05

BRAKE

8. Assemble cam arm to cam assembly using washer, lockwasher and hex nut. Tighten to a torque of [5.4-6,8 N.m] 50-60 Ibf.in.

23-06

BRAKE

INSTALLATION

1. Position brake assembly on drive motor. Install four fasteners and tighten to a torque of [19-22 N.m] 170-190 Ibf.in.

2. Make sure key is in keyway of motor shaft. Put brake drum on shaft (making sure shoes are parallel and released) and install flat washer, lock washer and retaining nut. Tighten nut to a torque of 13-5 N.m] 30-40 Ibf.in.

3. Mount bracket on motor end frame with two capscrews.and tighten to a torque of 19-11 N.m] 83-94 Ibf.in.

4. Install switch on bracket and snug fasteners.

Install leads on switch.

5. Install push rod (with adjusting nut installed) and spring on bracket. Install clevis pin in in end of push rod and lock with a new cotter pin. Spread the legs of the cotter pin.

6. Install small section of cable in slot in bracket and the move larger section of cable into position.

Position jam nuts and clevis at center of threaded cable end.

7. Install clevis pin in cable end to connect to brake arm. Install new cotter pin and spread legs of cotter.

8. Install cover over brake assembly and tighten fasteners to a torque of [21-23 N.m] 180-200 Ibf .in.

9. Refer to adjusting procedure for correct brake adjustment.

ASSEMBLY

1. Apply Lubriplate #630 AA or equivalent to sides of four threaded studs.

2. Put cam assembly on post nearest notches on mounting plate.

3. Assemble drive blocks with large end facing center of brake.

4. Assemble actuator arms with sides aligned with shoulders of cam assembly. Assemble washer and hex nut over actuator arms and torque to [3,4-4,4 N.m] 30-40 Ibf.in.

5. Assemble shoe return springs to friction shoe assembly and place over drive blocks. Be sure shoe body is level with actuator arms. Assemble washers and hex nuts over friction shoe assembly and torque to [3,4-4,4 N.m] 30-40 Ibf.in.

6. Assemble washer and locknut over cam and actuator arms and torque to [2,1-2.6 N,m] 18-23 Ibf.in.

7. Test unit for correct assembly by moving actuator arm to assure proper operation of brake.

SM538 23 - 01 - 3

2. Block truck frame at each side. (See GROUP 38 Machine Jacking and Blocking for correct method).

GROUP 25 SECTION 01 CASTER ADJUSTMENT PROCEDURE CONTENTS

NO.

CASTER DESCRIPTION CASTER REMOVAL CASTER SERVICE/ ADJUSTMENT

25-01 25-02 25-03

25-01

CASTER

DESCRIPTION

The truck caster assembly serves to stabilize the rear of the truck opposite the drive assembly and is designed to bear the weight imposed on that portion of the truck as well as accurately follow the movement demanded by the steered wheel.

Correct adjustment is necessary for it to serve this function.

NOTICE The caster wheels specified for the NP/NS 300C Series fork lift trucks were chosen after extensive testing as the best combination of tread and shape design and material compounding, including hardness, to provide the required wear and handling characteristics.

IMPORTANT that advised The user is original the replacement of equipment tires with casters or than those other wheels recommended by CLARK may result in decreased operating performance and stability.

25-02

CASTER SAFETY

REMOVAL

3. Remove four (4) fasteners attaching caster to frame and remove caster.

2503 CASTER ADJUSTMENT

SERVICE/

IMPORTANT CLEAN, REPACK AND ADJUST WHEEL BEARINGS EVERY 1000 OPERATING HOURS OR EVERY 6-MONTHS WHICHEVER COMES FIRST. 1. Use a portable jack of correct capacity placed under the frame of the- truck to raise the drive wheel off the ground.

2. Block truck frame at each side. (See section on Machine Jacking and Blocking).

3. Loosen nuts on adjustment eyebolts (on each side of assembly) until spring tension is completely relieved. Remove nuts, washers spring seats and springs.

4. Pry hubcaps off wheel.

Remove nut and washer and discard nut (This is a self-locking nut and should not be reused). Remove wheel with bearings intact.

NOTE

To perform this service procedure it is recommended that you first: Park truck on a level surface Return control(s) to neutral Turn key switch OFF. 1. Use a portable jack of correct capacity placed under the frame of the truck to raise the drive wheel off the ground.

SM538 25 - 01 - 1

7. Inspect wheels for damage to treads. Replace wheel(s) if badly worn or damaged.

Look for chunking, band separation, flat spots, imbedded material, bulges in surface, or badly worn treads.

8. Repack bearings with lubricant.

Refer to Lubrication Section for correct lubrication and method.

9. Install bearings in wheels and positon wheesl on axles. Install washers and be sure to use selfN.m] locking nuts. Tighten nuts to a torque of [ Ibf.ft.

10. Install springs, spring seats and nuts. Tighten nuts only enough to start loading springs.

5. Remove bearing cones and examine carefully for any evidence of damage.

Inspect bearing cones and look for evidence of wear or damage.

Inspect bearing cups for damage. If no damage to bearing cups, do not remove them. If they must be replaced, use a puller to remove them and replace with new. Be sure to replace same spacer(s) before pressing new cups into position on wheels.

11. Install caster on frame and tighten nuts to a torque of [224-305 N.m] 165225 Ibfft.

12. Lift rear of truck to remove blocking, then lower to floor.

13. Use a rule to check length of collapsed spring.

Spring collapsed length should be [124-127 mm] 4.88 -5.00 in. Adjust nuts to give this dimension and tighten jam nuts to lock.

Replace all defective parts.

-It-

6. Wash all parts in a petroleum-base solvent and DO NOT ‘SPIN’ allow bearings to air dry.

BEARINGS.

14. Check adjustment of stop bolts. Use a section of [6 mm] l/4 in. stock to check by inserting as a gage between end of bolt and stop surface on caster frame.

If not to this dimension (gap) loosen jam nut and adjust. bolt to correct setting, then tighten jam nut.

Be sure to check all four (4) jstop bolts.

SM538 25 -01 - 2

GROUP 26 SECTION 01 STEERING SYSTEM CONTENTS

NO.

POWER STEERING SYSTEM TORQUE GENERATOR REMOVAL SHAFT/GEAR REMOVAL TORQUE GENERATOR DISASSEMBLY TORQUE GENERATOR INSPECTION TORQUE GENERATOR IASSEMBLY SHAFT/GEAR INSTALLATION TORQUE GENERATOR INSTALLATION

26-01 26-02 26-03 26-04 26-05 26-06 26-07 26-08

26-01 POWER SYSTEM

TORQUE 26-02 RE,MOVAL.

GENERATOR

1. Disconnect battery.

2. Apply parking brake.

STEERING

All NP/NS 300C trucks are equipped with a hydrostatic power steering system.

Full-time power steering is provided by oil pressure from a separate electric motor and hydraulic pump. Oil for the power steering system is drawn from the main hydraulic sump and circulated back to the sump through the return-line filter.

The steering handwheel is directly mounted on a steering valve or torque generator This multiplies the steer effort applied by the handwheel and gives a mechanical advantage to actuate the steering system.

3. Remove the top cover by removing the three fasteners at the forward edge of cover, one fastener below control handle and one fastener mounted near sump tank.

By turning the handwheel, a valve is actuated in the torque generator that applies hydraulic power to the geroter assembly in the torque generator and produces the torque multiplication at the output of the torque generator.

When the handwheel is not turned, a selfcentering spool in the torque generator allows the hydraulic oil to flow thru the assembly to sump and no power is applied.

An additional mechanical advantage is the gear set mounted on the top of drive unit. The output of the torque generator is connected to the spur gear of this set by a universal joint shaft.

The steering system relief pressure is controlled by the pressure relief valve in the power steering pump. This valve is set at a fixed relief pressure value of 18274-8963 kPa] 1200-1300 psi.

To remove top cover, remove lower fastener from LH DOG leg, loosen upper fastener and swing leg out from center of machine. This will permit cover to be pulled rearward, clearing control handle and steer handle.

Disconnect two quick-disconnect fasteners from wire harness. Lift off cover and store in a safe place.

SM538 26 - 01 - 1

4. Remove and cap hydraulic lines into and out of torque generator and cap ends.

5. Remove capscrew generator.

locking handwheel

to torque

6. Remove three capscrews attaching torque generator to bracket. Loosen, but do not remove, setscrew in universal coupling locking key in keyway.

2. Remove cotter pin and nut from bottom end of gear shaft.

Remove gear and key from tapered end of shaft.

Make sure cut-out in drive is positioned to allow pinion gear and shaft to be removed.

3. Remove snap ring locking bottom bearing in base of truck.

4. Use a soft-faced hammer to drive gear shaft upward through bore. Remove shaft and bearing assembly.

5. Check bearings for evidence of damage by rotating bearings and checking for evidence of siezure, gritty sound or feel, excessive looseness or play, corrosion or rust, or seai damage. Replace with new if any damage is found.

Remove and discard faulty bearings using a puller

26-04 TORQUE DISASSEMBLY.

GENERATOR

1. Remove four (4) bolts securing to spool housing.

control end cap

Lift torque generator off shaft end.

Be careful when lifting unit out of shaft and watch for key.

26-03 SHAFT/GEAR REMOVAL 1. Unloosen but do not remove setscrew

at bottom end of universal shaft (locking key to final drive shaf)t.

Remove universal shaft and key.

Remove any snaprings (used as spacers) on shaft.

(2. Separate control end cap from spool housing.

3. Remove two (2) seals and seal back-up ring.

SM538

26 - 01 - 2

4. Remove seven bolts securing spool housing.

drive end cap to

7. Remove sleeve pin and separate control sleeve from spool.

TORQUE GENERATOR 26-05 INSPECTION 1. Wash all parts and dry thoroughly. Do not use material that leaves lint when drying parts. If parts must be left for a long period or overnight, cover them with a clean cover.

2. Replace all seals.

3. Carefully inspect all mating parts and shafts for nicks, burring, scoring or other damage. Replace if necessary.

4. Dip all parts in clean hydraulic fluid.

5. Separate drive end spool from housing to expose (1) output shaft with seal and seal back-up ring, (2) one control end coupling shaft, (3) two wear plates, (4) gerotor, and (5) gerotor ring.

TORQUE 26-06 ASSEMBLY

GENERATOR

1. Install control sleeve in spool and insert pin.

2. Insert spool assembly

into control end.

3. Install gerotor ring, gerotor, wear plates (2) control end coupling shaft, and output shaft with seal and seal back-up ring into spool housing.

4. Mount drive end cap and tighten seven (7) bolts attaching end cap to housing.

5. Install two (2) seals and back-up ring on shaft.

6. Install fasteners.

control

end cap and tighten

four

(4)

SHAFT/GEAR 26-07 INSTALLATION 6. Remove control spool assembly.

end coupling

shaft and entire

1.

If shaft bearings bearings on shaft.

were

removed,

replace

Slide lower bearing on shaft over straight shaft end and press into place against shoulder near taper end of shaft.

Make sure bearing seal is facing taper end. Use a tool that bears against inner race of bearing when pressing on bearing.

2. Install snapring in groove on upper bearing shaft segment. Position bearing over straight end of shaft with seal facing toward straight end. Press upper bearing into place against snapring.

3. Insert bearings and shaft assembly into bore in base of truck (taper end first) and press down until

SM538

26 - 01 - 3

snapring can be installed on bearing diameter from bottom of frame.

outer

Use soft-faced hammer to tap shaft assembly upward until snapring seats firmly against frame bore.

then move into position tighten all fasteners.

Install and

5. Install lower fastener on DOG leg and tighten both fasteners to a torque of [21-23 N.m]180-200 Ibf.in.

4. Install snapring on outer diameter of upper bearing, locking it in place in frame.

5. Put key in tapered end of shaft. Install gear on end of shaft. Install nut and tighten to a torque of [70-98 N.m] 52-72 Ibf.ft. Insert cotter pin to lock and spread cotter pin legs.

6. Put key in straight end of shaft and position universal shaft in place but do not tighten setscrew yet.

26-08 TORQUE INSTALLATION

on truck.

GENERATOR

1. Position torque generator on universal joint shaft making sure keyway is in place on output shaft.

With torque generator firmly against mounting surface, check endplay in universal shaft. Remove torque generator and universal shaft from lower gear shaft. Use snaprings of proper size placed on lower gear shaft to reduce end play. Continue adding snaprings until torque generator is just lifted off mounting plate.

Then remove one snapring, install universal joint and torque generator.

Tighten setscrews on universal joint to a torque of 134-38 N.m] 25-28 Ibf.ft.

2. Insert fasteners attaching torque generator to bracket. Tighten to a torque of [19-22 N.m] 170190 Ibf.in.

3. Mount steering handwheel on input shaft and insert fastener attaching wheel.

Tighten to a torque of [21-23 N.m] 180-200 Ibf.in.

NOTE: Position handwheel so that when drive wheel is pointing forward, the handwheel knob is between the 6:00 and 8:00 position.

4. Install hydraulic lines on torque generator.

5. Position cover on truck and connect two quickdisconnect wire harness fasteners. Thread cover over steering wheel and over control handle and

SM538 26-01 -4

GROUP 26 SECTION 02 POWER STEERING PUMP CONTENTS

NO.

GENERAL DESCRIPTION RELIEF PRESSURE CHECK PUMP TROUBLESHOOTING PUMP REMOVAL PUMP DISASSEMBLY PUMP ASSEMBLY PUMP INSTALLATION

26-01 26-02 26-03 26-04 26-05 26-06 26-07

26-01

GENERAL

DESCRIPTION

The power steering pump is a dual (or duplex) pump. Power steer section is mounted on motor mounted on and auxiliary (aux) pump (behind).power steer pump.

Both pumps are fixed-displacement, highperformance type gear pumps.

The steering system relief pressure is controlled by pressure relief valve in power steering pump. This valve is set at a fixed relief pressure value of [8274-8963 kPa] 1200-1300 psi. The aux pump does not have a reliefvalve but aux system has a relief valve in main valve.

26-02

RELIEF

PRESSURE

CHECK

The following procedure may be used to check steering pump relief pressure setting only.

No field service adjustment of pressure can be made.

This procedure requires installation of a pressure gauge in pump outlet line from pump to steering control valve, and pressure measured while steering handwheel is turned fully in one direction to put steering system in bypass. If relief pressure is not correct, it may be from dirt in valve or worn pans, including steering control valve and power steering pump.

Refer to respective overhaul sections.

SAFETY NOTE To perform this service procedure, it is recommended that you first: Park truck on a level surface and fully lower upright.

Return all controls to neutral, apply parking brake, and turn key switch OFF.

Relief

Pressure

Setting

Check

Steering system relief pressure setting may be checked using a MICO QUADRIGAGE (CLARK Part No. 1800106) or with a conventional pressure

SM538

gauge [0 -20,700 kPa] 0 - 3000 psi. The power steering system pressure can be checked by inserting a diagnostic port fitting at inlet to steering torque generator and connecting quadrigage or pressure gauge to this fitting.

Reinstall steering pump line. Install diagnostic check port with quickdisconnect adapter fitting (Clark Part No. 3798166) in tee fitting.

Connect pressure gauge to check port fitting. NOTE - Use quick-disconnect adapter fitting, Clark Part No. 3797029.

Turn key switch ON. Release brake. Steering pump should begin operating.

Turn steering handwheel in one direction until steering cylinder reaches its stop (relief position).

Hold steering handwheel in relief position until pressure reading is taken, and then release.

IMPORTANT - Do not operate system over relief any longer than required to read pressure gauge.

When relief pressure reading has been obtained, turn key switch OFF. Disconnect pressure gauge, remove temporary tee fittings, and reinstall steering pump line as initially installed. Be sure to correctly tighten all fittings.

26-03

PUMP

TROUBLESHOOTING

Before dual pump is removed and/or disassembled, check following list of problems and solutions. It could save cost, time and effort.

1. Noisy Pump. a) Low supply of oil.

Fill reservoir. b) Oil too heavy.

Change to correct viscosity. c) Inlet line has restriction.

Check for foreign material.

Clean filter or strainer. d) Air leak in inlet line.

Check plumbing tightness.

2. Foaming Oil. a) Cavitating pump.

See la,b,c, and d b) Wrong fluid.

Drain and fill with correct oil.

3. Heated Pump and/or Oil. a) Thin oil Drain/fill with correct oil. b) Contaminated oil.

Drain/clean filter/fill. c) Cavitating pump.

See 1 a, b, c, d d) Drive shaft not aligned.

Check mounting/alignment.

26 - 02 - 1

e) Axial loading on drive shaft.

Check shaft end clearance.

Check shaft alignment.

Check for worn key/spline. f) Relief valve usually in bypass.

Check relief setting.

4. Low Pump Output. a) Cavitating pump.

Seela,b,c,d b) Air in fluid.

See 2b. c) Relief valve leakage or set to low.

Check relief valve. d) Overheated oil.

Check oil temperature.

5. Shaft Seal Leakage. a) Damaged or worn seal.

Replace seal. b) Front cover bearing out of position.

Replace front cover assembly. c) Scratches on shaft seal housing bore.

See 5b. d) Improper fit of shaft.

See 5b.

6. External Leakage. a) O-ring damaged.

Replace O-ring. b) Damaged surfaces in O-ring groove.

Replace damaged part.

7. Failure to Build Pressure. a) Defective relief valve.

Repair and reset valve. b) Low oil supply.

Fill reservoir.

3. To remove top cover, remove lower fastener from LH DOG leg, loosen upper fastener and swing leg outward from center of machine. This will permit cover to be pulled rearward, clearing control handle and steer handle.

Disconnect two quickdisconnect plugs from wire harness. Lift off cover and store in a safe place. ,.,-..

‘.\.

l_

‘.x.,. ’ x.

I_

‘N

‘%,. ’ ...., “I. ... ,-I,,,/ ,./

, ,.I’-

26-04 PUMP REMOVAL 1. Disconnect battery.

4. Remove hose clamp on inlet line to pump, cap and move to one side. Remove outlet hose from pump to steering torque generator and cap line.

Remove hose from pump to check and dump valve and cap line.

5. Disconnect power leads to motor and replace terminal nuts on motor.

2. Remove the top cover by removing the three fasteners at the forward edge of cover, one fastener below control handle and one fastener mounted near sump tank.

SM538

26 - 02 - 2

6. Remove four (4) fasteners attaching motor to frame and lift out pump and motor assembly. Also remove filter mounting bracket and four (4) cushions under motor mount.

26-05

PUMP

further disassembly.

Otherwise proceed with I following disassembly.

6. Use a sharp scribe or marker to scribe a line or punch marks into adaptor, housing and cover to assure correct positioning of parts at assembly.

7. Clamp pump in a vise with shaft end pointing down. Use only a light clamping force by vise to avoid damaging pump.

8.

Remove eight (8) fasteners holding pump assembly together.

DISASSEMBLY

1. Before disassembling pump, be sure working area is clean. Clean exterior of pump and motor assembly.

Be sure to plug openings before brushing to avoid contaminating internal parts.

NOTE: Do not disassemble pump if still within warranty period of manufacturer or warranty will be voided.

2. Put an identification mark on pump and on motor to assure that pump will be reinstalled in same location on motor as when removed (ports and terminals will be in proper position).

3.

Remove four fasteners attaching pump to motor.

9. Carefully separate pump assembly by lifting pump cover off assembly.

It may be necessary to use a soft faced hammer to tap lightly on cover and assist separation of parts. Roller bearings will come off with cover. Do not rotate parts in an attempt to separate them for there is an alignment dowel in mating face. As parts are removed from assembly, carefully note position of each to be sure of correct reassembly.

10. Remove housing assembly from adaptor. Use care as parts are removed to keep gear sets separated.

11. Remove snap rings retaining gears on shafts.

Note that snap rings are different. Make sure snap rings are correctly located at assembly.

Remove keys and pin from shafts. Discard all gaskets.

12.

Remove seal from adaptor housing and discard.

13. Remove cap and gasket from relief valve.

14.

Remove adjusting screw. spring and ball assembly and small spring.

15. Removal of bearings is not normally useful; factory rebuilt pump replacement is recommended by manufacturer when these items must be replaced.

26-05 4. Carefully separate pump and motor. Remove coupling and discard gasket. Put motor in a safe place.

5. If only repair is to replace oil seal, seal may now be pried out, discarded, and replaced without

SM538

PUMP

INSPECTION

1. Wash all parts and dry thoroughly.

Do not use material that leaves lint when drying parts. If parts must be left for a long period or overnight, cover them with a clean cover.

26 - 02 - 3

2, Examine surfaces of cover, housing and adaptor where gears may wear. If any uneven or unusual wear is evident or if it is scratched, galled or eroded,lt should be replaced, A heavy wear pattern Is normal for low pressure (inlet) side of wear surface.

But there should be no heavy scoring visible. Deep scratches or pits will destroy pump efficiency.

3, Inspect bearings in both body and cover.

Replace assembly if bearings show any evidence of damage, 6, Carefully inspect gears and shafts (journals) for damage.

Worn or damaged teeth will greatly reduce performance of pump and should be replaced if any undue wear or damage is found.

The journals should be bright and free from any scoring. If any bearing or journal surfaces have eroded areas or deep scratches, they should be replaced with new parts.

6. Examine all port threads to be sure they have not been damaged and will form good seals.

9, Inspect relief valve parts to be sure they are not damaged or corroded. Make sure ball surface is not damaged. Replace all damaged parts.

26=06

PUMP ASSEMBLY

1. Install small spring in ball and spring assembly and insert in relief valve. Screw adjustment screw in place and use a new gasket under relief valve cap, 2, Install new seal in adaptor, Make sure it is fully seated.

Coat lips of seal with Lubriplate, or equivalent lubricant, 3. Choose gears for adaptor section. Install key, drlve gear and retainers on drive shaft. Install gear on driven shaft and install retaining rings. insert drive gear shaft into adaptor using slight rotary motion as shaft passes seal area to avoid damage to seal, Insert drive shaft assembly into bearing of adaptor, 4, Install new gasket and slide housing in place, Make sure dowels are aligned and that small pin is in place on driven shaft. Make sure match marks are aligned.

5. Install key in drive shaft and slide drive gear into place on shaft and into housing. Slide driven gear over driven shaft and into housing. Install a new gasket and put cover on assembly making sure match marks are aligned.

6, Insert fasteners attaching pump together and tighten finger tight. Rotate input shaft to make Tighten sure there is no binding of parts. fasteners alternately to a partial torque and again rotate shaft to be sure of no binding of parts.

Complete tightening to a torque of [13-14 N.m] 9.5105 Ibf,ft.

7, Position coupling on drive shaft and tighten

RELIEF VALVE ADJUSTMENT After overhaul and reassembly, relief valve pressure setting may be checked and adjusted either when pump is installed in truck or with pump mounted on a test stand. For bench test, inlet and outlet lines to pump should be conectly installed and the specified hydraulic fluid supplied, Connect a control valve to simulate steering cylinder in stopped (relief) position, a) Connect pressure test gauge in pump outlet line. b) Operate pump at 2500 rpm speed and allow test system to build up pressure.

1. Remove protective cap which covers relief valve adjusting screw.

2. Adjust relief valve pressure using a screwdriver to rotate adjusting screw to change setting.

3, Rotate CLOCKWISE to INCREASE pressure.

Turn COUNTERCLOCKWISE to REDUCE pressure.

4. The relief valve setting is correct when pressure is 18618 kPal 1260 osi and relief valve is operatina.

5, * Install protective plug and seal over screw anb tighten.

6. Recheck pressure setting.

Readjust, as necessary. DO NOT EXCEED THE SPECIFIED RELIEF PRESSURE SETTING. When correct, remove pressure gauge.

26-07

PUMP INSTALLATZON

1. Mount pump to pump motci r:.r;ki;_;: sure pu;r+ is mounted in same exact position as when removed. Tighten four fasteners to a torque of [21-23 N-m] 180-200 Ibf-in.

2. Position pump and motor assembly in place making sure oil filter bracket is in place and four (4) cushions are in place under mounting flange of motor. Install and tighten fasteners to a torque of [21-23 N-m] 180-200 Ibf.in.

3. Install hydraulic lines on pump making sure Oring seals are properly positioned.

4. Position cover on truck and connect two quickdisconnect wire harness plugs. Operate pump and check fittings for oil leaks. Thread cover over steering wheel and over control handle and then move Into position on truck. Install and tighten all fasteners.

5, Install lower fastener on DQG leg and tighten both fasteners to a torque of [21-23 N-m] 180-200 Ibf.in.

6. Connect battery. Start truck and note if pump is running properly and not making any unusual noise. Rotate steering handwheel and note if there are any unusual noises from pump. Examine hydraulic line fittings for leaks.

5. Install top cover.

SM538 26 - 02 - 4

GROUP 29 SECTION 01 HYDRAULIC LIFT PUMP PUMP PUMP PUMP PUMP PUMP PUMP PUMP

OVERVIEW MAINTENANCE REMOVAL DISASSEMBLY INSPECTION ASSEMBLY INSTALLATION

29-01

PUMP

The hydraulic performance compensated

29-02

29-01 29-02 29-03 29-04 29-05 29-06 29-07

OVERVIEW

pump is a fixed displacement high design pump.

It is a pressure gear type design.

PUMP

MAINTENANCE

Before lift pump is removed and/or disassembled, check following list of problems and solutions. It could save time, work and cost.

1. Noisy Pump. a). Low supply of oil.

Fill reservoir. b). Oil too heavy.

Change to correct viscosity. c). inlet line has restriction.

Check for foreign material.

Clean fifter or strainer. d). Air leak in inlet line.

Check plumbing tightness.

2. Foaming Oil. a). Cavitating pump.

See l.a,l.b,l.c, and 1.d b). Wrong fluid.

Drain/fill with correct oil.

3. Heated Pump and/or Oil. a). Thin oil Drain/fill with correct oil. b). Contaminated oil.

Drain/clean filter/fill. c). Cavitating pump.

See l.a, l.b, l.c, 1.d d). Drive shaft not aligned.

Check mounting/alignment. e). Axial loading on drive shaft.

Check shaft end clearance.

Check shaft alignment.

Check for worn key/spline. f). Relief valve usually in bypass.

Check relief setting.

4. Low Pump Output. a). Cavitating pump.

See l.a, l.b, l.c, 1.d b). Air in fluid.

See 2.b. c). Relief valve leakage or set to low.

Check relief valve. d). Overheated oil.

Check oil temperature.

5. Shaft Seal Leakage. a). Damaged or worn seal.

Replace seal. b). Front cover bearing out of position.

Replace front cover assembly. c). Scratches on shaft seal housing bore.

See 5.b. d). Improper fit of shaft.

See 5.b.

6. External Leakage. a). O-ring damaged.

Replace O-ring. b). Damaged surfaces in O-ring groove.

Replace damaged part.

7. Failure to Build Pressure. a). Defective relief valve.

Repair and reset valve. b). Low oil supply.

Fill reservoir.

16-03

LIFT

1. Disconnect

PUMP

REMOVAL

battery.

2. Remove top cover by removing three fasteners at forward edge of cover, one fastener below control handle and one fastener mounted near sump tank.

SM 538 29 - 01 - 1

3. To remove top cover, remove lower fastener from LH DOG leg, loosen upper fastener and swing leg outward from center of machine. This will permit cover to be pulled rearward, clearing control handle and steer handle. Disconnect two quickdisconnect plugs from wire harness. Lift off cover and store in a safe place.

4. Remove hose clamp on inlet line to pump, cap end, and pull free. Remove line to check and dump valve, cap end and push to one side.

5. Remove power leads to motor. Put nuts and washers back on motor for safe keeping.

6. Remove four (4) fasteners mounting pump and motor assembly to frame. (Access to screws is also from battery compartment).

7. Remove bolt, holding check and dump valve (to give room for removing pump and motor assembly).

8. Remove power leads from motor.

9. Lift pump and motor from truck and place on work bench.

SM538 29-01 -2

4.

Remove

pump from vise and tap shaft with a hammer to separate

wooden block or soft-faced pump halves.

10. Remove fasteners attaching pump to motor and remove pump. Make sure to note how pump is mounted to motor with respect to inlet and outlet ports.

29-04

PUMP

DISASSEMBLY

5. Remove rear cover. The dowel pins may remain with either section.

Keep parts in order as removed to assure correct positioning at assembly.

6. Remove thrust plates.

1. Before disassembling pump, be sure working area is clean. Overhaul pump only in a clean, dustfree location, using clean tools and equipment.

Dirt or grit will damage highly-machined surfaces and will result in leakage or premature failure of pump. Clean exterior of pump using a wire brush if necessary to remove accumulations.

Be sure to plug openings before brushing to avoid contaminating internal parts.

2. Use a sharp scribe or marker to scribe a line or put punch marks into body halves to assure correct positioning of parts at assembly.

7. Remove gears. Note location of match marks on ends of shafts and their location with respect to pump cover.

3. Carefully clamp pump in a vise (with shaft down) and remove external fasteners.

SM 538 29 - 01 - 3

3. A heavy wear pattern is normal for low pressure (inlet) side of wear plate. But there should be no heavy scoring visible.

8

0 8. Remove wear plate. plate and discard seal.

Remove

8

seal from wear

4. Remove and discard pressure loading seal from wear plate.

9. Remove gasket seal and lift out thrust plate from rear cover.

10. Invert pump body so shaft seal is up. Remove and discard the shaft seal using a screwdriver to pry it out. Be careful not to damage seal bore in cover when prying seal out.

29-05

PUMP

PARTS

INSPECTION

1. Wash all parts with clean solvent and dry thoroughly.

Do not use wiping cloth material that leaves lint when drying parts. If parts must be left for a long period or overnight, cover with a clean cover.

2. Examine wear and thrust plates. If any uneven or unusual wear is evident or if they are scratched or eroded, they should be replaced.

Install a new seal in the groove making sure smooth surface is out. The seal should extend a minimum of [0,12 mm] 005 in. beyond surface of wear plate. Do not push seal below surface of wear plate at any point.

5. Inspect bushings in both body and cover.

Replace assembly if bushings show any evidence of damage.

6. Carefully inspect gears and shafts (journals) for damage.

Worn or damaged teeth will greatly reduce performance of pump and should be replaced if any undue wear or damage is found.

The journals should be bright and free from any scoring.

If any bearing or journal surfaces have eroded areas or deep scratches, they should be replaced with new parts.

7. Inspect body and cover for wear and scoring. If gear contact surface on low pressure (inlet) side exceeds [0,012 mm] .0005 in. wear depth, replace the body assembly.

If body is usable, remove any burrs with a suitable burring tool.

SM 538 29 - 01 - 4

8. Examine threads in all ports to be sure they have not been damaged and will form good seals.

29-06

PUMP

ASSEMBLY

Put wear plate in bottom of bores making sure the pressure loading seal is positioned properly in seal grooves and installed against bottom of bore surface.

1. Put pump body on a flat surface with shaft seal up. Install new seal by pressing inward on seal until it is 16 mm1 l/4 in. below face of pilot. Pack area between double lips of seal with Lubriplate, or equivalent lubricant.

2. Turn body over, putting pump gear bores up.

NOTE - 180 o rotation of pressure plate will change pump rotation (CCW to CW).

Humps of “w” should face outlet side of pump.

IF PRESSURE PLATE IS INSTALLED IMPROPERLY, IT WILL CAUSE SEAL TO BE BLOWN. 3. Lubricate bushings in body and face of wear plate with SAE 10 oil.

4. Apply Lubriplate or equivalent lubricant to outer surface of drive shaft installation sleeve. Insert sleeve into shaft seal from front of pump until sleeve contacts drive gear bushing. Install drive gear with long journal toward front of pump.

Matchmarks on ends of drive and driven shafts must face rear of pump.

5. Lubricate rear gear faces and journals with SAE 10 oil and install thrust plate in its original position.

6. Apply a small amount of grease to rear cover seal groove and install new gasket seal into groove on cover.

7. Lubricate rear cover bushings with SAE 10 oil and install rear cover. Make sure match marks are in correct position.

8. To assure assembly, it may be necessary to put pump in an arbor press (shaft end down) and press cover into position. If press is not available, insert fasteners and tighten evenly to a torque of [38-43 N.m] 28-32 Ibf.ft.

9. After tightening, make sure drive shaft turns freely without binding or grabbing.

SM!538 29-01-5

PUMP

TEST

PROCEDURE

1. Install pump in test stand.

2. Run pump for 1 minute at minimum pressure loading.

3. Raise output pressure to [3448 kPa] 500 psi for 5 seconds, then lower to minimum pressure for 5 seconds.

Continue repeating this cycle for 1 minute.

4. Repeat this cycle (Step 3) for 3 minutes but using one-half the input speed as above.

5. Repeat this cycle for 3 minutes using full speed.

6. Repeat step 3, but increase pressure in 13448 kPa] 500 psi increments until maximum operating pressure, or [20658 kPa] 3000 psi is obtained.

Check flow by best method available.

7. With pump running at idle speed (approx. 500 rpm), check for leaks. No shaft seal leakage sufficient to form a droplet of oil is permissable. No external leakage is permissable.

29-07 PUMP INSTALLATION 1. Position pump on motor making sure ports are in correct position. Tighten fasteners to a torque of 32,5-365 N.m] 24-27 Ibf.ft.

2. Put assembly in place on truck and insert and tighten four (4) fasteners to a torque of [20-25 N.m] 177-221 Ibf.in.

3. Attach power leads to motor.

4. Install fastener holding check and dump valve (removed to give room for removing pump and motor assembly) and tighten to a torque of [ll-15 N.m] 8-11 Ibf.ft.

5. Install hose on inlet port and tighten clamp.

6. Install line going to check and dump valve.

7. Position cover on truck and connect two quickdisconnect wire harness plugs. Operate pump to check for oil leaks. Thread cover over steering wheel and over control handle and then move into position on truck. Install and tighten all fasteners.

8. Install lower fastener on DOG leg and tighten both fasteners to a torque of [21-23 N.m]180-200 Ibf.in.

9. Connect battery.

10. Check operation of truck, making trial test for pump in no-load condition, then in by-pass Listen for any unusual noise in condition. hydraulic system.

SM 538 29 - 01 - 6

GROUP 30 SECTION 01 MAIN HYDRAULIC VALVE CONTENTS

NO.

GENERAL DESCRIPTION MAIN VALVE RELIEF PRESSURE CHECK AND ADJUSTMENT MAIN VALVE TESTING MAIN VALVE TROUBLESHOOTING MAIN VALVE REMOVAL MAIN VALVE DISASSEMBLY MAIN VALVE’INSPECTION MAIN VALVE ASSEMBLY MAIN VALVE INSTALLATION

30-01 30-02 30-03 30-04 30-05 30-06 30-07 30-08 30-09

The check valve functions as a load check to prevent flow of oil from cylinder port as spool is moved into a power position.

When inlet oil pressure is in excess of relief valve setting, with open center side of circuit shut off, relief valve plunger is forced off seat, bypassing oil to outlet port. When inlet oil pressure drops to less than relief valve setting, a spring forces plunger back against seat.

VALVE BODY All component parts of valve are available for service replacement except valve body. If valve body contains damaged threads, cracks, or deep score marks in spool bore, valve is not repairable and should be replaced.

VALVE SPOOLS Valve spool may be replaced if there is no damage to valve body.

30-01

GENERAL

DESCRIPTION

The Hydraulic System uses one main control valve to regulate fluid flow to alll hydraulic actuators (cylinders).

Solenoid valves are used to direct flow to selected functions. These solenoid valves are actuated by electrical relays mounted on a panel above main control panel.

The Aux functions are selected by choice of operator handle control (only one choice permitted to be selected at any given time).

The main control valve is a one piece casting cored to contain passages for a full parallel circuit Body ports are tapped ‘with S.A.E. straight thread O-ring connections for leak-proof joints and to prevent possible distortion of body when tightening connections.

Spools are plated for corrosion resistance and contain notches to obtain metering control of load.

Spools are dynamically balanced, radially and axially.

The check valve will prevent back flow from cylinder port to inlet port.

An adjustable relief valve is incorporated in valve to prevent excesssive oil pressure in hydraulic system.

OPERATION A source of oil is supplied to INLET port. With spools in neutral position, flow of oil is through bypass or OPEN CENTER side of parallel circuit. to OUTLET port. When a spool is moved to a power position, open center side of circuit is closed and oil flows through spool check valve to cylinder port.

At same time, other cylinder port is opened to OUTLET port.

SYSTEM The hydraulic system uses a TIME DELAY module in the circuit to prevent residual pressure causing a “jerk” when selecting one of the AUX functions (REACH, TILT, etc.).

When the control handle is returned to neutral, the solenoid is de-energized (after a 0.1 set time delay) which dumps the oil pressure in the line and prevents the surge (due to pressurized oil) which would otherwise occur when one of the AUX functions is selected..

30-02 MAIN VALVE PRESSURE CHECK ADJUSTMENT

RELIEF &

IMPORTANT If adjustment is necessary, do not exceed relief pressure setting specified for truck model capacity rating. Changing pressure will not increase lifting speed.

SAFETY NOTE - To perform this service procedure, it is recommended that you first: Park truck on a level surface and fully lower upright.

Return all controls to neutral and turn key switch OFF.

Relief

Pressure

Setting

Check

Hydraulic system relief pressure setting may be checked using a MICO QUADRIGAGE (Clark Part No. 1800106) or with a conventional pressure gauge [0 to 20,700 kPa] 0 to 3000 psi.

Turn key switch ON.

SM538 30 - 01 - 1

Move tilt control lever to full back-tilt relief position.

Hold tilt lever in relief position until pressure reading is obtained, and then release.

IMPORTANT - Do not operate system over relief any longer than necessary to read pressure gauge.

It ._ Gressure is not correct, adjus:ment procedure.

Relief

Pressure

refer to following

Adjustment

Remove acorn nut from relief valve. Loosen jam nut and hold while backing off adjusting screw until no tension is felt on relief valve.

With pump running at maximum speed, move spool to a power position.

Turn adjusting screw clockwise until correct pressure setting of [20160 kPa] 2000 psi. is obtained.

After correct pressure setting has been obtained, hold screw and tighten jam nut. Install and tighten acorn nut.

Recheck relief pressure setting, to verify that setting has not been inadvertently changed during tightening of lock nut. If relief pressure setting is not correct, repeat adjustment procedure.

30-03

MAIN

VALVE

TESTING

EXTERNAL LEAKAGE TEST Move spool to a power position and hold against relief valve. Check all external port positions and seals for possible leakage.

SPOOL OPERATION Move spool to power position, then release spool.

Spool should immediately move smoothly to neutral position CHECK VALVE LEAKAGE TEST Move spool to power position under load and hold until lift cylinder has reached about one-half its stroke.

Return spool to neutral position, then again move spool to power position. There should be no cylinder drop when this shift is made by spool to again move to power position.

Move spool to neutral position. With cylinder port still under load, stop pump flow to control valve by either turning off test stand pump motor or turning off key switch.

Then carefull move valve spool from neutral position to power position.

Load If load does not should remain stationary. remainstationary, check valve should be repaired.

30-04 MAIN SHOOTING

VALVE

TROUBLE

1. Oil leaks at either end of spool. a). Defective O-ring in valve body.

SM538

Remove cap.

If it contains oil, replace spool seal O-rings. Check O-ring retainer to see if it is flat. If it has been ‘belled’, check for restriction from outlet to tank (T) of valve which would cause excessive back pressure.

2.

Spool does not return to neutral when released. a). Broken spring.

Replace. b). Bent spool.

Return for factory repair or replace spool with new of same size and type. c). Excessive back pressure.

Relieve condition.

Usually is restriction If so remove from outlet to tank. restriction. d). Foreign particles in system.

Purge system and valve with clean oil. e). Misalignment of operating linkage.

Check linkage for binding condition.

3. No motion, slow or jerky action of hydraulic system. a). Defective pump.

Check pressure. b). Defective cylinder.

Repair or replace. c). Load larger than capacity.

Refer to manual for correct maximum rated capacity. d). Relief valve not set properly.

Check pressure setting. e). Relief valve not functioning properly.

Repair and readjust. f). Foreign particles in system.

Purge system with clean oil.

If condition still persists, disassemble and clean. Problem may be lint that will cling. g). Weak or broken relief valve spring.

Replace spring. h). Scored relief valve plunger.

Replace plunger. j). Valve body cracked.

Replace valve. k). Spool will not move to full stroke.

Check travel for restriction.

If cause is not external, disassemble valve and check for damaged parts.

4. Load will not hold. a). Oil by-passing between spool and body.

Return for factory repair or replace valve. b). Worn cylinder(s) Refer to cylinder section.

5. Load drops when spool is moved from neutral to power position. a). Foreign particle lodged between check valve poppet and seat.

Disassemble, clean, reassemble.

30 - 01 - 2

b). Scored check valve poppet.

Replace poppet. c). Defective check valve poppet seat in valve body.

Lap new poppet body seat.

6. Electric motor driving pump will not shut off when spool is returned to neutral. a). Control switch not breaking contact.

Readjust or replace switch.

30-05

MAIN

VALVE

REMOVAL

1. Disconnect battery.

2. Apply parking brake.

4. Remove hose at fitting on valve port to sump, cap end, and pull hose free. Remove line to check and dump valve, cap end and push to one side.

Remove lines to lift selection valve, cap ends of lines and move to safe location.

5. Remove two wires from valve switch.

6. Remove cotter pins from connector link joining control handle to valve spool end. Remove link plate and link.

7. Remove three (3) capscrews fastening valve to plate. Lift valve off truck.

3. Remove top cover by removing three fasteners at forward edge of cover, one fastener below control handle and one fastener mounted near sump tank.

NOTE - Be sure to clean up any oil spills and dry floor to prevent accidents.

30-06

VALVE

DISASSEMBLY

IMPORTANT - Overhaul valve only in a clean, dust-free location, using clean tools and equipment.

Dirt or grit will damage highly-machined surfaces and will result in leakage or premature failure of components.

Cleanliness of hydraulic circuit is extremely important to proper operation and maintenance of system.

Clean outside of valve with a good grade solvent and dry thoroughly.

To remove top cover, remove lower fastener from LH DOG leg, loosen upper fastener and swing leg outward from center of machine.

This will permit cover to be pulled rearward, clearing control handle and steer handle.

Disconnect two quick-disconnect plugs from wire harness. Lift off cover and store in a safe place.

SM538

TOOLS No special tools are required for disassembling or assemblling control valve. Those described below may be of help.

For compressing spring on spring-centered spool, two (2) retainer plates with bolts and nuts may be used.

To operate spring compressor, place one retainer plate over eye end of spool and against bottom spring spacer and other retainer plate against top spring spacer. Line up holes and install bolts and nuts.

Tighten nuts evenly to compress spring sufficiently to allow removal of snap ring.

30 -01-3

Caution should be exercised as spring is compressed. Unscrew bolts slowly until all spring pressure has been released.

A sleeve tool can be made for ease in snap ring installation on spring-centered or 3-position detent type spools.

Select a piece of round bar stock approximately five (5) inches in length and slightly larger in diameter than shaft snap ring is being installed on Remove any sharp edges.

To use tool when snap ring is installed, compress spring, then positon snap ring on stud end of spool. Position tool against snap ring and tap rather sharply with a soft-faced hammer until snap ring is seated in groove.

Keep parts in order as removed.

1. Loosen clamping screws on switch body and pull switch off spool cap.

5. Remove screws holding retainer plate, retainer and O-rings from opposite end (control end) of valve body.

2. Unscrew and remove spool cap.

3. Grasp spring end of spool and remove spool assembly with springs attached.

4. Place spool assembly in a soft-jawed vise and compress spring to remove snap ring, spring spacer, spring and spring spacer.

SM538 30 - 01 - 4

6. Turn valve body over to switch end. Unscrew plug from check valve, then remove poppet valve It may require a soft wire spring and spring. (formed to a hook) to remove this assemlby.

paint or burrs on mating portions of sliding or rotating parts.

5.

Inspect valve spools and bores for burrs, scratches, paint, corrosion or erosion or scoring.

If any damage is evident but is not of a depth that would cause objectionable leakage, flaw can be removed by carefully stoning or burnishing with crocus cloth.

If flaw is excessive, part must be replaced.

6. Inspect relief valve for damage. Insert it in bore and make sure it is free to move without binding and will move by its own weight.

7. Inspect valve body to make sure it has not been physically damaged.

Examine all threads to be sure they are clean and not damaged or burred.

Inspect all bores to be sure they are free from damage.

8. Make sure all springs are free of corrosion and not broken or bent.

9. Examine poppet seats to make sure they are not damaged.

10. Before assembly, coat all parts with a thin layer of clean hydraulic oil.

Petroleum jelly can be used to hold seals in place at assembly.

NOTE - If parts must be left unasssembled for a period of time or overnight, cover with a lint-free clean material.

30-08

7. Remove plug and O-ring from relief valve section (on control end of valve).

Unscrew and remove acorn nut, two seals and jam nut.

Then back off adjusting screw to relieve spring tension.

Remove cap with adjusting screw installed.

Remove 0- rings and back-up washer from cap.

Remove pilot plunger spring, pilot plunger, pilot seat, large spring, poppet assembly and seat from body bore.

8. Remove all other plugs and O-rings from body.

30-07

MAIN

VALVE

INSPECTION

1. Make sure all parts are identified and in correct assembly order.

2 Discard all old seals and replace with new seals.

3. Wash all parts carefully in a clean mineral oil solvent and place them on a clean surface for inspection.

4. If any burrs are found, they should be removed by light stoning or lapping.

Be certain there is no

SM538

MAIN

VALVE

ASSEMBLY

1. Install seal and retainer on spool.

To assemble spring on spool, clamp spool in a softjawed vise. Assemble guide and washer on spool, then install spring and then add final guide.

Compress the spring, then add snap ring to retain assembly.

Be sure snap ring is fully seated in groove.

Remove spring compressor and then remove spool from vise.

2. Put new O-ring and O-ring retainer on spool assembly and coat with a film of clean hydraulic oil.

Care should be taken to Then install spool. prevent cutting O-ring. When spool has been fully installed in body, install spool cap.

3. Install O-ring, O-ring retainer, wiper and retainer plate over control end of spool (eye end) and put in position on valve body.

Install and tighten retaining fasteners.

4. Install check valve Slide poppet seat in valve bore making sure it is fully seated.

Slide poppet in valve bore until fully seated, then insert spring in poppet bore.

Put a new O-ring on cap and install cap. Make certain that spring centers in cap. Screw cap in until it bottoms out.

5. Install relief valve seat in bottom of bore.

30 - 01 - 5

Install poppet assembly so that points toward seat.

Install large spring in inner diameter Insert new small O-ring and back-up groove of cap and insert spring with bore of cap.

Insert pilot seat into end of cap bore O-ring under shoulder of cap, screw body.

plunger

shaft

of plunger. washer around pilot plunger in

9. Connect battery.

10. Check operation of truck, making trial test for pump in no-load condition, then in by-pass condition.

Listen for any unusual noise in hydraulic system.

and with large cap into valve

CAUTION Use care during assembly so that pilot plunger and spring remain in their correct positions with pilot seat firmly resting on bottom of cap.

6. Tighten cap securely.

Install two seals, adjusting screw, jam nut and acorn nut. Do not tighten acorn nut at this time.

NOTE: Do not attempt to adjust relief valve to its proper setting at this time.

Refer to Relief Valve Adjustment.

7. Put new O-rings on all body plugs and install in valve body.

8. Install switch on spool cap. Adjust switch by observing switch contact action through clear plastic cover. Move switch on cover until moving contact is mid-way between stationary contacts with spool in neutral position.

Tighten switch clamping screws to maintain this setting.

Test switch by operating spool in each direction and visually observe plunger contacting stationary contacts. Readjust if necessary.

30-09 MAIN VALVE INSTALLATION 1. Put valve in place on truck frame. Install three fasteners and tighten nuts to a torque of [34-38 N.m] 25-28 Ibf.ft.

2. Install link and plate ( insert link pins from top and put plate on bottom) from hand control to valve spool end. Insert new cotter pins and spread legs to lock pins in place.

3. Install two wires on switch.

4. Install lines to lift selection of valve.

5. Install line to check and dump valve.

6. Install hose to sump tank.

7. Position cover on truck and connect two quickdisconnect wire harness plugs. operate lift pump and check fittings for oil leaks. Thread cover over steering wheel and over control handle and then move into position on truck. Install and tighten all fasteners.

8. Install lower fastener on DOG leg and tighten both fasteners to a torque of [21-23 N.m]180-200 Ibf.in.

SM538

30-01-6

GROUP 32 SECTION 01 TILT CYLINDER MODEL C CONTENTS

NO.

TILT TILT TILT TILT TILT

32-01 32-02 32-03 32-04 32-05

CYLINDER ADJUSTMENT CYLINDER REMOVAL CYLINDER DISASSEMBLY CYLINDER ASSEMBLY CYLINDER INSTALLATION

32-01 TILT ADJUSTMENT

TILT

1. Insert caps in ports and carefully clean exterior of cylinder with a petroleum base solvent. Air dry and place assembly on a clean surface. Remove caps.

CYLINDER

The tilt cylinder does not require adjustment. Tilting of forks is accomplished by action of cylinder pushing roller carrier shaft and rollers along a ramp that causes the fork bar assembly to pivot in the desired tilt mode from the adapter assembly.

32-02

32-03 TILT CYLINDER DISASSEMBLY.

CYLINDER

REMOVAL

1. Make sure truck is on a level surface. Block the wheels to prevent truck from moving. Fully lower upright and extend reach mechanism.

2. Tilt fully back.

Insert hardwood blocking between bottom rail of adapter assembly and bottom fork bar. Tilt slightly forward to release rollers from ramp. Disconnect battery.

3. Disconnect hydraulic lines from cylinder and cap ends of hoses.

INTERIOR SNAP RING

2. Remove exterior snap ring on cylinder gland.

3. Push gland into cylinder to expose interior snap ring. Remove interior snap ring.

4. Pull on piston rod assembly to withdraw rod and gland assembly from barrel Discard gland retainer.

5. Withdraw cylinder rod from gland.

6. Remove and discard retainer lock and retainer from gland.

7. Use flat on rod to prevent rod from rotating and remove cylinder rod nut.

8. Remove piston (and spacer if present) from cylinder rod.

9. Remove and discard piston seal and wear ring.

10. Remove and discard gland seal and back-up ring.

32-04

4. Loosen setscrew retaining tilt cylinder to tilt carriage adaptor and remove cylinder anchor pin.

5. Remove nut from tilt roller carriage anchor bolt (shoulder bolt) connecting tilt-cylinder rod to tilt roller carrier assembly 6. Lift tilt cylinder assembly out off of truck.

SM538

CYLINDER

ASSEMBLY

1. Check rod, cylinder bore, gland and piston for any evidence of corrosion or contamination.

If any contamination, flush all part with clean hydraulic fluid and air dry. Check cylinder rod for any evidence of nicks, scratches, gouges, pitting or mechanical damage. Small defects may be removed using very fine emery cloth or by stoning.

2. Install new gland seal and back-up ring on gland.

3. Install new gland seal and retainer on gland .

4. Install new piston seal and wear ring on piston.

5. Coat all seals, retainers, cylinder rod and cylinder bore with a light coat of clean hydraulic fluid.

6. Install spacer (if used) and piston on cylinder rod.

Install nut and tighten to a torque of [136 N.m] 100 Ibf.ft.

7. Insert cylinder rod into gland.

8. Insert piston into barrel of cylinder using care not to damage seal as it enters cylinder. Use same care to insert gland assembly into cylinder bore.

32 - 01 - 1

9. Install internal snapring in cylinder bore (serves as a stop for gland outward movement).

Make sure snapring is firmly seated in groove.

10. Pull on cylinder rod until gland is firmly seated against snapring. Install gland retainer. Insert outer snapring in gland, locking gland in place.

32-05 TILT CYLINDER INSTALLATION 1. Insert tilt cylinder rod into tilt roller carrier assembly.

Make sure to align hole in rod parallel with hole in carrier to enable insertion of shoulder bolt.

2. Insert shoulder bolt (tilt roller carriage anchor bolt). and install nut. Tighten to a torque of [ N.m] Ibf.ft.

3. Position anchor end of cylinder on cylinder bracket on adapter and Install tilt cylinder anchor end pin Tighten retaining setscrew.

4. Install hydraulic lines to cylinder.

5. Connect battery and tilt upright up to loosen wooden blocks. Remove blocks.

6. Install forks.

SM538

32 - 01 - 2

GROUP 32 SECTION 02 REACH CYLINDER MODEL C CONTENTS REACH REACH REACH REACH REACH

CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER

32-01 REACH ADJUSTMENT

NO. ADJUSTMENT REMOVAL DISASSEMBLY ASSEMBLY INSTALLATION

32-01 32-02 32-03 32-04 32-05

CYLINDER

1. Raise upright until forks are [300 mm] 12 inches off floor. Fully retract forks. Measure distance from rear of fork bar to forward edge of outer rail.

4. Use drift to drive out retainer on yoke end of reach cylinder Use drift to remove reach cylinder yoke end pivot pin 5. Use drift to drive out retainer on anchor end of reach cylinder.

Use drift to remove reach cylinder anchor end pivot pin 6. Remove reach cylinder assembly from truck.

32-03 REACH DISASSEMBLY.

CYLINDER

1. Insert caps in ports and carefully clean exterior of cylinder with a petroleum base solvent. Air dry and place assembly on a clean surface. Remove caps.

L-

+ 2. Fully extend forks. Measure distance from same points.

3. Subtract difference.

This is REACH. It should measure [605 mm] 23.8 inches.

4. If it is not to specification, loosen locknut on reach cylinder rod and move rod on yoke (by using wrench flats on rod to turn rod) until correct REACH is obtained.

5. Tighten nut against yoke.

32-02 REACH REMOVAL

CYLINDER

1. Make sure truck is on a level surface. Block the wheels to prevent truck from moving. Fully lower upright and extend reach mechanism part way.

2. .Raise upright a small distance and place hardwood blocks under fork bar assembly.

Lower forkbar to rest on hardwood blocking.

3. Disconnect hydraulic lines from reach cylinder and cap ends of hoses.

SM538

SNAP RING 2. Remove exterior snap ring on cylinder gland.

3. Push gland into cylinder to expose interior snap ring. Remove interior snap ring.

4. Pull on piston rod assembly to withdraw rod and gland assembly from barrel Discard gland retainer.

5. Withdraw cylinder rod from gland.

6. Remove and discard retainer lock and retainer from gland.

7. Use flat on rod to prevent rod from rotating and remove cylinder rod nut.

8. Remove piston (and spacer if present) from cylinder rod.

9. Remove and discard piston seal and wear ring.

32 - 02 - 1

10. Remove and discard gland seal and back-up ring.

32-04 REACH ASSEMBLY

CYLINDER

1. Check rod, cylinder bore, gland and piston for any evidence of corrosion or contamination. If any contamination, flush all part with clean hydraulic fluid and air dry. Check cylinder rod for any evidence of nicks, scratches, gouges, pitting or mechanical damage. Small defects may be removed using very fine emery cloth or by stoning.

2. Install new gland seal and back-up ring on gland.

3. Install new gland seal and retainer on gland .

4. Install new piston seal and wear ring on piston.

5. Coat all seals, retainers, cylinder rod and cylinder bore with a light coat of clean hydraulic fluid.

6. Install spacer (if used) and piston on cylinder rod.

Install nut and tighten to a torque of 168 N.m] 50 Ibf.ft.

7. Insert cylinder rod into gland.

8. Insert piston into barrel of cylinder using care not to damage seal as it enters cylinder. Use same care to insert gland assembly into cylinder bore.

9. Install internal snapring in cylinder bore (serves as a stop for gland outward movement). Make sure snapring is firmly seated in groove.

10. Pull on cylinder rod until gland is firmly seated against snapring. Install gland retainer. Insert outer snapring in gland, locking gland in place.

32-05 REACH INSTALLATION

CYLINDER

1. Install nut and yoke on end of piston rod but do not tighten nut.

2. Insert reach cylinder anchor end into bracket on lift carriage assembly. insert anchor pivot pin into bore and lock anchor pin by inserting pivot pin retainer.

3. Position yoke end of reach cylinder on cylinder bracket on inner arm assembly and Install reach cylinder rod end pivot pin. Insert pivot pin retainer to lock pivot pin.

4. Install hydraulic lines to reach cylinder.

5. Connect battery and lift upright. Remove blocks.

6. Adjust reach position and tighten nut. (Refer to Adjustment section).

SM538 32 - 02 - 2

GROUP 32 SECTION 03 LIFT CYLINDER MODEL D

Disconnect other end of wire harness leading to pantograph by unlocking quick disconnect plugs on harness leading into pantographassembly.

6

NO.

CONTENTS LIFT CYLINDER LIFT CYLINDER LIFT CYLINDER LIFT CYLINDER LIFT CYLINDER LIFT CYLINDER LIFT CYLINDER LIFT CYLINDER

32-01

REMOVAL (STD UPR) DISASSEMBLY (STD) ASSEMBLY (STD) INSTALLATION (STD) REMOVAL (TSU UPR) DISASSEMBLY (TSU) ASSEMBLY (TSU) INSTALLATION (TSU)

32-01 32-02 32-03 32-04 32-05 32-06 32-07 32-08

LIFT CYLINDER REMOVAL (STANDARD UPRIGHT)

3. Remove hydraulic line to lift cylinder. of hose and cap cylinder port.

Cap end

1. Make sure truck is on a level surface.

Disconnect battery.

Block wheels to prevent truck from moving.

Fully lower upright and extend reach mechanism.

2. Disconnect wire harness assemblies from upright by unllocking two (2) quick-disconnect plugs located below middle tie bar of outer rail assembly. One is for pantograph and other is for speed limit switch on top or upright.

4. Remove roll pins from cylinder anchor pins at top of cylinder barrel.

NOTE: When inner rail assembly is raised, cylinder will be released and must be supported to prevent it tipping away from upright assembly.

SM538 32 - 03 - 1

Fasten a chain hoist to top of inner rail assembly and lift inner rail assembly to clear cylinder anchor pins at top tie bar of inner rail assembly.

4.

Remove

retaining

nut from bottom

of piston

rod. Then remove pin, spring and ball from end of piston rod.

5. Lift piston off piston rod. from the piston and discard it.

Remove

wear ring

i

5. Lift cylinder off of lower support assembly and store in a safe place.

of outer

6. Remove bleed cylinder barrel.

32-02 LIFT CYLINDER DISASSEMBLY (STANDARD UPRIGHT)

32-03 LIFT (STANDARD

1. Position cylinder in a clean work area.

j\\ n

Remove bearing end from cylinder unscrewing bearing (RH thread).

I

rail

screw

/ and seal washer

CYLINDER UPRIGHT)

from

ASSEMBLY

1. Inspect cylinder rod, piston, barrel and bearing for any visible damage. Look for nicks or scratches Make sure on bearing and sealing surfaces. threads are clean and not damaged.

Look for evidence of wear or of corrosion.

Any damage must be repaired or parts replaced with new before assembly.

Thoroughly clean all parts with a petroleum base cleaner and air dry.

Be sure all parts are clean and lint-free.

If parts must be left exposed, cover with a clean dry cover to elimnate any contamination. barrel

by

2. Pull bearing head and piston rod assembly out of cylinder barrel.

Be careful when removing piston assembly to avoid damaging parts on threaded portion of assembly.

3.

Pull bearing assembly off of piston rod.

Remove wiper, oil seal, wear ring, back-up ring and O-ring from bearing. Discard these removed parts and replace with new at assembly.

SM538

32-03-2

2. Install a new wear ring on piston. on piston rod.

Install piston 1. Position cylinder in upright assembly making sure studs on outer rail lower cylinder support engage holes on plate on bottom of cylinder barrel.

2. Lower inner rail assembly making sure studs on top tie bar engage holes in guide assembly on top of cylinder 3. Install roll pins in cylinder anchor studs on top tie bar.

4. Install hydraulic

line on cylinder.

5. Remove hoist chain.

6. Install and adjust lift chains.

3. install ball, spring and pin on piston rod and secure with nut. Tighten nut to a torque of [407447 N.m] 300-330 Ibf.ft.

4. Carefull slide piston rod assembly over threads of cylinder barrel and slide assembly to bottom of cylinder barrel.

5. Apply a thin film of hydraulic oil to a new O-ring and back-up ring and install O-ring and back-up ring on bearing.

6. Slide bearing assembly over piston rod and screw bearing onto cylinder barrel until snug.

7. Install bearing.

new wear

ring, oil seal and wiper

in

7. Attach wire harness quick-disconnect 8. Connect battery and check phases of lift and reach functions.

Look for any evidence of leaks.

plugs.

operation

of all

32-05 LIFT CYLINDER REMOVAL (THREE STAGE UPRIGHT) The three stage upright has three (3) cylinders, two STAGING CYLINDERS (side by side) and a FREE-LIFT CYLINDER. The staging cylinders are supported on bottom tie bar of outer rail assembly with piston rods pinned to top tie bar of intermediate rail assembly.

The free-lift cylinder lower end is mounted on lower tie bar of inner rail assembly by two pins on tie bar engaging holes in blocks mounted on sides of cylinder barrel. The top end of cylinder barrel has a plate with a pin extending rearward that engages the slotted hole in the middle tie bar of inner rail assembly.

A roll pin and washer through this pin fastens the cylinder to the rail assembly.

This cylinder also has chain sheaves mounted on a shaft passing thru its piston rod.

1. Make sure truck is on a level surface.

Disconnect battery.

Block wheels to prevent truck from moving.

Fully lower upright and extend reach mechanism.

8. Install bleed screw and washer in cylinder barrel.

32-04 INSTALLATION UPRIGHT)

LIFT

CYLINDER (STANDARD

SM538

32 - 03 - 3

2. Disconnect wire harness assemblies from upright by unllocking two (2) quick-disconnect plugs located below middle tie bar of outer rail assembly. One is for pantograph and other is for speed limit switch on top or upright.

4. Remove nuts from chain anchors and remove chain anchors from top plate of free-lift cylinder barrel. Remove lift chain retainer plate and spacer from piston rod. Remove lift chains from sheaves and secure in a safe position. Removeone cable from sheave on right hand side of cylinder and two cables from sheave on left hand side of cylinder.

3. Remove hydraulic lines to lift cylinders. Two lines go to staging cylinders. Third line goes to sheave on intermediate rail. Cap ends of hose and cap cylinder ports.

5. Remove snap rings and washers from bottom tie bar pins on inner rail assembly.

Remove free-lift cylinder assembly by lifting anchor plates on cylinder barrel off of pins on lower inner rail tie bar. Slot in middle tie bar of inner rail assembly will allow pin on cylinder barrel to lift up.

Store cylinder in a safe place.

6. Use a chain hoist to lift intermediate rail assembly a slight amount. Place a [lo0 mm] 4 inch hardwood block under upright rail and remove chain hoist.

SM538 32-03-4

7. Use a nylon sling (or similar support) around top of staging cylinder barrels to lift cylinders when they are free of upright.

8. Remove fastener and spacer attaching pistons of staging cylinders to each other and separate cylinder upper ends.

9. Move tops of cylinders to clear upright and lift out of upright assembly. Store in a safe place.

32-06 DISASSEMBLY UPRIGHT)

Pull bearing assembly off of piston rod.

3.

Remove wiper, oil seal, wear ring, back-up ring and O-ring from bearing. Discard these removed parts and replace with new at assembly.

4. Remove retaining nut from bottom of piston rod. Then remove pin, spring and ball from end of piston rod.

5. Lift piston off piston rod. from the piston and discard it.

Remove wear ring

6. Remove the bleed screw and seal washer from cylinder barrel.

LIFT CYLINDER (THREE STAGE

FREE-LIFT CYLINDER

STAGING CYLINDER

1. Position cylinder in a clean work area.

1. Position cylinder in a clean work area.

Remove bearing end from cylinder unscrewing bearing (RH thread).

barrel

by

2. Remove fastener from end of sheave roller shaft. Use soft-faced hammer and brass drift to tap on end of sheave shaft and remove sheaves, bearings and spacers.

2. Pull bearing head and piston rod assembly out Be careful when removing of cylinder barrel. piston assembly to avoid damaging parts on threaded portion of assembly.

SM538 32 - 03 - 5

2. Remove fastener from end of sheave roller shaft. Use soft-faced hammer and brass drift to tap on end of sheave shaft and remove sheaves, bearings and spacers.

32-07 LIFT CYLINDER ASSEMBLY (THREE STAGE UPRIGHT) 1. Inspect cylinder rod, piston, barrel and bearing of both cylinders for any visible damage.

Keep parts of each cylinder assembly separted and identified to avoid mix-up of parts.

Look for nicks or scratches on bearing and sealing surfaces. Make sure threads are clean and not damaged.

Look for evidence of wear or of corrosion. Any damage must be repaired or parts replaced with new before assembly.

Thoroughly clean all parts with a petroleum base cleaner and air dry.

Be sure all parts are clean and lint-free. If parts must be left exposed, cover with a clean dry cover to elimnate any contamination.

STAGING CYLINDER

3. Remove bearing end from cylinder barrel by unscrewing bearing (RH thread).

4. Pull bearing head and piston rod assembly out of cylinder barrel.

Be careful when removing piston assembly to avoid damaging parts on threaded portion of assembly.

5. Pull bearing assembly off of piston rod.

Remove wiper, oil seal, wear ring, back-up ring and O-ring from bearing. Discard these removed parts and replace with new at assembly.

1. Install a new wear ring on piston. Install piston on piston rod.

2. Install ball, spring and pin on piston rod and secure with nut. Tighten nut to a torque of [340407 N.m] 250-300 Ibf.ft.

3. Carefull slide piston rod assembly over threads of cylinder barrel and slide assembly to bottom of cylinder barrel.

6. Remove retaining screw from bottom of piston rod. Then remove washer and both belleville washers from end of piston rod.

4. Apply a thin film of hydraulic oil to a new O-ring and back-up ring and install O-ring and back-up ring on bearing.

7. Lift piston off piston rod. from the piston and discard it.

5. Slide bearing assembly over piston rod and screw bearing onto cylinder barrel until snug.

Remove wear ring

8. Remove the bleed screw and seal washer from cylinder barrel.

SM538 32 - 03 - 6

6. Install bearing.

new wear

ring, oil seal

and wiper

in

belleville washers oppose each other and do not nest.

Rims of washers should touch.

Install retaining screw and tighten to a torque of [150 N.m] 110 Ibf.ft.

3. Carefull slide piston rod assembly over threads of cylinder barrel and slide assembly to bottom of cylinder barrel.

Q 8

4. Apply a thin film of hydraulic oil to a new O-ring and back-up ring and install O-ring and back-up ring on bearing.

5. Slide bearing assembly over piston rod and screw bearing onto cylinder barrel until snug.

6. Install bearing.

7. Install bleed screw and washer in cylinder barrel.

new wear

ring, oil seal and wiper

in

7. Install bleed screw and washer in cylinder barrel.

FREE-LIFT CYLINDER

8. Install bearings, spacers, sheaves and washers on piston. Install retaining nut and tighten.

1. Install a new wear ring on piston. on piston rod.

Install piston 9. Do not install lift chain retainer until cylinder is installed in truck and lift chains have been installed.

II

2. Install both belleville washers and small washer on piston rod and secure with nut. Make sure

SM538

32 - 03 - 7

32438 LIFT CYLINDER I.NSTALLATION (THREE UPRIGHT)

STAGE

3. Install free-lift cylinder by inserting pins on lower tie bar into holes on plates on each side of cylinder barrel and at same time inserting pin on top plate of cylinder barrel into slotted hole in middle tie bar of same rail asembly.

4. Install washers and retaining rings on pins thru lower tie bar trapping cylinder to rail assembly.

1. Install staging cylinders in upright assembly making sure bottoms of cylinders are supported by lower tie bar of outer rail assembly.

2. Attach a chain hoist to top tie bar of intermediate rail assembly and raise rail assembly a slight amount [50 mm] 2 inches. Position pistons of staging cylinders to allow retaining sleeve and fastener to be inserted thru plate on top tie bar undersurface to lock pistons to top tie bar of intermediate rail assembly. Lower rail assembly and remove hoist chain.

5. Install lift chains over sheaves and secure lift chain anchors using new fasteners. Adjust chains to-correct tension (see lift chain adjustment) and tighten locking nuts.

Install cables over sheaves making sure cables are installed in correct position.

Install lift chain retainer and spacer on cylinder piston rod and tighten fasteners.

6. Install hydraulic lines. Make sure hydraulic lines are correctly installed and do not rub against upright rails or tie bars when upright is moving.

Correct looping of lines is assured by carefully positoning line before tightening fittings.

7. Connect quick disconnect harness cables.

fasteners of wire

8. Remove all blocking and install battery.

9. Check all operations of upright and of reach assembly to be sure all functions operate correctly.

Check for oil leaks.

SM538 32 - 03~- 8

GROUP 32 SECTION 04 TILT CYLINDER NP300D

3. Disconnect hydraulic cap ends of hoses.

CONTENTS

NO.

TILT TILT TILT TILT TILT

32-01 32-02 32-03 32-04 32-05

CYLINDER ADJUSTMENT CYLINDER REMOVAL CYLINDER DISASSEMBLY CYLINDER ASSEMBLY CYLINDER INSTALLATION

32-01

TILT CYLINDER ADJUSTMENT

lines from cylinders

and

4. Remove roll pin locking cylinder anchor pivot pin to front frame trunions.

Remove cylinder anchor pivot pin and remove cylinder.

Tilting of forks is accomplished by action of cylinders pushing rollers along a ramp that causes the fork bar assembly to pivot in the desired tilt mode from front plate assembly.

To adjust tilt, fully retract tilt cylinders.

Cylinder rollers should be in contact with ramp on fork bar assembly on each side with fork bar vertical. Adjust each cylinder until correct by turning cylinder rod (use wrench on flat on cylinder rod), while preventing yoke from turning, until rollers are in correct position.

5. Remove cylinder manner.

from opposite

side in same

NOTE: Tilt cylinders are not identical.

Note that RH cylinder has an external bleed screw near anchor end of cylinder barrel.

Tilt forward and backward several times to check operation.

Open bleed screw in RH tilt cylinder to release any trapped air and close screw when all air Repeat has been released and oil flows. adjustment check.

When adjustment is correct, secure yoke positions on rod by tightening locking nuts on piston rods.

32-02

TILT

CYLINDER

REMOVAL

1. Make sure truck is on a level surface.

Block wheels to prevent truck from moving. Fully lower upright and extend reach mechanism.

6. Remove yoke and roller assembly cylinder by loosening and unscrewing and locking nut from piston rod.

2. Tilt fully back.

Insert hardwood blocking between bottom rail of front plate assembly and bottom fork bar. Tilt slightly forward to release rollers from ramp. Disconnect battery.

7. Disassemble each yoke and roller assembly by driving roll pin from yoke and then using soft-faced hammer and drift to remove shaft. Remove rollers and thrust washers.

SM538

32 - 04 - 1

from each assembly

32-03

4. Pull on piston rod assembly to withdraw rod and gland assembly from barrell.

TILT CYLINDER DISASSEMBLY.

When disassembling cylinder, it is necessary to have a clean workbench.

Cover parts if left exposed for any period of time (such as overnight).

Cylinder may be held by carefully clamping in a vise. Be careful and avoid damaging cylinder by applying excessive pressure that will permanently damage cylinder.

1. Insert caps in ports and carefully clean exterior of cylinder with a petroleum base solvent.

Air dry and place assembly on a clean surface.

Remove caps.

5. Withdraw cylinder rod from gland.

6. Remove cylinder rod nut.

7. Remove piston from cylinder rod.

8. Remove and discard small O-ring.

9. Remove and discard piston seal and backing ring.

10. Remove and discard gland seal and O-ring from cylinder barrel area of gland and remove and discard wiper and seal from rod area of gland.

2. Begin disassembly of RH tilt cylinder. Pry tab of exterior locking ring from hole in cylinder barrel and lift out to unlock cylinder gland end from barrel.

Rotate ring slightly to move tab away from lock hole.

11. Remove bleed screw from barrel.

c

\ ‘I-\ 0

3. Clamp cylinder carefully in vise and rotate gland to remove locking wire from inner grooves of cylinder and gland. Lockwire easily “flows” out as gland is rotated. Discard this locking wire . Use a new lockwire when assembling cylinder.

-@@+OO-

12. Repeat disassembly of LH cylinder.

32-04

CYLINDER

ASSEMBLY

1. Check rod, cylinder bore, gland and piston for any evidence of corrosion or contamination. If any SM538 32 - 04 - 2

contamination, flush all part with clean hydraulic fluid and air dry.

Check cylinder rod for any evidence of nicks, scratches, gouges, pitting or mechanical damage.

Small defects may be removed using very fine emery cloth or by stoning.

TILT CYLINDER INSTALLATION

32-05

1. Install yoke and roller assemblies and locking nut on each cylinder. Do not tighten locking nut.

2. Position anchor end of cylinder on front frame trunion and Install tilt cylinder anchor end pin.

Install roll pin to lock pivot pin.

3. Install hydraulic lines to cylinder.

4. Connect battery and tilt upright up to loosen wooden blocks. Remove blocks.

5. Install forks.

6. Adjust tilt as described in front of this section.

7. Remove all blocking.

2. Begin assembly of RH tilt cylinder. Install new gland seal and O-ring on gland and install new seal and wiper in gland.

8. Check hydrauylic lines for leaks. Make sure all hoses are in correct positon and that they do not rub on any moving parts. Check all operations of upright for correct movement.

3. Install new piston seal and backing ring.

4. Install new small O-ring on rod 5. Coat all seals, retainers, cylinder rod and cylinder bore with a light coat of clean hydraulic fluid.

6. Install piston on cylinder rod. Install nut and tighten to a torque of [81-88 N.m] 60-65 Ibfft.

7. Insert cylinder rod into gland.

8. Insert piston assembly and gland into barrel of cylinder using care not to damage seal as it enters cylinder. Use same care to insert gland assembly into cylinder bore.

9. Carefully clamp cylinder in a vise to prevent it from turning. Install new locking wire into inner groove and rotate gland assembly in opposite diretion as when removing wire.

10. Install bleed screw in barrel.

11. If necessary, install new rollers and thrust washers in yokes and install on piston rod. Be sure to insert roil pin flush with yoke surface.

112. Repeat assembly of LH cyllinder. Tighten piston rod nut to a torque of [200-230 N.m] 150170 Ibf.ft SM538 32 - 04 - 3

GROUP 32 SECTION 05 TILT CYLINDER NS300D

3. Disconnect hydraulic cap ends of hoses.

CONTENTS

NO.

TILT TILT TILT TILT TILT

32-01 32-02 32-03 32-04 32-05

CYLINDER ADJUSTMENT CYLINDER REMOVAL CYLINDER DISASSEMBLY CYLINDER ASSEMBLY CYLINDER INSTALLATION

32-01

TILT CYLINDER ADJUSTMENT

in mounting

and there

is no

5. Remove drift pin locking carriage plate trunions.

TILT

CYLINDER

rear anchor

pin to

6. Remove cylinder by using drift and soft-faced hammer to remove cylinder rear anchor pin.

7. Remove manner.

32-02

and

4. Remove cylinder rod anchor pin clips from fork bar by removing fasteners attaching clips to fork bar.

Tilting of forks is accomplished by action of cylinders attached to carriage frame pushing against pivoted fork bar assembly, moving it to desired tilt.

Cylinders are fixed adjustment.

lines from cylinders

cylinder

from opposite

side in same

REMOVAL

1. Make sure truck is on a level surface.

Block wheels to prevent truck from moving. Fully lower uprightand remove forks.

2. Tilt fully forward and insert hardwood blocking between carriage frame and lower portion of fork bar. This will provide room for removal of cylinder rod pin clips.

Disconnect battery.

32-03

TILT CYLINDER DISASSEMBLY.

When disassembling cylinder, it is necessary to have a clean workbench.

Cover parts if left exposed for any period of time (such as overnight).

Cylinder may be held by carefully clamping in a vise. Be careful and avoid damaging cylinder by applying excessive pressure that will permanently damage cylinder.

1. Insert caps in ports and carefully clean exterior of cylinder with a petroleum base solvent.

SM538

32 - 05 - 1

Air dry and place assembly on a clean surface.

Remove caps.

10. Remove and discard gland seal and O-ring from cylinder barrel area of gland and remove and discard wiper and seal from rod area of gland.

11. Repeat for disassembly of opposite cylinder.

32-04

CYLINDER

ASSEMBLY

1. Check rod, cylinder bore, gland and piston for any evidence of corrosion or contamination. If any contamination, flush all part with clean hydraulic fluid and air dry.

Check cylinder rod for any evidence of nicks, scratches, gouges, pitting or mechanical damage.

Small defects may be removed using very fine emery cloth or by stoning.

2. Begin disassembly of tilt cylinder. Pry tab of exterior locking ring from hole in cylinder barrel and lift out to unlock cylinder gland end from barrel.

Rotate ring slightly to move tab away from lock hole.

3. Clamp cylinder carefully in vise and rotate gland to remove locking wire from inner grooves of cylinder and gland. Lockwire easily “flows” out as gland is rotated. Discard this locking wire . Use a new lockwire when assembling cylinder.

4. Pull on piston rod assembly to withdraw rod and gland assembly from barrell.

2. Begin assembly of tilt cylinder. Install new gland seal and O-ring on gland and install new seal and wiper in gland.

3. Install new piston seal and backing ring.

4. Install new small O-ring on rod.

5. Coat all seals, retainers, cylinder rod and cylinder bore with a light coat of clean hydraulic fluid.

6. Install piston on cylinder rod. Install nut and tighten to a torque of [270-305 N.m] 200-225 Ibf.ft.

5. Withdraw cylinder rod from gland.

7. Insert cylinder rod into gland.

6. Remove cylinder rod nut.

8. Insert piston assembly and gland into barrel of cylinder using care not to damage seal as it enters cylinder. Use same care to insert gland assembly into cylinder bore.

7. Remove piston from cylinder rod.

8. Remove and discard small O-ring.

9. Remove and discard piston seal and backing ._ ring.

9. Carefully clamp cylinder in a vise to prevent it from turning. Install new locking wire into inner

SM538 32 - 05 - 2

groove and rotate gland assembly diretion as when removing wire.

in opposite

10. Repeat assembly of opposite cyllinder.

32-05 TILT CYLINDER INSTALLATION 1. Position anchor end of cylinder on carriage frame trunion and install tilt cylinder anchor end pin. Install roll pin to lock pivot pin.

2. Insert cylinder rod pivot pin in piston rod and secure pivot pin to fork bar using clips and fasteners to retain pin to fork bar.

3. Repeat for opposite cylinder.

4. Install hydraulic lines to cylinders.

5. Connect battery and tilt upright up to loosen wooden blocks. Remove blocks.

6. Install forks.

7. Check hydraulic lines for leaks. Make sure ali hoses are in correct position and that they do not rub on any moving parts. Check all operations of upright for correct movement.

SM538 32 - 05 - 3

GROUP 32 SECTION 06 REACH CYLINDER NP300D CONTENTS REACH CYLINDER REACH CYLINDER REACH CYLINDER REACH CYLINDER REACH CYLINDER

32-01

NO. ADJUSTMENT REMOVAL DISASSEMBLY ASSEMBLY INSTALLATION

32-01 32-02 32-03 32-04 32-05

REACH CYLINDER ADJUSTMENT

4. Remove roll pin locking cylinder aichor pivot pin to rear frame trunions.

Remove cylinder anchor pivot pin while supporting cylinder.

Remove roll pin locking cylinder rod pivot pin to inner arm assembly. Remove cylinder rod pivot pin and remove cylinder.

Adjustment of reach cylinders is not required.

32-02

3. Disconnect hydraulic lines from reach cylinders and cap ends of hoses.

REACH REMOVAL

CYLINDER

1. Make sure truck is on a level surface. Block wheels to prevent truck from moving. Fully lower upright.

2. Fully extend reach mechanism. Retract reach mechanism slightly and use blocking and chain binding to retain spacing between front and rear assemblies of carriage frame to prevent accidental movement of parts.

5. Remove reach cylinder from opposite side in same manner.

32-03

REACH CYLINDER DISASSEMBLY.

When disassembling cylinder, it is necessary to have a clean workbench.

Cover parts if left exposed for any period of time (such as overnight).

Cylinder may be held by carefully clamping in a vise. Be careful and avoid damaging cylinder by applying excessive pressure that will permanently damage cylinder.

1. Insert caps in ports and carefully clean exterior of cylinder with a petroleum base solvent.

SM538 32 - 06 - 1

Air dry and place assembly on a clean surface.

Remove caps.

10. Remove and discard gland seal and O-ring from cylinder barrel area of gland and remove and discard wiper and seal from rod area of gland.

12. Repeat disassembly of other reach cylinder.

32-04

REACH CYLINDER ASSEMBLY

1. Check rod, cylinder bore, gland and piston for any evidence of corrosion or contamination. If any contamination, flush all part with clean hydraulic fluid and air dry.

2. Begin disassembly of cylinder.

Pry tab of exterior locking ring from hole in cylinder barrel and lift out to unlock cylinder gland end from barrel.

Rotate ring slightly to move tab away from lock hole.

Check cylinder rod for any evidence of nicks, scratches, gouges, pitting or mechanical damage.

Small defects may be removed using very fine emery cloth or by stoning.

3. Clamp cylinder carefully in vise and rotate gland to remove locking wire from inner grooves of cylinder and gland. Lockwire easily “flows” out as gland is rotated. Discard this locking wire . Use a new lockwire when assembling cylinder.

4. Pull on piston rod assembly to withdraw rod and gland assembly from barrell.

2. Begin assembly of cylinder. Install new gland seal and O-ring on gland and install new seal and wiper in gland.

3. Install new piston seal and backing ring.

4. Install new small O-ring on rod.

5. Coat all seals, retainers, cylinder rod and cylinder bore with a light coat of clean hydraulic fluid.

5. Withdraw cylinder rod from gland.

6. Install piston on cylinder rod. Install nut and tighten to a torque of [81-88 N.m] 60-65 Ibfft.

6. Remove cylinder rod nut.

7. Remove piston from cylinder rod.

7. Insert cylinder rod into gland.

8. Remove and discard small O-ring.

9. Remove and discard piston seal and backing ring.

8. Insert piston assembly and gland into barrel of cylinder using care not to damage seal as it enters

SM538 32 -.Q6 - 2

9. Carefully clamp cylinder in a vise to prevent it from turning. Install new locking wire into inner groove and rotate gland assembly in opposite diretion as when removing wire.

10. Repeat assembly for opposite cyllinder.

32-05 REACH INSTALLATION

CYLINDER

1. Position anchor end of cylinder on rear frame trunion and Install reach cylinder anchor end pin.

Install roll pin to lock pivot pin.

2. Install pivot pin in piston rod mounting rod to trunion on inner arm assembly. Install roil pin in pivot pin locking pivot pin in place.

3. Repeat installation of opposite reach cylinder.

4. Install hydraulic lines to cylinders.

Release binding chains.

5. Connect battery.

Move cylinders to loosen chain and blocking.

Remove chain and blocking.

6. Install forks.

7. Check all motions of upright. Check for leaks and make sure all hoses are in correct position and do not bind or rub on moving parts.

SM538 32 - 06 - 3

GROUP 34 UPRIGHTS

SECTION 01 MODEL C

CONTENTS

NO.

UPRIGHT REMOVAL UPRIGHT INSTALLATION

34-01

UPRIGHT

34-01 34-02

REMOVAL

1. Park truck on a level floor.

2. Block wheels and fully lower upright. has reach mechanism, retract reach.

Turn key switch to OFF. Disconnect battery.

LIFT CYLINDER

If truck

LINE\‘

4. Unfasten aux. hose on RH side of upright at hose coupling to steel tubing connection. Cap hose end.

5. Unfasten aux. hose on LH side of upright at hose coupling to steel tubing connection. Cap hose end.

6. Disconnect lift cylinder line at fitting to selector valve. Cap hose end.

UPRIGHT

3. Disconnect wire harness from unfastening two (2) quick disconnect located on RH side of upright below middle tie bar. (One is for pantograph for speed limit switch on upright).

upright by assemblies and behind and other is

TRIPLE-STAGE UPRIGHT

7. Attach a lift chain of adequate capacity.to the top rail tie bars. Make sure the chain is securely fastened to bars and will not slip.

Use an overhead hoist (or a lift truck of adequate capacity) attached to this lift chain to remove upright from truck.

SM538 34 - 01 - 1

11. Lift upright up to clear saddle, then remove from truck and store in a safe manner.

34-02 UPRIGHT INSTALLATION 1. Make sure truck is on level surface, that wheels

8. Remove fasteners attaching DOG to upright (two bolts per side).

are blocked to prevent truck movement, and battery is disconnected.

2. Make sure upright is secured by chains as described for UPRIGHT REMOVAL above.

Use a chain hoist and chains of adequate capacity for lifting.

Raise upright to vertical position. Put washers and upright mounting block on mounting trunions. Bored hole in mounting block should be toward front of truck. Use correct washers on mounting trunions to shim clearance for mounting upright.

NOTE: Use only number of washers required to reduce clearance without forcing upright mounting blocks into place. Divide washers evenly for each side to center upright (use of one extra washer acceptable)

9. Remove four (4) locking setscrews from main frame upper upright support. Loosen exposed setscrews to unlock upright from upper frame saddle.

3. Raise upright and insert upper bars (on side of outer rail) into saddles in frame.

Lower upright and align mounting blocks with bolt holes in frame. Insert fasteners into mounting block and tighten to a torque of [289-325 :I. -1 220-240 Ibf ft.

4. Remove lifting and securing chains.

5. Use a level on outer rail of upright to measure vertical alignment. Use setscrews in frame saddle to adjust upright outer rail assembly to a back tilt of O” 15’ to O” 30’ back tilt.

Tighten setscrews to maintain this position and then insert locking setscrews and tighten.

6. Install fasteners connecting DOG to upright side rails (two per side). Tighten nuts to a torque of [340-380 N.m] 250-280 Ibfft.

7. Remove lifting chains.

8. Connect lift cylinder hose to fitting at selector valve.

9. Connect aux. hoses to tubing on each side of upright.

Connect wiring harness to upright by 10. connecting two quick disconnect fittings located on RH side just behind upright and just below middle tie bar.

11. Connect battery. Check all operations of upright making sure lines have been connected correctly and that there are no leaks.

10. Remove four (4) fasteners which attach upright mounting block to main frame.

SM538 34-01-2

GROUP 34 UPRIGHTS

SECTION 02 MODEL C

CONTENTS

NO.

UPRIGHT MAINTENANCE (STD) ROLLER CHECWADJ. LIFT CHAIN CHECWADJ BLEEDING CYLINDERS UPRIGHT DOWNDRIFT TEST UPRIGHT DESCRIPTION (TSU) OPERATIONAL CHECKS (TSU) LATCH OPERATION (TSU) INTERMEDIATE RAILS (TSU) CARRIAGE CHAIN ADJ. (TSU) CHECKING ROLL PA-l-TERN CHECKING CYLINDER SEALS LOAD TESTING LIFT CYLINDER DRIFT TEST TILT CYLINDER DRIFT TEST CARRIAGE REMOVAL ADJUSTING CARRIAGE ROLLERS CARRIAGE INSTALLATION UPRIGHT CLEARANCE (TSU) ROLLER SHIM INSTALLATION (TSU)

34-01

UPRIGHT

34-01 34-02 34-03 34-04 34-05 34-06 34-07 34-08 34-09 34-l 0 34-l 1 34-12 34-13 34-14 34-15 34-l 6 34-l 7 34-18 34-19 34-20

MAINTENANCE

Shim inspection operation.

at least

every

500

hrs of

Check mounting fasteners.

Check for leaks at hydraulic connections.

Check for interference during lift operations.

of hosing,

chains,

etc.

Keep piston rods and tops of cylinders clean.

Always keep piston rods in retracted position when not in use.

Lubricate lift chain.

Check chain adjustment and chain anchor adjustor jam nuts.

34-02 AND

UPRIGHT ROLLER CHECK ADJUSTMENT PROCEDURES

1. Remove carriage. (Refer to carriage removal section).

2. Before checking roller clearance, position inner rail about [125 mm] 5 inches above full down position.

Check both sides for roller clearance at inner rail (top and bottom). Use tool to record this number on rail. , FEELERGUAGE

WARNING AN UPRIGHT OR CARRIAGE CAN MOVE UNEXPECTEDLY Chain or block the carriage and rails when doing upright maintenance.

FAILURE TO FOLLOW THIS WARING CAN RESULT IN SERIOUS INJURY Do not walk or stand under raised forks.

Do not reach through upright open areas.

Use only hardwood blocks which are free from cracks and other visual damage. These blocks must be square on ends and not tapered or rounded.

Tuck blocks specified.

into

channel

under

rail where

Review all described procedures before starting any maintenance or service function. Failure to follow this warning can result in serious injury.

on outer rail section and record the number of shims to be used for bottom roller on inner rail.

There is some clearance, but it is not to exceed [0,8 mm] l/32 inch.

3. Raise inner rail to l/2 of its full up position. Use tool and bar to check roller clearance in same manner as before.

Record number of shims to be used for top roller on outer rail.

SM538 34 - 02 - 1

Record number of shims to be used for bottom roller on inner rail.

4. Raise inner rail to full up position and use tool and bar to check roller clearance in same manner as before.

Record number of shims to be used for top roller on outer rail.

Record number of shims to be used for bottom roller on inner rail.

5. Raise inner rail about [125 mm] 5 inches and remove stop block.

(a). Outer Rail Rollers: 1). Count number of shims in right and left hand rollers.

2). Look at three (3) numbers recorded on outer rail in steps 2, 3 and 4. The smallest of these numbers is total number of shims to be added. An “0” means do not add shims.

3). The optimum target is to have same number of shims at each upper roller. If there is an extra shim, do not remove it, but do mark side having extra shim.

6. Lower inner rail until upper and lower rollers are clear for removal.

(b). Inner Rail Rollers: 1). Count number of shims in right and left hand rollers.

2). Look at three (3) numbers recorded on inner rail in steps 2, 3 and 4. The smallest of these numbers is total number of shims to be added. An “0” means do not add shims.

3). If there is an extra shim, make sure it is on same side as extra shim above.

7. Roller adjustment procedure:

8. Raise inner rail about [125 mm] 5 inches above tie bar (of outer rail) and install stop block and pad assembly.

SM538 34-02-2

9. Remove carriage support chain and wheel blocks.

10. Raise and lower carriage to full up and down positions, checking all phases of operation.

6. Raise carriage and measure distance form where center of BOTTOM CARRIAGE ROLLER stopped to bottom edge of inner slide. Distance must not be less than [12 mm] l/2 inch.

7. Be certain to wipe grease from rail.

34-03 UPRIGHT LIFT CHAIN CHECK AND ADJUSTMENT PROCEDURE

34-04 LIFT

LIFT CHAINS

1. Raise carriage about [1200 mm] 4 feet or until bleeder screw on side of barrel is accessible.

BLEEDING CYLINDERS

COMPOUND

NOTE: Check for proper oil level in sump before and after bleedina.

Lift chains are mounted to chain anchors on lift carriage and at chain anchor rods near lift cylinder piston head.

If it becomes necessary to adjust lift chains, proceed as follows: 1. Elevate carriage to about [i 200 mm] 4 feet.

I

2. Loosen side bleeder screw using Allen wrench.

The piston will drop a small amount (perhaps several inches) as air escapes. When air stops and oil starts to flow, tighten bleeder screw.

GREASE

2.

:

Smear grease on inner slide channel making

sure it is in path of roller contact.

3. Pick up a capacity load.

NOTE: It is important that chain adjustment be made with capacity load. This will assure correct adjustment for maximum chain stretch.

3. Loosen top bleeder screw using Allen wrench.

Piston will drop a small amount as air escapes.

When air stops and oil starts to flow, tighten bleeder screw.

4. Check oil in sump and add if necessary.

4. Lower load to down position.

5. Remove capacity load.

SM538 34 - 02 - 3

34-05 TEST

UPRIGHT

DOWNDRIFT

A TEST LOAD is used to check for drift.

A TEST LOAD is one of same weight as CAPACITY LOAD shown on truck SERIAL NAME PLATE for CAPACITY RATING. It should be on a 48 x 48 pallet and should be equally distributed. It must be secure on pallet.

Material used for test load must be arranged (stacked) to provide load stability and material must not extend beyond sides of pallet.

1. Adjust fork width to maximum which will accommodate TEST LOAD. Space forks as wide as possible to provide most even disposition of weight.

2. Keep forks level during pick up of load (do not drag forks on floor).

3. Enter pallet as far as possible until forks completely engage pallet and TEST LOAD. TEST LOAD and pallet should be in contact with load back rest.

4. Elevate carriage raising TEST LOAD until pallet is about (300-350 mm] 12-15 inches off floor. Tilt load slightly back (about lo from vertical).

These numbers, called DECK NUMBERS, located in front of outer rail.

34-07 AND

OPERATIONAL ADJUSTMENTS

are

CHECKS (TSU)

The triple stage upright should be load tested to determine if adjustments are needed.

NOTE: The upright is a very heavy assembly with many moving parts.

Maintenance procedures should be followed carefully.

WORK SAFELY. KEEP HANDS, FEET AND ALL BODY PARTS OUT FROM BETWEEN MOVING PARTS UNLESS PARTS ARE SECURED TO PREVENT MOVEMENT. DO NOT ALLOW OTHERS TO DISRUPT WORK. KEEP ALL PERSONS AWAY FROM TRUCK CONTROLS WHEN MAKING MEASUREMENTS OR ADJUSTMENTS.

MARK ON ALL RAILS

The following operational checks should be made to determine if upright is operating properly.

5. Stand clear of load. Use a pencil to make a horizontal mark across all rails as a reference point.

6. Begin timing of five minute test. Check after each minute. Upright drift should not exceed [25 mm] 1 inch per minute.

34-06 (TSU)

UPRIGHT

Any adjustments should be made prior to load Equipment in unsatisfactory condition testing could fail under load and cause injury or damage to truck.

34-08

DESCRIPTION

The following procedures cover FULL FREE LIFT TRl?LE STAGE UPRIGHTS equipped with sixroller carriages. ,Service procedure applies to all uprights with M SEf%AL NUMBER designation.

LATCH

OPERATION

(TSU)

A two-piece latch, located on top inner rail tie bar, is designed to prevent inner rails from raising before carriage is fully extended.

As carriage is raised, it passes through area of full free-lift (height to which carriage can move without rail movement).

SM538 34 - 02 - 4

LATCH

RETAINING BOLTS

When it reaches end of full free-lift, the latch is tripped by a finger that protrudes slightly from piston head.

Latch should be checked immediately after it has been tripped to be sure it is working properly.

Check latch from behind upright with key switch OFF. Latch should move up and down about [12 mm] l/2 inch with slight finger pressure.

34-09 (TSW

INTERMEDIATE

Lift cylinder base should move slightly out of mounting socket when upright is fully extended.

However, movement should not be excessive causing it to jam against retaining bolts.

Lack of free movement of lift cylinder base when upright is fully extended, indicates that intermediate rail chains are too long.

RAILS

i: i: i: ........,..., . ... .....; ... :: :: : ii : ;; ii ii ii ii ii .T : : ii

:

;; ii ;; ii

;

ii ii

i .i.F.

ii

:

ii: :

~ . .

. .

... . .

.._._;

..A..

: . .

:..

Intermediate rail chains extend downward from anchor points on lift cylinder, pass around sheaves on intermediate rail tie bar, and anchor near top of outer rail.

Inspect chains for wear and for equal tension, Refer to index for complete coverage of UPRIGHT LIFT CHAIN CHECK and ADJUSTMENT PROCEDURES.

They should be shortened by means of their adjusting nuts on the anchor plate, which is attached to lift cylinder.

If adjusting nuts are removed, be sure nuts with conical seats are inserted first, which will permit self-aligning design to work properly.

SM538 34 - 02 - 5

34-13

34-10 CARRIAGE CHAIN ADJUSTMENT (TSU)

The carriage chains are attached to bottom of carriage, then travel around rollers mounted on sheave carrier, then anchor to same plate as intermediate rail chains, but enter anchor plate from above.

Carriage chains should be adjusted to put forks [12 mm] l/2 inch above ground when upright is fully lowered.

As with intermediate chains, conical ends on anchor nuts should seat in anchor plate. inspect carriage chains for wear.

34-11

CHECKING

ROLL

PATTERN

Impressions made by rollers on upright rails are called roll patterns.

Roll patterns can give an indication of upright adjustment.

Excessive metal scoring or gouging of roller paths may indicate excessive pressure caused by damaged or misadjusted rollers.

Roll pattern can be checked by applying a light coat of spray paint or a thin layer of grease to roller contact area and then operating upright several times with a load.

Roll pattern of carriage rollers (including thrust rollers) and main upright rollers can all be checked in this manner.

34-12 CHECKING AND SEALS

CYLINDER

Cylinder rod seals should be checked for leakage.

Seals of primary piston rod, secondary piston rod and feed tube assembly should be checked.

Cylinder rods should be free of grit, chemical residues, paint, and nicks on ground or polished surfaces.

SM538

LOAD

TESTING

Center a capacity load on forks . Tilt load slightly back to help retain it, and raise load to maximum Note smoothness of height several times. operation , carriage play (clearance), and play between rails.

If operation is satisfactory, load should then be positioned [l 00 mm] 4 inches off-center. Again tilt load slightly back and raise load to maximum height several times. Note smoothness of operation and ptay of carriage and rails.

Repeat with load placed off-center in opposite direction.

Experienced mechanics have found that both conditions of play (too little and too much) can cause binding and/or uneven operation.

The design of interlocking rails requires some lateral movement of carriage within inner rails.

Adequate clearance between rollers and rails is necessary to insure smooth operation and minimum wear.

Providing operation works NOTE: smoothly with a capacity load, service man should consider application for which truck is used in making a decision as to whether carriage or rail adjustments are necessary.

If product handled by truck is very delicate or operation is sensitive, service man should take these factors into account.

The adjustment of new uprights that have minimal operating time is not recommended unless there is some indication that upright is not working properly.

NOTE: Rollers require some time to seat in rails, and initial stress relieving at weld areas will cause some dimensional changes that affect roller clearance.

Operators should be consulted on a regular basis as to any unusual operation of upright as well as other parts of truck.

34-14 TEST

LIFT

CYLINDER

DRIFT

Lift cylinder drift is checked with a capacity load on upright.

Make sure brake is engaged and put blocks at wheels to prevent truck moving.

34 - 02 - 6

DOWN DRIFT WILL APPEAR LIKE THIS.

Raise load to approximately one half of full lift height. Turn key switch to OFF. Stand to one side of truck and use tape or marking pen to make a horizontal line across all rails on one side of upright.

At the end of a five minute period from when mark was made, measure drift and compare with specifications for allowable downdrift.

If specifications are exceeded, refer to index for DOWNDRIFT CHECK AND ADJUSTMENT PROCEDURES.

34-15 TEST

TILT

CYLINDER

Place a 4x4 post squarely beneath carriage lower fork bar, centering post on carriage chain anchor bracket.

Stand clear of upright and lower carriage until it contacts post.

Continue lowering lift cylinder approximately [25 mm] one inch more to allow carriage chains to go slack.

Check to be sure chains are loose and that post is squarely in place.

DRIFT

Use a capacity load centered on forks.

Raise load a few feet off ground. Tilt carriage fully back and turn key switch OFF. Immediately measure tilt cylinder extension (distance from endcap of cylinder barrel to center line of rod pin).

After a five (5) minute waiting period, again measure this distance. Compare drift with specifications for allowable drift.

If specifications are exceeded, refer to adjustment procedures for tilt cylinder repair.

34-16

CARRIAGE

REMOVAL

Use this procedure to adjust cariage if binding or excess play is suspected.

Make sure brake is set and wheels blocked to prevent truck moving.

Raise carriage to height where work can be done comfortably.

SM538

Stand behind upright and remove cotter keys from carriage anchor pins.

Obtain machine bolts of at least same length as carriage chain anchor pins (but of slightly smaller diameter) and have near at hand.

Hold carriage chain with one hand and remove anchor pin with other (carriage chains must be held to prevent them from flipping up and over sheaves). When pin has been removed, replace it with a bolt.

Repeat procedure for opposite side.

After both pins have been replaced, stand to one side of upright, turn key switch to ON, raise carriage until it is well clear of post, remove post and lay it on floor just in front of fork heels (or use shorter post of same cross section if post is longer than outrigger spacing).

34 - 02 - 7

Slide a standard pallet about three-fourths of way onto forks and then lower carriage all the way until lift chains are slack.

Make sure carriage is stable. assembly.

Remove bolts from both carriage anchor points.

Push carriage chains up around their sheaves on piston head so that they are out of way of carriage.

Remove blocking from wheels.

Turn key switch ON and raise lift cylinder until carriage rollers are clear of inner rails.

34-17 ADJUSTING ROLLERS

It is a very heavy

CARRIAGE

Obtain a set of calipers for making carriage adjustments. One is an inside caliper and other is an outside caliper. See end of this section for instruction/dimensions for making calipers.

RAILS MUST CLEAR ROLLERS

Release ,brake and slowly move truck backward allowing truck to back away from carriage.

Lower lift cylinder until upright rails are down (but not enought to lower piston head). Turn key switch OFF. Tie carriage chains front to back, just below piston head.

Use inside caliper first to measure inner rail span.

Loosen thumb screw and place it squarely across inside surfaces on inner rail making sure it is in contact with both sides. Tighten thumb screw.

Then move caliper up and down inner rails, continually checking until narrowest point is located.

SM538 34-02-8

At this narrowest point, use a [0,8 mm] l/32 inch thick shim under one leg of caliper. Unloosen thumb screw and make sure shim and leg are firmly against one side of rail and opposite leg is against other side, and that caliper is square with upright.

Tighten thumbscrew.

The shim will provide correct operating clearance for carriage rollers within ir- * rails.

Remove shim and calico: put shim away. Set outside calipers by posZ5.;:.rng outside caliper legs to contact extreme points on inside calipers and lock outside calipers with thumbscrew.

If thrust rollers are in good condition, place outside caliper across middle (or intermediate) set of carriage rollers. Put caliper on side of rollers near back of carriage fork bar.

Remember that carriage rollers are canted. The caliper must be placed so that maximum distance across the set of rollers is measured.

Position outside caliper carefully to measure across rollers, Select shims to fill gap between leg of caliper and roller (do not force shims into gap).

Shims are [0,8 mm] l/32 inch thick.

Do not add shims behind rollers yet.

Move to rear of carriage and inspect side thrust rollers on rear of carriage. Check these rollers for damage to contact surfaces, seal damage, and excessive play. These rollers are important when making measurements. Their positions are located and fixture-drilled during carriage manufacture.

They can be removed by loosening a socket head screw in their centers.

Use a steel rule to measure distance from carriage roller front face to thrust roller side face.

Make same measurent on rollers on opposite side of carriage.

Compare measurements. This will determine on which side of carriage to add odd shim should initial shim requirement demand an uneven number of shims.

SM538 34 - 02 - 9

Remove carriage rollers by working them off with a pry bar or by tapping them loose using a soft-faced hammer.

Divide required number of shims in half (if odd number, place odd shim on side where shortest distance from face of carriage roller to thrust roller Put shims on roller shafts.

Inspect occured). rollers for damage. Install rollers on shaft and make sure they are fully seated against shims.

Recheck measurements taken above to be sure correct number of shims were added and odd shim (if used) was added to the correct side.

Next, span bottom set of carriage rollers.

Note these rollers are canted in opposite direction from set above.

Thus, caliper measurement is taken across side of roller nearest operator (most distant from fork bar).

Again use shims to determine number required to fill clearance of caliper lea.

Rollers must be directly in line with each other. To determine this, use a carpenters square. Use one leg against intermediate and bottom rollers and other leg along top fork bar. Make sure leg of square rests against intermediate roller at side nearest fork bar and against bottom roller at side away from fork bar.

SM538

Use a steel rule to check distance from opposite leg of square to top fork bar. Measure at both ends of square leg and use this set of measurements to determine where to add or subtract shims to bottom rollers.

Remove and inspect bottom rollers in same manner used for middle rollers.

Add or subtract shims behind rollers as determined.

Replace rollers making sure they are firmly seated.

Recheck bottom rollers by first using outside calipers, then using square.

If correct number of shims were installed, outside caliper measurement should indicate no additional shims are now needed and square should indicate that rollers are now in line and measurements from edge of leg of square to top fork bar are equal.

The top carriage rollers are checked last. Note that top rollers extend out of inner rails when carriage is fuly extended.

To make sure of re-entry of these rollers into inner rail assembly, additional clearance is given for this top set of rollers.

34 - 02 - 10

SHIM

After both thrust rollers have been adjusted, rollers should be lubricated.

This completes procedure for adjusting six-roller carriage used on triple stage upright. If upright rails are also going to be adjusted, carriage would not need to be installed at this time.

34-18 CARRIAGE INSTALLATION Movetruck up to carriage slowly. Raise lift cylinder

Use one leg of a carpenters square to check top Place leg of square directly through rollers. centers of the intermediate and top rollers.

A gap of [0,8 mm] l/32 inch is required between leg of square and top roller face (top rollers are closer together). Use a shim to measure gap.

Top rollers are removed by first removing a socket head capscrew, then removing roller.

After removal of roller, inspect roller for damage.

Correct shims as measurement indicated, replace roller, and tighten screw. Recheck measurement to be sure correct shim replacment was made.

Repeat for opposite side of carriage.

The final step for adjusting carriage rollers is to adjust carriage side thrust rollers that contact inside of inner rails.

Use carpenters square and place one leg across diameters of lower and center carriage rollers. The face of thrust roller should overlap edge of rule by [0,4 mm] l/64 inch on both thrust rollers.

The side thrust rollers should also be checked with lower fork bar for squareness.

U-shaped shims are used and are added or removed as needed, beneath either or both of socket head mounting screws on these thrust rollers.

SM538

to position carriage rollers directly below inner rails and lower lift cylinder completely.

Turn key switch OFF, make sure brake is engaged and block wheels to prevent truck from moving.

Untie carriage chains.

Actuate lower contol of valve and block control in this position.

This will allow pulling on carriage chains to lower piston head.

NOTE:

Refer to manual for this position.

Put lift chains over load back rest on carriage.

When carriage chains are fully down, temporarily insert machine bolts to connecct chain to carriage.

Remove blocking on hydraulic valve.

Turn key switch ON and actuate valve to raise carriage to clear blocking. Remove pallet and blocking.

Raise carriage until 4x4 block (used for removal of carriage) can again be placed squarely under carriage centered on lift chain bracket.

Lower carriage until carriage is fully suported on post. Make sure post is square under pallet.

Turn key switch OFF. Remove temporary carriage bolts and replace with correct chain anchor pins.

Insert new cotter pins to lock chain anchor pins and spread ends of cotter pins.

Turn key switch ON, raise carriage and remove 4x4 blocking.

Lower carriage and remove blocking from wheels.

Cycle upright to full lift height several times to be sure it is operating properly.

Make operational checks and load test before placing truck in service.

This concludes service procedure for making operational checks, load testing, and carriage adjustments on triple stage uprights with six-roller carriages.

34-02-

11

34-19 (TSU)

UPRIGHT

CLEARANCE

INNER INTERMEDIATE

INSIDE SPANNING TOOL (Used in adjusting carriage rollers)

The triple stage upright has three sets of rails: The inner rails The intermediate rails.

The outer rails.

When lift cylinder is raised, fork carriage moves through what is called FREE-LIFT portion of cylinder travel (carriage moves up but rails do not move).

OUTSIDE SPANNING TOOL (Used in adjusting carriage rollers)

SCRIBE

(OR) PENCIL

WING NUT(l/.%X)) PART NUMBER

-HEX

SOCKET

16C0l

SET SCREW (1x1/4-20)

PARTNUMBER p-2

15Gl16~

BOLT (1x1/4-273)

li’l

PARTNUMBER

DRILL A l/4-INCH MRU

19316

GRADE#2

HOLE STRAIGHT

BLOCK.

DRILL 6 TAP 114-x) COURSE

THREAD

HOLE.

Just beyond maximum free lift position, carriage top rollers become visible as they extend out from top of inner rails.

When top end of free-lift travel is reached, primary cylinder piston head trips a latch that permits inner and intermediate rails to rise to maximum fork height.

The triple stage upright has 8 rollers.

UPRIGHT MOUNTING BLOCK (Used in determining upright clearance)

SM538 34-02-12

Clearance

when rails

pried right (exaggerated

%

for clarification) OUTER RAIL INTERMEDIATE

Four rollers work between

RAIL

outer and intemediate

INTERMEDIATE

RAIL

INNER RAIL

Four rollers work between intemediate and inner rails.

Experienced service men are aware that with age and wear, clearance between upright rails can increase and cause excessive looseness between rails.

Upright rollers become worn, rail surfaces wear, and stress relieving due to handling of heavy loads over an extended period of time may cause slight dimensional changes between upright rails.

RAIL

TO

ROLLER

CLEARANCE

The triple stage upright has four sets of rollers, one set at top of outer rails and a second set at bottom of intermediate rails. A third set is at top inside of intermediate rails and a fourth set is at bottom of inner rails.

By prying all rails to right, all clearances are moved to left side. In like manner, prying all rails to left moves all clearances to right side.

Using this method, clearances of rail to roller can be measured.

Measuring clearances at only one point is not a satisfactory method for rail assemblies are not perfect but have a variance due to manufacturing tolerances.

For a more reliable measurement, rail to roller clearance is checked at more than one place for each roller set. Clearance check points should be taken at: Upright fully lowered Upright raised to one half extension Upright fully raised.

And for each roller set.

NOTE: Upright rails are actually welded in a slight “A” type configuration to give minimal clearance at maximum upright extension.

To check and adjust rail to roller clearance, the following items are needed: Common hand tools.

Four or 5 hardwood posts in lengths from [1200-3600 mm] 4 -12 feet A [3000 mm] 10 foot chain with screw type clevises or locking hooks.

A steel mechanics rule [O,l mm] l/32 inch graduations.

A marking block equipped with steel scribe or a sharply pointed pencil.

The block needs to have square edges and a locking bolt to hold pencil or scribe firmly.

Pry bars (also known as “lady slippers”).

Drive truck onto short pieces of 2x6 (or wider) boards, or elevate truck and place boards under wheels to raise truck a short distance above floor.

NOTE: It is assumed that carrige already been removed from upright.

SM.538 34 - 02 - 13

has

Make sure brake is set. Turn key switch to OFF. Block wheels to prevent truck moving.

MEASURING RAIL TO ROLLER CLEARANCE Begin by measuring clearance between set of outer rail and intermediate rails.

scribe a short line on outer rail. two marks parallel to each other.

This should

give

top roller

NOTE: WHEN MARKING AND MEASURING CLEARANCES FOR RAILS AND ROLLERS, ALWAYS MAKE SURE KEY SWITCH IS IN OFF POSITION AND THAT WHEELS ARE BLOCKED TO PREVENT TRUCK FROM MOVING.

WRITE CLEARANCES ON RAIL THAT ROLLERS ARE Al-l-ACHED

With upright fully lowered, insert pry bar between outer and intermediate rail on left side and pry with moderate force to right.

Use a rule, a pencil or marking pen, and a marking block.

Hold marking block flush with flange of intermediate rail and scribe a short line on outer rail.

Then place pry bar between outer and intermediate rail on right side and pry gently to left.

Again hold marking block flush with flange of intermediate rail (on same side as above) and again

SM538

TO.

Measure distance between these marks.

Use pencil or marking pen and mark this measurement below scribe mark.

This is total clearance between this roller set and intermediate rails with upright fully lowered.

Next, raise upright to approximately one-half maximum lift height.

Repeat same process of marking after prying between intermediate rails and outer rails on right side and then on left side. Measure and record distance between marks (which is ?otal cleara,. ‘5 between roller and rail).

Then raise upright to full lift height and turn key switch to OFF. Again, pry between intermediate and outer rails from right side and mark, then pry rails from left side and mark. Measure and record distance between marks (which is total clearance).

Fully lower upright.

\ Compare value as thick. In [3,2mm]

34-02-14

all three measurements and use smallest shim value. Shims are [0,8mm] l/32 inch this example, the smallest clearance was 4/32 inch, therefore it would require four

shims (use same number of shims for each roller set) on each roller.

This determines number of shims that need to be added to pair of rollers at top of outer rails (2 shims on each roller).

Next, determine clearance between roller set at bottom of intermediate rails. With upright raised just slightly, and key switch in OFF position, pry intermediate rail to left and then to right as before and mark, measure, and record clearance.

Repeat with upright raised to about one-half of fully raised position.

Notice, that to measure, requires ladders and/or maintenence stands.

Use equipment that meets applicable OSHA standards.

Use same procedure for comparing clearance measurements and again choose smallest value for shim selection which must be added to roller set at top of intermediate rails.

Boll-OM

INNER

ROLLERS

SHIM VALUE IN THIS EXAMPLE-

Raise upright to maximum fork height and mark, measure and record clearance.

Compare measurements as before and choose smallest value as shim value to be added to roller set at bottom of intermediate rails.

The final shim selection will be for bottom rollers on the inner rails.

With upright fully lowered, pry between ‘-rner and intermediate rails at bottom of inner r&II. Mark, measure and record total clearance.

Raise upright to one-half fully raised position and repeat.

Raise upright to fully raised position and again repeat.

Lower upright. Compare measurements as before to determine number of shims to be added to bottom rollers on inner rails.

This concludes the shim determination process.

Recheck all figures to be sure of correct determination of how many shims are to be applied to each roller set.

34-20 ROLLER INSTALLATION

Next step is to measure clearance of roller set for top rollers on intermediate rail.

Fully lower upright.

Pry between intermediate rail and inner rail and mark, measure, and record as before Note that marking block is now placed on intermediate rail.

Next, raise upright to mid point of lift and repeat.

Raise upright to maximum fork height and repeat.

SM538

SHIM (TSU)

Be sure parking brake is on. Be sure wheels are blocked.

The piston head should be up and carriage chains tied back.

All rails should be marked with roller clearances.

Always block inner and intermediate rails when working on the upright.

Do not put hands or feet between parts that move unless all pans are secured to prevent movement.

Keep all personnel away from truck controls during service procedure. The key switch should be OFF at all times, except when truck operation is indicated in the procedure.

34 - 02 - 15

/ f < Start truck and raise lift cylinder until 4x4 posts can be placed under inner and intermediate rails.

A longer post is placed beneath inner rail since it extends higher than intermediate rail.

Lower lift cylinder until rails make solid contact with posts, and intermediate rail chains become slack.

Turn key switch OFF.

Remove lifting bracket (or “moosehorn”) from intermediate rail lower tie bar.

To remove, first remove 8 bolts. Note position of any shims behind lifting bracket and save them for replacment at time of assembly.

Push bracket downward until it is clear of tie bar, then rotate it 180°, then push downward again.

CAUTION PUSH LIFTING BRACKET FULLY DOWN. IF IT IS NOT FULLY DOWN, HYDRAULIC PRESSURE WILL PUSH IT DOWN FORCEFULLY WHEN CYLINDER IS OPERATED.

Remove two-piece latch from back of inner rail tie bar by first removing an Allen head setscrew, then pulling latch apart.

(On older machines, latch is disassembled by removing a cotter pin, driving out a roll pin, then separating halves of latch.

Put a couple of blocks that are about [150 mm] 6 inches thick on outer rail upper tie bar. The blocks should be placed directly below intermediate rail upper tie bar.

Stand away from upright, turn key switch to ON, and slowly raise lift cylinder until inner and intermediate rails are clear of 4x4 posts. Remove 4x4 posts and lower lift cylinder until intermediate rail upper tie bar is seated firmly on blocks.

Continue to lower lift cylinder until lift cylinder is completely down. Inner rails will not lower further.

Turn key switch OFF.

SM538

34-02-16

Pass inner chain through bend area of intermediate rail tie bar. Use a chain with sufficient capacity to support inner rails ( but not so large that it will not pass between tie bars).

CAUTION USE A SERVICE CHAIN WITH ENDS THAT CLOSE SECURELY. EITHER SNAP HOOKS OR SCREW CLEVICES ARE ACCEPTABLE.

Rollers at torof intermediate rails, and at bottom of inner rails are now exposed.

Remove rollers at bottom of inner rails. Note number of shims already on roller. Add shims per determination procedure.

Inspect and replace rollers.

It is important that number of shims on each roller in set be same. Should there be an odd shim in set, it should always be put on same side.

Turn key switch on and raise lift cylinder until blocks under intermediate rail can be removed.

Continue to raise lift cylinder until a 4x4 can be placed beneath inner and intermediate rails.

Longer posts are needed here.

Normally inner rail is about one foot higher than intermediate rail. There must be some slack in intermediate rail chains.

After blocks have been placed under rails, and have been inspected to be sure rails are resting securely on blocks, turn key switch OFF. Work from a secure ladder or maintenance stand.

c

3

Remove intermediate rail chains. Be sure chains are slack.

Remove both chain retainers by removing bolts at center of chain sheaves.

Then remove chains at their anchor points on outer rails.

Some uprights have anchor plates welded onto outer rails. To remove chains on these models, cotter pins must be removed from first link on chains.

Drape a service chain between inner rail tie bar and intermediate rail tie bar so that two loops are formed.

SM538 34 - 02 - 17

Drape chains and coil them on floor where they are out of the way. Protect them from dirt by covering them if this can be a problem.

Stand to one side of upright. Turn key switch to ON and raise lift cylinder until posts can be removed. Lower lift cylinder until intermediate rails rest on floor.

Then put 4x4 post underneath inner rail and lower inner rail onto post making sure it rests squarely on post. Turn key switch OFF.

This allows inner rails to lower intermediate rail to floor and allows roller sets at bottom of intermediate rail and top of outer rails to be exposed.

Remove top rollers on outer rails first. Be sure to note number of shims already in place.

Add additional shims (determined by measuring).

Be sure to put odd shim (if any) on correct side.

Inspect rollers for damage. Install rollers making sure they are fully seated against shims.

+.

To begin assembly, turn key switch to ON and raise lift cylinder until block beneath inner rail can be removed.

Then place longer blocks (used earlier) beneath inner and intermediate rails.

Turn key switch OFF. Install intermediate chains at anchor points on each side of outer rails and replace chain retainers.

Remove service chain. _

Replace latch on inner rail. Tighten setscrew.

Position lifting bracket on rail assembly. To do so, main valve must be held in open position (prop valve to LOWER position in same manner ac at disassembly procedure). This will allow bracket tc be pried upward.

Then rotate bracket 180°. A short block is placed between bracket and cylinder base. Remove prop from LOWER position on main valve.

Stand to one side of upright. Turn key switch ON. Raise lift cylinder and remove long blocks.

Position short blocks beneath inner and intermediate rails.

Repeat this process for lower rollers. Again be sure to count shims already in place and to add correct number of shims. Inspect all rollers and make sure they are fully installed.

SM538 34 - 02 - 18

9

Lower cylinder until bolt holes for bracket are in line.

Turn key switch OFF. Replace 8 bolts in lifting bracket (replace any shims that were removed when bracket was removed).

Turn key switch to ON and raise cylinder until posts can be removed from under rails, and from under lift bracket. Fully lower lift cylinder.

Remove blocks from wheels.

Replace carriage using procedure for assembling carriage given earlier in this section.

After carriage has been installed, operate upright and note any unusual operation.

Make operational checks and load test upright before placing truck in service.

SM538 34 - 02 - 19

GROUP 34 SECTION 03 UPR. LIFT CYL. MODEL C CONTENTS

NO.

LIFT CYLINDER DESCRIPTION UPRIGHT MAINTENANCE STANDARD CYLINDER DISASSEMBLY STANDARD CYLINDER ASSEMBLY COMPOUND CYLINDER DISASSEMBLY CYLINDER PARTS INSPECTION COMPOUND CYLINDER ASSEMBLY

34-01 34-02 34-03 34-04 34-05 34-06 34-07

34-01 UPRIGHT DESCRIPTION

4. Remove load and disconnect vent line. Put end of vent line in suitable container to catch any oil which may be purged through vent line. Raise carriage to maximum height.

A. If oil gushes out of vent line, problem is in lift cylinder (for example, scoring around piston may permit seepage of oil past piston).

B. If no oil comes out of vent line, problem is in control valve. If it is not a simple matter of a bad O-ring seal, the spool and valve housing assembly will require replacement as a unit. Replacing spool alone as a unit would not help if real cause is a worn housing.

To locate cause of downdrift in COMPOUND CYLINDER: 1. Raise carriage with maximum load.

CYLINDER

The information contained in this section covers a series of constructions of upright cylinders, standard type as well as compound type. Always refer to your PRODUCT INFORMATION CARD to verify application.

34-02 UPRIGHT MAINTENANCE TROUBLE SHOOTING To locate cause of downdrift in STANDARD LIFT CYLINDER: 1. Raise carriage to maximum height. This is to purge system by forcing oil out of top of lift cylinder piston.

2. Lower carriage and pick up maximum load.

3. Keep load in raised position for five minutes to see if load drifts down. If load drifts, proceed to item 4.

STANDARD LIFT CYLINDER

_I

PRIMARY CYLINDER

%gK LEAKS

NOTE: When installing O-rings and back-up rings, lubricate O-ring grooves with hydraulic oil to facilitate assembly and to prevent damage to seals (cutting, scratching, etc.)

I

-

VENT LINE FROM SUMP

SECONDARY CYLINDER

A. If cylinder drifts down in excess of one inch per minute, check for leaks around seals.

If there is detectable drift, there will be evident leakage if problem is in cylinder.

LIFT CYLINDER GLAND CAP

-

B. If there is downdrift in excess of one inch per minute with no evident leakage around seals, the trouble is in control valve. If spool valve leaks, and O-ring seals are all right, replace entire valve assembly (not just spool) if housing is worn beyond tolerance.

SM538 34 - 03 - 1

34-03 STANDARD DISASSEMBLY

CYLINDER

There is very little maintenance to perform on the lift cylinder other than a periodic check on security of mounting and leaks at hydraulic connections.

When lift cylinder is removed from upright, place cylinder on a clean surface and remove piston head from cylinder cap (machines so equipped).

Note position of hydraulic connection on cap in relation to position of cylinder base so this position may be duplicated at time of reassembly.

CAUTION CLEANLINESS CANNOT BE OVEREMPHASIZED. THE SMALLEST PARTICLES (LINT, DIRT, DUST, WATER, SEALING COMPOUND, ETC.) ARE HARMFUL TO THE HYDRAULIC SYSTEM. Clean the cylinder tube with solvent or mineral spirits before disassembly.

Remove cap from cylinder tube. This will very likely be tight, and tapping with a soft-faced mallet on cap flange will release cap. Rotate cap until free, then remove.

NOTE; For caps equipped with a set screw, LOOSEN screw before removing cap from tube.

There is a bronze bushing located inside the cylinder cap which will not have to be removed, except for replacement, if damaged or worn.

Upon removal of internal threaded cap, remove back-up ring and/or O-ring from inside portion of cap.

The cap will contain one or both of these items.

On some models, there is a smaller inner O-ring.

Remove and discard it.

Note location of each item as removed to be sure of duplication of position at assembly.

The seal wiper or rod wiper need not be removed except in event of replacement.

Models equipped with a seal guard kit need to be disassembled for replacement of worn or damaged parts only. When reassembling seal guard kit, beveled sides of these components should mate or properly seat in each other.

The flat side of the rubber retainer ring should fit flat against inner portion of the cap lip (located on top side of cap). Refer to cylinder sketches in this section.

EFECTIVE FOR CYLINDERS WITH REMOVABLE BASES ONLY: Remove lift cylinder base from tube by tapping on base flange with a soft-faced hammer to loosen base.

NOTE: LOOSEN base set screw before removing base. Then rotate base from tube until free.

EFFECTIVE ON CYLINDERS WITH WELDED NON-REMOVABLE BASE: Remove piston from top end of cylinder tube. Be careful not to damage, scratch, etc. cylinder wall. .

EFFECTIVE ALL CYLINDERS: From the bottom end of piston rod, remove retainer ring (or snap ring) releasing piston follower (or followers if there are two), filler ring, U-cup and piston.

NOTE: On some models, piston is equipped with a back-up ring and/or Oring. Both of these items are located on/in piston rod groove inside piston. If used, back-up ring must be positoned on top of O-ring (or on far side of O-ring) backing up O-ring against fluid pressure when properly assembled.

Remove spacer if so equipped.

Take special note of position and location of these items to be sure of correct placement at assembly.

The filler ring is partially positioned in U-cup and Ucup is faced downward toward rod-end (or base end) of piston rod.

Piston rod follower fits flat against filler ring and Ucup.

Retainer ring holds these components in position (in a compressed state).

NOTE: Early model cylinders contain a cushion valve positioned in bottom end of piston rod and held in place with a retainer ring. Check and replace worn parts.

34-04 STANDARD ASSEMBLY

LIFT

CYLINDER

NOTE: Upon reassembly of lift cylinders, take care not to damage O-rings. Check cylinder, making sure sealing areas are free of nicks, burrs or sharp edges that might damage O-rings. Clean all parts in solvent or mineral spirits. Clean O-rings in hydraulic fluid ONLY.

SM538 34 - 03 - 2

Lift Cylinder - Standard Upright (1) Cylinder Cap (2) Back-up Ring, Cylinder (3) O-ring, Cylinder Cap (4) Bronze Bushing (will need to be removed in event of replacement) (5) Piston Rod Wiper (6) Cylinder grease fitting (Grease at assemblv oer Clark Spec. MS-g) Setscrew, Cylinder Cap Plug, Cylinder Cap Setscrew Piston Rod Cylinder Tube Spacer (when used) Plug, Cylinder Base Setscrew Setscrew, Cylinder Base Back-up Ring, Cylinder Base O-ring, Cylinder Base Snap Ring, Piston Rod Cylinder Base Piston Follower Filler Ring u-cup O-ring, Piston Rod Piston

Lift Cylinder - Standard Upright (1) Plug, Cylinder Cap Setscrew (2) Setscrew, Cylinder Cap (3) Cylinder Cap (4) O-ring, Cylinder Cap (5) Back-up Ring, Cylinder Cap (when used) (6) O-ring, Piston Rod (7) Seal Guard Kit (8) Bronze Bushing ( will need to be removed in the event of replacement only) (9) Cylinder Tube (10) Spacer (when used) (11) Piston (split rings) (12) Piston Followers (13) Retainer Ring, Piston Rod (14) Snap Ring, Flow Regulator Assembly (15) Snap Ring, Flow Regulator Assembly (16) O-rings, Flow Regulator Assembly (17) Filler Ring (18) U-cup (19) Piston Rod (20) Flow Regulator Assembly

SM.538 34 - 03 - 3

Lift Cylinder - (Hi-Lo) (1) O-ring, Cap (2) Cap, Back-up Ring (3) Bronze Bushing ( will need to be removed in the event of replacement only) (4) Cylinder Cap (5) Piston Rod Wiper (6) Cylinder Grease Fitting (Grease at assembly per Clark Spec. MS-g) Piston-Rod Cylinder Tube Spacer (when used) Piston Back-up Ring, Piston Rod O-ring, Piston Rod Cylinder Base Back-up Ring, Cylinder Base O-ring, Cylinder Base Snap Ring, Piston Rod Piston Follower Filler Ring u-cup Setscrew, Cylinder Base Plug, Cylinder Base Setscrew

Lift Cylinder - (Hi-Lo) (1) Cylinder TUBE (2) O-ring, Cylinder Cap (3) Back-up Ring, Cylinder Cap (4) Bronze Bushing (will need to be removed in event of replacement) (5) 0-rino, Inner, Cylinder Cap SealGuard Kit Cylinder Cap Piston Rod Spacer (when used) Back-up Ring, Piston Rod O-ring, Piston Rod Snap Ring, Piston Rod O-ring, Flow Regulator Assembly Snap Ring, Flow Regulator Assembly Flow Regulator Assembly Cylinder Base (welded Assembly) Piston Follower Filler Ring u-cup Piston EFFECTIVE ON CYLINDERS WITH REMOVABLE BASE ONLY: When installing O-rings and back-up rings in cylinder base, first lubricate groove with hydraulic oil, then insert O-rings.

EFFECTIVE ON ALL CYLINDERS: Install piston and piston follower (if so equipped) on bottom end or base end of piston rod.

Install U-cup and filler ring on rod. Be sure filler ring is facing downward (toward end of rod). Viewed in another way, U-cup will be on topside of filler ring.

Install piston follower.

SM538 34 -03-4

tighten setscrew until cylinder is compieteiy assembled and hydraulic connections of cap and base are in proper alignment (as previously explained).

Tubular stock (3-x 3” oi larger if necessary).

Bcre

a hole (dimension A) slightly larger than the outside diamenter

of the

piston rod in one end, 318 of an inch deep.

Push retainer ring on rod as far as possible by hand. Use a special tool (shown in sketch above) placed against retainer ring and tap on tool with a soft-faced hammer until ring is in correct location on piston rod.

Put piston rod into cylinder tube NOTE: Piston rod installation in lift cylinders with a welded non-removable base is accomplished by inserting the base end of piston rod through the top end of cylinder tube. Install spacer on rod if so equipped. Caution should be exercised to not damage filler ring and Ucup on assembly.

Piston rod installtion in lift cylinder with a removable base should be accomplished as follows: CAUTION WHEN INSTALLING PISTON ROD INTO CYLINDER TUBE (FROM BOTTOM END), EXTREME CARE SHOULD BE TAKEN NOT TO SCORE. SCRATCH OR DAMAGE INSIDE DIAMETER OF CYLINDER TUBE. THIS MAY BE ACCOMPLISHED

BY WRAPPING A CLEAN, LINT-FREE, HYDRAULICSOAKED CLOTH AROUND PISTON ROD END AND THEN SLIDING ROD THROUGH CYLINDER TUBE INTO POSITION. EFFECTIVE ON CYLINDERS WITH REMOVABLE BASE ONLY: Lubricate O-ring groove (in the cylinder base) with hydraulic oil and install O-rings, then install back-up ring on top of side of O-ring. For models equipped with cylinder hold-down bolt, bolt should be installed in base before installing base to tube.

(Refer to cylinder diagrams in this section).

Install cylinder base to cylinder and tighten until base bottoms with tube (metal to metal). Do not

SM538

EFFECTiVE ON ALL CYLINDERS: Reassemble cap.

Be sure all components arc thoroughly cleaned.

Press seal wiper into cap.

Caution should be exercised not to damage sea! wiper upon installation.

Models equipped with seai guard kit must be assembled with beveled sides of components mating or properly seating with each other.

Flat side of rubber retaining ring should be fiat against inside portion of cap lip (located on top side of cylinder cap).

These components are installed through top side of cylinder cap only.

Place O-ring and back-up ring in cap making sure back-up ring is installed correctly (see cylinder diagrams for correct location of components).

Before placing O-ring and back-up ring in cap, lubricate O-ring groove with hydraulic oil, then install components.

If used, replace smaller inner O-ring to correct location in cap.

EFFECTIVE ON CYLINDERS WITH REMOVABLE BASE ONLY: Tighten cap to top end of cylinder tube until it bottoms (metal to metal). Secure cap in position with setscrew and new plug inserted underneath setscrew.

Position cylinder base with hydraulic connections of cap and base in original position (as noted in disassembly procedure).

Cylinder connections must be in proper alignment to prevent damage to vent pipe. Lock base in this position with cylinder base setscrew if so equipped.

EFFECTIVE ON CYLINDERS WITH WELDED NON-REMOVABLE BASE: Tighten cylinder cap until it bottoms (metal to metal). This is important as cap must be tightened as close as possible to tube. If cap is not in proper alignment with piston head, back it off until it is in alignment.

When cap has been put in proper alignment with piston head, lock in position with setscrew and plug.

Cylinder connections must be in proper alignment with each other to orevent damage to vent pipe at assembly.

34 - 03 - 5

NOTE: Cylinders equipped with a grease fitting located at top portion of cylinder cap should be greased at assembly with grease per Lubrication Specification and Recommendations, GROUP 40.

Put cylinder in base support of upright and install piston head to upright slide guides (if so equipped). Or install piston rod through welded support and secure with snap ring (if so equipped).

Install cylinder hold down bolt (if so equipped).

When air stops and oil starts flowing, bleeder screw.

4. Check oil in sump and add if needed.

34-05 COMPOUND DISASSEMBLY

tighten

CYLINDER.

SECONDARY

LIFT CYLINDER BLEEDING: 1. Raise carriage about 11220 mm] 4 ft. or until bleeder screw is accessible.

NOTE: Check for proper oil level in sump before and after bleeding.

I

BARREL -ASSEMBLY

.‘c ’

ASSEMBLY

STATIONARY PISTON ASSEMBLY

GLAND NUTS

2. Loosen side bleeder screw using Allen wrench.

Piston wil drop a few inches as air comes out.

When air stops and oil starts flowing, tighten bleeder screw.

1. Remove all glands. cylinder to catch oil.

3. Loosen top bleeder screw using allen wrench.

Piston will drop a few inches as air comes out.

SM538 34 - 03 - 6

Put a container under

“V” PACKINGS

(BOTTOM)

(BOTTOM)

Remove stationary piston from barrel assembly by removing piston end cap.

3.

“V” PACKINGS

(Boll-OM)

4.

Remove both Allen head setscrews.

NOTE TEFLON U-CUP PACKINGS TYPICAL OF ALL CURRENT PRODUCTION EXCEPT HI-LO

(V-PACKINGS

SHOWN IN OTHER PICTURES.)

STATIONARY

2. Remove all “V” packings. If “v” packings do not come out with piston, remove packings by hand.

5. Remove stationary piston cap from stationary piston by pulling secondary piston out until drill rod will go through oil flow hole in stationary piston.

Then use spanner wrench on stationary piston end cap.

SM538 34 - 03 - 7

6. Remove secondary piston assembly from stationary piston. The brass stop ring shown on stationary piston can be removed at this time if necessary.

OIL FLOW

9. Remove flow tube guide bushing, if necessary, by placing tool (see end of section for tool specifications) in slots of bushing and turning it out. It will be necessary to put a piece of drill rod through oil flow hole at opposite end of secondary piston in same manner to allow removal of end cap.

/3

SECONDARY

(TOP) (BOTTOM)

7. Remove end cap from secondary piston assembly by placing drill rod through oil flow hole in piston. Use spanner wrench on end cap.

fi/

10. Remove primary piston from barrel.

11. Remove all “V” packings that did not come out with movement of piston.

FILL TUBE

5/l 6”

’

114”

(TOP)

----___-

IO 314” FLOW TUBE BUSHING TOOL

8. Remove fill tube from secondary piston.

34-06 CYLINDER INSPECTION

PARTS

1. Clean all parts in solvent and blow dry. Remove all chips or foreign objects including any weld spatter not previously filed down.

(BOTTOM)

SM538 34 - 03 - 8

BARREL

PRIMARY

OIL FILL TUBE ROD

STATIONARY

SECONDARY

(BOTTOM VIEW)

2. Examine cylinder tubes for distortion or scoring.

3. Inspect threaded parts for signs of leakage or damage. Chase or replace.

4. Replace all damaged or unservicable parts.

5. Examine cylinder barrel for scoring or internal damage by using a bright light and a mirror.

6. Reseal cylinder during overhaul and replace locking pellets and wear bearings and bushings.

34-07 COMPOUND ASSEMBLY

2. Install primary piston in barrel by compressing primary piston ring with screwdriver and pushing on piston with both hands. Oil piston ring with hydraulic oil before installing.

CYLINDER

Where “V” packings are being replaced by U-cups, omit male and female adapters at ends of packings, as well as “V” packings. Omit all springs and invert brass rings if new solid brass rings are not available.

NOTE: Where “V” packings are being replaced by U-cups, be sure to screw down gland nut tight against barrel during reassembly of lift cylinder.

1. Dip all packings and rings in hydraulic oil before assembly.

3. Replace fill tube guide bushing. Put drill rod through oil flow hole in opposite end of secondary piston to support shaft.

OLD DESIGN: Place packings on clean surface and put them in order as follows: Start with brass ring, then alternate the rubber and plastic, always starting with rubber and ending with plastic. If there is any rubber left over, place it between brass ring and first rubber packing.

FILL TUBE FILL TUBE BUSHING

NEW DESIGN: Start with brass ring, then U-cup packing, nut and wiper.

4 I IWNAHY

TUBE

w

DRILL ROD

4. Install fill tube into secondary piston. Line up feed end of fill tube by putting a piece of drill rod in

SM538 34 - 03 - 9

oil flow hole and lift upward. This will allow fill tube to clear stops and bushing.

7. Replace O-ring and back-up ring on stationary piston end cap. Place back-up ring on opposite side of oil pressure. Oil O-ring and back-up ring with hydraulic oil before installing.

(TOP) STOP RING

5. Install secondary piston assembly end using spanner wrench to turn, and drill rod to hold parts.

NOTE THE STATIONARY PISTON END CAP MUST BE TIGHTENED ON STATIONARY PISTON TO A MINIMUM TORQUE OF [407 N.m] 300 Ibf.ft.

8. Installbrass stop ring over stationary piston, if removed.

Install stationary piston end cap %_ 7 stationary piston assembly.

STATIONA;.

1

6. Install secondary piston into stationary piston by compressing ring by hand and push secondary piston assembly into place.

Oil piston with hydraulic oil before installing.

9. Install both setscrew and set screw lock screw.

BACKUP RING

SM538 34 - .03 - 10

ALTERNATE CONSTRUCTION: Where “v” packings have been replaced by Ucup, omit male and female adapter(s) , as well as “V” packings and eliminate springs from spring seat. Spring seat may be either inverted or replaced with solid brass ring.

Use tool for “V” packings (see end of section for tool specifications). Do not tighten gland nut yet.

ALTERNATE CONSTRUCTION: Use appropriate driver for U-cup packing.

(BOTTOM)

10. Install stationary piston assembly into barrel assembly.

13. Replace spring seat, “V” packings and gland nut on secondary piston. Do not tighten gland nut yet. Oil packings with hydraulic oil before installing.

Use tool for “V” packings.

11. Support opposite end of stationary piston assembly and center within barrel assembly to prevent cross threading.

“V” PACKINGS

“V” PACKINGS SPRING SEAT

(BOTTOM)

14. Replace “V” packings and gland nut on stationary piston. Oil packings with hydraulic oil before installing. Do not tighten gland nut yet.

SPRING SEAT (Boll-OM)

12. Replace spring seat, “V” packings and gland nut on fill tube. Oil packings with hydraulic oil before installing.

SM533 34-03-11

ALTERNATE CONSTRUCTION: Where “V” packings have been replaced by Ucup packing, omit male and female adapter(s), as well as “V” packings. Use appropriate driver for U-cup installation.

STATIONARYPISTON PRIMARY/ CYLINDER

GLAND NUTS

>

Use tool for “‘\I” packings.

SECONDARY PISTON -

“v” PACKINGS

II> GLAND NUTS

16. Tighten all gland nuts using a spanner wrench.

CAUTION DO NOT USE A PUNCH OR HAMMER. USE OF SUCH WILL DISTORT AND DAMAGE PACKING GLAND.

STATIONARY

15. Replace “V” packings and gland nut on primary piston. Oil packings with hydraulic oil before installing.

(FOR U-CUP, TIGHTEN DOWN GLAND NUT SECURELY).

“V” PACKINGS

l/8 IN. NORMAL l/4 IN .AMAX I

PISTON (FOR U-CUP. TIGHTEN DOWN GLAND NUTS)

“V” PACKINGS ONLY: ALTERNATE CONSTRUCTION: Where “V” packings have been replaced by Ucup, omit male and female adapter(s), as well as “V” packings, and eliminate springs from spring seat. Spring seat may be either inverted or replaced with solid brass ring.

Use

WARNING IT IS EXTREMELY IMPORTANT THAT THE GLAND NUTS BE ADJUSTED TO MEET THE SPECIFICATIONS IN THE ABOVE ILLUSTRATION. GLAND NUT(S) THAT ARE BACKED OFF FROM ABOVE SPECIFICATIONS WILL CREATE AN OPERATING HAZARD.

tool for “V” packing.

ALTERNATE CONSTRUCTION: Use appropriate driver for U-cup packing.

U-CUP PACKINGS: SECURELY TIGHTEN GLAND NUTS.

SM538 34-03-12

“V” PACKING REPLACEMENT LIST Select your old “V” packing number in column “a” and order the corresponding U-cup part number shown in column “b”.

NOTE: CORRECT INSTALLATION OF THE V-CUP STYLE PACKING IS EXTREMELY IMPORTANT SO PLEASE SELECT THE CATEGORY WHICH YOUR CYLINDER PACKING FALLS INTO AND FOLLOW ITS INSTALLATION INSTRUCTIONS. COL. “A” ‘V’ PACKING

COL. “B” U-CUP

1623076 1623077 1626372 1626373 1739695 1639696 1771244 1771245

1780412 1780364 1780411 1780361 1780396 1780413 1780364 1780411

STYLE 2 If cylinder has this construction and packing designated “x” is being replaced, the springs (item 2) must be discarded and thrust washer (item 1) must be reversed, then install the U-cup and thrust washer as shown in STYLE 4(b).

If packing designated “Z” is being replaced, discard springs (item 4) and reverse bushing (item 3), then install U-cup and bushing as shown in STYLE 4(b).

STYLE 1 If cylinder has this construction, replacement Ucup must be installed as shown in STYLE 5

STYLE 3 If cylinder has this construction, packing designated “x” is being replaced, the bushing (item 1) must be retained and then install U-cup as shown in STYLE 5 If packing designated “Z” is being replaced, discard springs (item 3) and reverse bushing (item 2), then install U-cup and bushing as shown in STYLE 4(b).

SM538 34 - 03 - 13

STYLE 4 Appropriate installation of U-cup packing reversed bushings and springs removed.

\”

A

I

with

\

STYLE 5 Appropriate installation of U-cup packing.

USE 20 GUAGE

“V” PACKING INSTALLATION TOOL.

SM538 34 - 03 - 14

GROUP 34 SECTION 04 PANTOGRAPH MODEL C CONTENTS

NO.

PANTOGRAPH REMOVAL PANTOGRAPH INSTALLATION

34-01 34-02

34-01 (WITH

PANTOGRAPH TILT)

Loosen setscrews securing pivot shafts of tilt carriage to tilt carriage adaptor and remove shafts.

This will allow tilt carriage to be free of tilt carriage adaptor.

REMOVAL

1. Make sure truck is on a level surface. Block the wheels to prevent truck from moving. Fully lower upright and extend reach mechanism. Disconnect battery.

2. Remove forks from carriage.

5. Remove fasteners attaching retainers and shims of upper brackets of tilt carriage adaptor to outer arms. Remove retainers and shims, then remove shafts. This will allow tilt carriage adaptor to tilt forward away from upright and rest on floor. Pull tilt carriage adaptor forward removing it from assembly and store in a safe place.

SETSCREW

3. Loosen setscrew retaining tilt cylinder to tilt carriage adaptor and remove cylinder anchor pin.

6. Remove nut from shoulder bolt and remove shoulder bolt. Pull tilt cylinder rod end out of rod end assembly.

7. Remove roll pins from end of rod end assembly.

Remove thrust washers, outer rollers and inner rollers. Rotate assembly to move tab ends of retainers away from tilt carriage. Remove retainers.

SETSCREW

4. Use blocking under tilt carriage to prevent it from dropping as mounting shafts are removed.

SM538 34 - 04- 1

34-02 PANTOGRAPH INSTALLATION (WITH OUTER ARM ROLLER PROCEDURE

TILT)

SHIMMING

1. Assemble outer arm to inner arm.

2. Assemble outer arm rollers (without shims) to outer arms.

3. Determine dimension “C”, smallest inside distance between webs of channels (which form main carriage assembly). Measure distance over outside rollers on inner arm assembly (rollers must be firmly against inner arm assembly).

4.

From TABLE 1 determine correct shim requirement to be used.

8. Use drift to drive out groove pin on rod end clevis anchor of reach cylinder. Then drive out cylinder rod end pivot pin.

9. Use drift to drive out retainer on yoke end of reach cylinder and then use drift to remove reach cylinder anchor end pivot pin and remove reach cylinder from carriage assembly CAUTION SUPPORT INNER ARM ASSEMBLY BEFORE REMOVING UPPER PIVOT SHAFT MEMBERS TO PREVENT ACCIDENTAL COLLAPSE OF ARM AND CARRIAGE.

TABLE 1 DIM C INCH .366-.350 .349-.320 .31 g-.290 .289-.270 .269-.240 .239-.210 .209-.180 .179-.150 .149-.130 .129-.l OO

MM 9,2-8,9 8,8-8,2 8,1-7,4 7,3-6,9 6,8-6,l 6,0-5,4 5,3-4,6 4,5-3,8 3,7-3,3 3,2-2,5

ITEM NO. Sl s2 s3 2 1 2 1 2 1 1 2 1 1 1 1 1 1 1 1 2 1 1

NOTE

NO. OF SHIMS REQ’D PER SIDE

5. Remove rollers and reassemble with correct number of shims inserted before rollers.

6. Assemble outer and inner arms to main carriage frame assembly.

7. After assembly, there should be [0,8 mm] 0.03 inches + [0,25 mm] 0.010 inches clearance between face of rollers and inner surface of channels. Reshim as required to obtain [7,62 mm] 0.300 inches clearance.

8. Note that slot in retainer matches slot in trunnion Insert fasteners and tighten to a torque of [352-380 N.m] 260-280 Ibfft.

I___

10. Remove fasteners attaching retainers to pantograph arm pivot shafts. Remove shafts and bearings.

11. Move outer arm assemblies to position rollers (in carriage assembly) at slots in rail and remove rollers and assemblies from carriage.

12. Remove fasteners attaching retainers, thrust washers and outer arms to inner arm assembly.

Remove outer arms.

13. Remove rollers and shims from outer arms.

INNER ARM ROLLER SHIMMING PROCEDURE 1. Assemble inner arm rollers (without shims), to inner arm assembly.

2. Determine smallest inside dimension between webs of channels on tilt carriage adaptor assembly.

Measure outside distance over inner arm rollers with rollers tight against frame of inner arm assembly.

3. Compute dimension “F”. This is clearance, obtained by subtracting distance over rollers from distance between webs.

SM538 34 - 04- 2

From TABLE 2 determine 4. requirement to be used.

correct

shim

TABLE 2 DIM F INCH .180-.170 .169-.140 .139-.llO .109-.lOO .099-.070

MM 454,3 4,2-3,6 3,5-2,8 2,7-2,6 2,5-1,7

ITEM NO. S5 S6 S7 1 1 1 1 1 1 1 1 -

NOTE NO. OF SHIMS REQ’D PER SIDE

5. Remove rollers and reassemble using correct number of shims as determined.

6. Assemble inner arm assembly to adaptor assembly.

7. After assembly, there should be [0,8 mm] 0.30 f [0,25 mm] 0.030 inches clearance between face of rollers and inner surface of channel web.

Reshim to obtain [7,62 mm] 0.300 in clearance.

MAIN CARRIAGE ROLLER SHIMMING PROCEDURE 1. Assemble rollers without shims on main carriage assembly. Do not fasten rollers in place.

2. Use inside spanning tool to measure dimension between webs of inner rail of upright assembly at various points to determine minimum carriage roller measurement.

3. At point of minimum measurement, put one (1) shim under one Ceg of spanning tool.

Reset spanning tool to have one shim clearance at minimum measurement. Use inside spanning tool to set outside spanning tool. Do not use shim between spanning tool points when making this setting.

4. Check number of shims required (to make rollers match outside spanner tool dimension) by inserting shims under legs of outside spanning tool placed over rollers. Do not force shims into position.

5. Divide shims equally and place one half on each side. Install rollers and secure with fasteners.

Tighten fasteners to [34-41 N.m] 25-30 Ibf.ft torque.

6. Align upper bores of inner arm assembly with bores of carriage assembly and insert shaft pins.

7. Clearance between outer arms and tilt carriage adaptor must be reduced by inserting shims between carriage brackets and outer arm assembly.

Use shims on each side to reduce clearance to [0,26-l ,Ol mm] 0.01 O-0.040 inches.

8. Insert retainers from inside of carriage brackets and insert fasteners. Tighten fasteners to a torque of [122-129 N.m] 90-95 Ibf.ft.

9. Align holes of reach cylinder barrel end clevis with bracket on carriage assembly and insert reach cylinder anchor end pivot. Insert reach cylinder pivot retainer.

10. Install reach cylinder rod end nut and clevis, but do not tighten nut to clevis at this time.

11. Insert bushing in reach cylinder clevis bracket on inner arm assembly. Align clevis hole with bracket hole on inner arm assembly and insert reach cylinder rod end pivot. Secure this pivot by inserting reach cylinder pivot retainer.

REACH CYLINDER ADJUSTMENT 1. Extend pantograph and loosen piston rod lock nuts. Turn each piston rod to obtain [128,5 mm] 5.06 in. f [0,8 mm] 0.03 in. from gland assembly to face of clevis.

NOTE: One full turn of rod equals [1.3 mm] 0.055 in. travel.

2. Retract and extend pantograph while checking for side kick as tilt carriage stops. Both sides of carriage must stop at same time. If not, adjust one clevis only (other clevis must remain at [128,5 mm] 5.06 in. setting). When fully retracted, carriage When extending stops must contact.

3. pantograph stops evenly and smoothly, tighten lock nuts.

TILT CARRIAGE ASSEMBLY 1. Push retainers over ends of rod end assembly.

Insert ends of retainers into slots in tilt carriage assembly by rotating assembly until tabs on retainers lock on carriage.

2. Push inner rollers on rod end assembly making sure they are fully in place. Then push outer rollers onto rod end assembly.

Install thrust washers against outer rollers and secure in place by inserting roll pins into holes in end of rod end assembly.

3. Install rod end of tilt cylinder into pilot hole in rod end assembly. Align hole in rod end of cylinder with hole in rod end assembly. Insert shoulder bolt into place locking piston rod to rod end assembly.

Install nut and tighten to a torque of [83-93 N.m] 61-69 Ibf.ft. Insert grease fitting into cylinder.

4. Make sure bushing is in place in barrel end mount of cylinder. Align cylinder mount hole with clevis mount on carriage and insert shaft pin. Make sure groove on shaft is aligned with set screw locking it in place. Tighten set screw.

5. Align upper mounting bracket holes of carriage assembly with holes on tilt carriage adaptor. Insert shafts and spacers, make sure grooves on shafts align with set screw holes. Tighten set screws.

6. Attach hydraulic hoses to cylinders. Be sure lines are positioned correctly.

SM538 34 - 04- 3

GROUP 34 SECTION 05 MODEL D UPRIGHT REMOVAL NO.

CONTENTS

34-01 34-02

UPRIGHT REMOVAL UPRIGHT INSTALLATION

34-01 UPRIGHT REMOVAL 1. Park truck on a level floor.

2. Block wheels and fully lower upright. has reach mechanism, retract reach Turn key switch to OFF. Disconnect battery.

3. Disconnect wire harness from unfastening two (2) quick disconnect located on RH side of upright below middle tie bar. (One is for pantograph for speed limit switch on upright).

4. Unfasten aux. hose on RH side of upright at hose coupling to steel tubing connection. Cap hose end.

5. Unfasten aux. hose on LH side of upright at hose coupling to steel tubing connection. Cap hose end.

6. Disconnect lift cylinder line at fitting to selector valve. Cap hose end.

7. Attach a lift chain of adequate capacity to the top rail tie bars. Make sure the chain is securely fastened to bars and will not slip.

Use an overhead hoist (or a lift truck of adequate capacity) attached to this lift chain to remove upright from truck.

If truck

upright by assemblies and behind and other is

For added safety, fasten upright rails together as follows: (a) STANDARD 2 STAGE: put chains around center inner rail tie bar and top outer rail tie bar.

(B) 3 STAGE: put chains around inner rails and top outer rail tie bar.

8. Remove fasteners attaching DOG to upright (two bolts per side).

SM538 34 - 05 - 1

forcing upright mounting blocks into place. Divide washers evenly for each side to center upright (use of one extra washer acceptable)

9. Remove four (4) locking setscrews from main frame upper upright support (two per side).

Loosen exposed setscrews to unlock upright from upper frame saddle.

REMOVE

3. Raise upright and insert upper bars (on side of outer rail) into saddles in frame.

Lower upright and align mounting blocks with bolt holes in frame. Insert fasteners into mounting block and tighten to a torque of [289-325 N.m] 220-240 lbf.ft.

4. Remove lifting and securing chains.

5. Use a level on outer rail of upright to measure vertical alignment. Use setscrews in frame saddle to adjust upright outer rail assembly to a back tilt of O” 15’ to O” 30’ back tilt.

Tighten setscrews to maintain this position and then insert locking setscrews and tighten.

6. Install fasteners connecting DOG to upright side rails (two per side). Tighten nuts to a torque of [340-380 N.m] 250-280 Ibf.ft.

7. Remove lifting chains.

8. Connect lift cylinder hose to fitting at selector valve.

9. Connect aux. hoses to tubing on each side of upright.

Connect wiring harness to upright by 10. connecting two quick disconnect fittings located on RH side just behind upright a..~! just tolow middle tie bar.

11. Connect battery. Check all operatiolIs _. upright making sure lines have been connected correctly and that there are no leaks.

10. Remove four (4) fasteners which attach upright mounting block to main frame.

11. Lift upright up to clear saddle, then remove from truck and store in a safe manner.

34-02 UPRIGHT INSTALLATION 1. Make sure truck is on level surface, that wheels are blocked to prevent truck movement, and battery is disconnected.

2. Make sure upright is secured by chains as described for UPRIGHT REMOVAL above.

Use a chain hoist and chains of adequate capacity for lifting.

Raise upright to vertical position. Put washers and upright mounting block on mounting trunions. Bored hole in mounting block should be toward front of truck. Use correct washers on mounting trunions to shim clearance for mounting upright.

NOTE: Use only number of washers required to reduce clearance without SM538 34 - 05 - 2

GROUP 34 SECTION 06 MODEL D UPRIGHT MAINTENANCE CONTENTS

UPRIGHT

Always keep piston rods in retracted position when not in use.

Lubricate lift chain.

NO.

UPRIGHT MAINTENANCE ROLLER CHECK/ADJ. LIFT CHAIN CHECK/ADJ BLEEDING CYLINDERS UPRIGHT DOWNDRIFT TEST CHECKING ROLL PATTERN CHECKING CYLINDER AND SEALS) LOAD TESTING LIFT CYLINDER DRIFT TEST TILT CYLINDER DRIFTTEST CARRIAGE REMOVAL ADJUSTING CARRIAGE ROLLERS CARRIAGE INSTALLATION

34-01

Keep piston rods and tops of cylinders clean.

34-01 34-02 34-03 34-04 34-05 34-06 34-07 34-08 34-09 34-l 0 34-l 1 34-l 2 34-l 3

MAINTENANCE

WARNING

Do not reach through upright open areas. Use only hardwood blocks which are free from cracks and other visual damage. These blocks must be square on ends and not tapered or rounded. under

rail

at least

every

If upright is a three-stage upright, there are four sets of rollers. Outer rail assembly has one set of top rollers, intermediate rail assembly has one set of bottom rollers on outside of assembly and one set of top roller on inside of assembly, and inner rail assembly has one set of rollers on bottom.

(Refer to carriage removal

1. Check both sides of upright for roller clearance at inner rail (top and bottom). Begin by checking clearance of bottom roller of inner rail assembly.

Use a C-clamp or a tool to move rail assembly fully to one side for clearance check.

Insert shims between roller and the rail surface roller contacts until all clearance is removed.

Do not force shims into position. [1,6 mm] l/16 inch clearance is acceptable.

where

500 hrs of

Check mounting fasteners.

Check for leaks at hydraulic connections.

Check for interference during lift operations.

CHECK

If upright is a two-stage upright, there are two sets of rollers. Outer rail assembly has one set of top rollers and inner rail assembly has one set of bottom rollers.

Review all described procedures before starting any maintenance or service function. Failure to follow this warning can result in serious injury.

Shim inspection operation.

anchor

TWO-STAGE UPRIGHT ROLLER CHECK

Do not walk or stand under raised forks.

into channel

and chain

34-02 UPRIGHT ROLLER AND ADJUSTMENT PROCEDURES

1. Remove carriage. section).

This Group 34 describes procedures which can produce unexpected movement of upright rails and other parts.

Tuck blocks specified.

Check chain adjustment adjustor jam nuts.

of hosing, chains,

etc.

SM538 34 - 06- 1

Record number of shims required on outside of rail at same point where measurement was made. , FEELER GUAGE

r

then check clearance between roller and rail of intermediate rail assembly.

Mark number of shims required to eliminate excessive clearance on each rail at measured location.

2. In same manner, record number of shims to be

5.. Raise inner rail assembly and insert lift chain anchor pins. Be sure cotter pins are in place and have legs spread to prevent removal.

Raise upright fully and repeat measurements. Remove all clearance using tool or C-clamp and record number of shims required on appropriate location on rail assembly.

A small amount of clearance is aceptable, [0,8 mm] l/32 inch total, with rails in raised position.

Record number of shims required on outside of rails at locations where measured.

Underline those measurements made when upright was fully raised.

used for top roller on outer rail section.

Clearance is permitted, but it is not to exceed [1,6 mm] l/16 inch total.

6. Check clearance of top roller on inside of outer rail assembly.

4

5

3. Raise inner rail to full up position and use tool and bar to check roller clearance in same manner as before.

A small amount of clearance is permitted, [0,8 mm] l/32 inch total with upright in raised position.

8. Check clearance of top roller on intermediate rail assembly.

4. Record number of shims to be used for top roller on outer rail.

9. Check clearance of bottcm roller on innt. assembly.

5. Record number of shims to be used for bottom roller on inner rail.

SHIMMING PROCEDURE

THREE STAGE UPRIGHT ROLLER CHECK 1. Attach a chain hoist to top of inner rail assembly and lift rail assembly to loosen lift chains. Remove lift chain anchor pins.

2. Check both sides of upright for roller clearance at inner rail (top and bottom) and at intermediate rail. Begin by checking clearance of bottom roller of inner rail assembly.

Use a C-clamp or a tool to move rail assembly fully to one side for clearance check.

Insert shims between roller and rail surface roller contacts until all clearance is‘removed.

Do not force shims into position. [0,8 mm] l/32 inch clearance is acceptable.

Record number of shims required on outside of rail at same point where measurement was made.

3. Check clearance between roller and rail at bottom of intermediate rail assembly.

4. Move to top of assembly and check clearance between roller and rail of outer rail assembly and

Check clearance of bottom 7. intermediate rail assembly.

roller

on

”

Upright shimming can be done with upright on truck or upright can be removed from truck.

(Refer to upright removal section for correct procedure for upright removal).

If upright is left on truck, truck must be lifted [300 mm] one foot off floor (refer to section on raising and jacking truck for correct procedure).

STANDARD UPRIGHT 1. Loosen lift chains by attaching a chain hoist to inner rail assembly and lifting. Remove chain anchor pins.

NOTE: Roll pins supporting top of lift cylinder will now be removed, but first support lift cylinder to prevent it from falling when pins are removed.

With cylinder supported, remove roll pins.

2. Lower inner rail assembly until bottom roller is exposed. Remove rollers and shims. Carefully

SM538 34 - 06- 2

count number of shims behind each roller. Add the additional shims noted on rail.

When adding shims, keep number of shims on each side balanced and do not add more than one shim excess to any side. This will prevent rollers and rails from ‘racking‘. Also, if uneven number of shims are required, always add extra shim to same side.

Remove top rollers of intermediate rail 3. assembly and again carefully count shims behind rollers. Add additional shims as noted on rail and follow same procedure used for shimming bottom roller above.

8. Recheck roller clearance.

9. Lower truck to ground (refer to section on correct jacking and raising procedure).

10. Install carnage assembly (refer to carriage installation section for correct procedure).

11. Raise and lower carriage to full up and down positions, checking all phases of operation.

TRIPLE STAGE UPRIGHT 1. Loosen lift chains by attaching a chain hoist to inner rail assembly and lifting. Remove chain anchor pins.

2. Lower inner rail assembly until bottom roller is exposed. Remove rollers and shims. Carefully count number of shims behind each roller. Add additional shims as noted on rail.

When adding shims, keep number of shims on each side balanced and do not add more than one shim excess to any side. This will prevent rollers and rails from ‘racking’. Also, if uneven number of shims are required, always add extra shim to same side.

Typical shimming procedure: 1). Count number of shims in right and left hand rollers.

2). add shims in accordance recorded on rails.

with

numbers

3). The optimum target is to have same number of shims at each roller. If there is an extra shim, mark side having extra shim and keep extra shims on same side.

4. After shimming of rollers, raise inner rail assembly to fully raised position and note if any ‘tight’ spots occur as rail assembly is being raised.

If such spots are found. remove only one shim at a time (from behind roller causing binding) until binding is removed.

5. Raise inner rail assembly and insert roll pins attaching lift cylinder.

6. Attach lift chains by inserting chain anchor pins and cotter pins. Make sure legs of cotter pins are spread to lock them in position.

7. Remove chain hoist.

3. Raise inner rail assembly to its normally fully raised position using chain hoist. As rail assembly is being raised, note if any binding occurs. If binding occurs, remove shims (one at a time) behind the roller casusing binding) until binding is removed.

4. Lower rail assembly and insert chain anchor pins.

5. Atach a chain hoist to both inner intermediate rail assemblies.

Lift hoist and remove chain anchor pins.

and

NOTE: Before removing top fastener for cylinder, support cylinder to prevent it falling away from upright assembly.

6. Remove fastener attaching intermediate rail assembly.

lift cylinder to

7. Lower both rail assemblies down until bottom roller on intermediate rail assembly is exposed.

Remove bottom rollers and follow same procedure for installing shims.

8. Remove top rollers on outer rail assembly and again use same procedure for installing shims.

SM538 34 06- 3

9. Raise both rails to the extended oostion of the intermediate rail assembly noting if binding occurs as rails are raised., If binding occurs, use the same procedure as above to remove the binding.

OCCUR CAUSING LOAD OR CARRIAGE TO FALL. 1. Elevate carriage to about [1200 mm] 4 feet.

10. Lower the rail assemblies and install the fastener ,attaching lift cylinder to intermediate rail assembly.

GREASE

11. Attach lift khaihs by inserting chain anchor pins and cotter pins. Make sure legs of cotter pins are spread to lock them in position.

12. Remove chain hoist.

13. Recheck roller clearance.

14. Lower truck to ground (refer to section on correct jacking and raising procedure).

15. Install carriage assembly (refer to carriage installation secfion for correct procedure).

2. Smear grease on inner slide channel making sure it is in path of roller contact.

3. Pick up a capacity load.

16. Raise and lower carriage to full up and down positions, checking all phases of operation.

34-03 UPRIGHT LIFT CHAIN CHECK diEiD ADJUSTMENT PROCEDURE

4. Lower load to down position.

5. Remove capacity load.

STAN.OARb UPRiGHT Lift chains are r&&ted to chain anchors on lift carriage and at chain anchor rods on lift cylinder. #

TRIPLE STAGE UPRIGHT One lift chair&et ‘j-s attached between center tie bar on outer raif,assembiy and lower tie bar on inner rail a$&embQ, and passes over sheaves attached to top tie bar on intermediate rail assembly. : ..

Other lift _cha’ih set is attached between lift cylinder a& &if@&$iage ancf‘passes over sheaves attached to&tc!@r@r piston. “m

If it becomes necessary to adjust lift chains, proceed as follows: ..

WARNING i-;.-.,y ‘. jl.,.. , KEEP~,&E&@F LGAb AND CARRIAGE Wl%N”fWKI&‘& ANY ADJUSTMENTS OR ADJUSTMENT CHECKS, TO AVOID INJURY SI$IULQ At MALFUNCTION .,

-

-

,-. . : ’ :.

NOTE: It is important that chain adjustment be made with capacity load.

This will assure correct adjustment for maximum chain stretch.

6. Raise carriage and measure distance form where center of BOTTOM CARRIAGE ROLLER stopped to bottom edge of inner slide. Distance must not be less than [12 mm] l/2 inch.

7. Be certain to wipe grease from rail.

8. Both chains must be adjusted to have same tension on each with load on forks.

Make sure chain is not twisted. Make sure locking nuts are tightened.

L. 9. As a check procedure it may also be nofed that upright lift carriage chains should be adjusted to position bottom of forks [12,1 mm] 0.5 inches above floor with fork carriage vertical.

.l.

r34%04 BLEEDING CYCIN’DERS

1. Raise carriage about hl.200 mm] 4 feet or until bleeder screw on side of barrel is accessible.

SM538 34 - 06- 4 _

LIFT

I

‘\

NOTE: Check for proper oil level in sump before and after bleeding.

possible weight.

to provide

most even disposition

of

2. Keep forks level during pick up of load (do not drag forks on floor).

3. Enter pallet as far as possible until forks completely engage pallet and TEST LOAD. TEST LOAD and pallet should be in contact with load back rest.

6. Begin timing of five minute test. Check after each minute. Upright drift should not exceed 125 mm] 1 inch per minute.

2.

Loosen side bleeder screw located on cylinder. The piston will drop a small amount (perhaps several inches) as air escapes. When air stops and oil starts to flow, tighten bleeder screw.

34-06 CHECKING PATTERN

ROLL

Impressions made by rollers on upright rails are called roll patterns.

Roll patterns can give an indication of upright adjustment.

Excessive metal scoring or gouging of roller paths may indicate excessive pressure caused by damaged or misadjusted rollers.

Roll pattern can be checked by applying a light coat of spray paint or a thin layer of grease to roller contact area and then operating upright several times with a load.

Roll pattern of carriage rollers (including thrust rollers) and main upright rollers can all be checked in this manner.

3. Check oil in sump and add if necessary.

34-05 TEST

UPRIGHT

34-07 CHECKING AND SEALS

DOWNDRIFT

CYLINDER

A TEST LOAD is one of same weight as CAPACITY LOAD shown on truck SERIAL NAME PLATE for CAPACITY RATING.

Cylinder rod seals should be checked for leakage. Seals of primary piston rod, secondary piston rod and feed tube assembly should be checked. Cylinder rods should be free of grit, chemical residues, paint, and nicks on ground or polished surfaces.

It should be on a 48 x 48 pallet and should be equally distributed. It must be secure on pallet.

34-08

Material used for test load must be arranged (stacked) to provide load stability and material must not extend beyond sides of pallet.

Center a capacity load on back to help retain it, and height several times. operation, carriage play between rails.

A TEST LOAD is used to check for drift.

1. Adjust fork width to maximum which will accomodate TEST LOAD. Space forks as wide as

LOAD

TESTING forks. Tilt load slightly raise load to maximum Note smoothness of (clearance), and play

If operation is satisfactory, load should then be positioned [lo0 mm] 4 inches off-center. Again

SM538 34 - 06- 5

tilt load slightly back and raise load to maximum height several times.

Note smoothness of operation and play of carriage and rails.

Repeat with load placed off-center in opposite direction.

34-09 TEST

LIFT

CYLINDER

Lift cylinder drift is checked with a capacity load on upright. Make sure brake is engaged and put blocks at wheels to prevent truck moving.

Experienced mechanics have found that both conditions of play (too little and too much) can cause binding and/or uneven operation.

The design of interlocking rails requires some lateral movement of carnage within inner rails.

DOWN DRIFT WILL APPEAR

Adequate clearance between rollers and rails is necessary to insure smooth operation and minimum wear.

NOTE: Providing operation works smoothly with a capacity load, service man should consider application for which truck is used in making a decision as to whether carriage or rail adjustments are necessary.

If product handled by truck is very delicate or operation is sensitive, service man should take these factors into account.

DRIFT

LIKE THIS.

Raise load to approximately one half of full lift height. Turn key switch to OFF. Stand to one side of truck and use tape or marking pen to make a horizontal line across all rails on one side of upright.

The adjustment of new uprights that have minimal operating time is not recommended unless there is some indication that upright is not working properly.

NOTE: Rollers require some time to seat in rails, and initial stress relieving at weld areas will cause some dimensional changes that affect roller clearance.

Operators should be consulted on a regular basis as to any unusual operation of upright as well as other parts of truck.

At the end of a five minute period from when mark was made, measure drift and compare with If specifications for allowable down&i; specifications are exceeded, refer to ind?, DOWNDRIFT CHECK AND ADJUSTMENT PROCEDURES.

34-10 TEST

TILT

CYLINDER

DRIFT

Tilt cylinder arrangment and fixed upright of this truck design do not require a tilt cylinder drift test.

34-11

CARRIAGE

REMOVAL

Use this procedure to remove cariage if binding or excess play of rollers is suspected.

Make sure brake is set and wheels blocked to prevent truck moving.

Remove forks.

Stand behind upright and remove cotter keys from carriage anchor pins and remove carriage anchor pins.

SM538 34 - 06- 6

Attach a chain hoist to top of inner rail assembly and lift rail assembly until carriage rollers are clear of rail.

Remove carriage assembly.

Make sure carriage is stable. assembly.

34-12 ADJUSTING ROLLERS

It is a very heavy

10. Install reach cylinder rod end nut and clevis, but do not tighten nut to clevis at this time.

11. Insert bushing in reach cylinder clevis bracket on inner arm assembly. Align clevis hole with bracket hole on inner arm assembly and insert reach cylinder rod end pivot. Secure this pivot by inserting reach cylinder pivot retainer.

CARRIAGE 34-13

CARRIAGE

INSTALLATION

1. Assemble rollers without shims on main carriage assembly. Do not fasten rollers in place.

Make sure carriage is stable. assembly.

2.

Use inside spanning tool to measure dimension between webs of inner rail of upright assembly at various points to determine minimum carriage roller measurement.

Make sure brake is set and wheels blocked to prevent truck moving.

3. At point of minimum measurement, put one (1) shim under one leg of spanning tool. Reset spanning tool to have one shim clearance at Use inside spanning minimum measurement. tool to set outside spanning tool. Do not use shim between spanning tool points when making this setting.

4. Check number of shims required (to make rollers match outside spanner tool dimension) by inserting shims under legs of outside spanning tool placed over rollers. Do not force shims into position.

It is a very heavy

1. Attach a chain hoist to top of inner rail assembly and lift rail assembly until rail is above top of carriage rollers.

2. Move carriage into position that will allow inner rail to be lowered and engage carriage rollers.

Lower inner rail until carriage rollers are trapped in inner rail assembly and lift chains are tight.

Remove chain hoist from inner rail assembly.

3. Stand behind upright and install carriage anchor pins and new cotter pins. Spread legs of cotter pins to lock them.

4. Remove blocks from wheels.

5. Divide shims equally and place one half on Install rollers and secure with each side. fasteners. Tighten fasteners to [34-41 N.mJ 2530 Ibf.ft torque.

5. After carriage has been installed, upright and note any unusual operation.

6. Align upper bores of inner arm assembly with bores of carriage assembly and insert shaft pins.

6. Make operational checks and load test upright before placing truck in service.

7. Clearance between outer arms and tilt carriage adaptor must be reduced by inserting shims between carriage brackets and outer arm assembly. Use shims on each side to reduce clearance to [0,26-l ,Ol mm] 0.010-0.040 inches.

8. Insert retainers from inside of carriage brackets and insert fasteners.

Tighten fasteners to a torque of [122-129 N.m] 90-95 Ibf.ft.

9. Align holes of reach cylinder barrel end clevis with bracket on carriage assembly and insert reach cylinder anchor end pivot. Insert reach cylinder pivot retainer.

SM538 34 - 06- 7

operate

1. Remove carriage rollers and shims from each side of carriage assembly. Note number of shims on each roller shaft and mark this number on frame next to each shaft.

GROUP 34 SECTION 07 NP300D PANTOGRAPH CONTENTS

NO.

PANTOGRAPH REMOVAL PANTOGRAPH DISASSEMBLY PANTOGRAPH INSTALLATION

34-01 34-02 34-03

34-01

PANTOGRAPH

2. Carefully remove chain from front and rear frames (used to prevent movement of frames).

Block reach mechanism to prevent it from closing.

REMOVAL

1. Make sure truck is on a level surface. Block the wheels to prevent truck from moving.

2. Remove forks from carriage.

Raise lift carriage to top of inner rail assembly. Fully retract reach mechanism.

Disconnect battery.

3. Attach a chain hoist to top of rear member of carriage assembly.. At same time wrap a chain around front and rear frames of pantograph to prevent it accidentally moving (extending).

3. Attach a chain hoist to top of rear member of carriage assembly.. At same time wrap a chain around front and rear frames of pantograph to prevent it accidentally moving (extending).

4. Raise hoist to allow lift chains to loosen.

Remove chain anchor pins.

5. Remove hydraulic lines and cap ends of lines.

Lift carriage assembly out of upright assembly.

3. Remove roll pins and cylinder anchor pins from both cylinder bases of reach cylinders.

NOTE: Use caution when removing these cylinders.

Disconnecting cylinders from assembly will allow free movemment of entire mechanism.

4. Remove rollpins and cylinder rod anchor pins from inner arm assembly. Remove reach cylinders and store in a safe place.

34-02 PANTOGRAPH DISASSEMBLY

SM538 34 - 07- 1

5. Remove load back rest frame from carriage assembly.

6. Remove roll pins and carriage tilt pin from front frame of pantagraph assembly. Remove carriage fork bar assembly.

NOTE:When attaching members removed, parts are free to move.

are

Remove roll pins and inner arm top pivot pins from rear frame.

7. Remove roll pins and cylinder trunion pins from carriage front frame and move tilt cylinders out of mounting brackets. Store tilt cylinders in a safe place.

10. Remove roll pins from pivot studs on middleof Remove nut on each of studs. outer arms.

Remove bearings and shims from studs. Note number of shims on each stud and mark number of shims on respective arm.

8. Attach a chain hoist to front frame. Remove roll pins and outer arm pivot pins from top rear trunions of front frame. Lift front frame off rollers and store front frame.

11. Lift arm assemblies off rear frame.

9. Support both inner arms and rear lift frame assembly.

SM538 34 - 07- 2

12. Bearings on inner arms can be removed by driving out, using a proper size drift and soft-faced hammer.

After shimming to remove any looseness, tighten drag link screw, then back screw off until hole in screw and groove in rear frame are aligned. Install roll pin to lock screw. Repeat for opposite side.

5. Install wear plates and shims on rear frame.

Bearing rollers are removed by removing flat head screws and caps. Shim plates are fastened with flat head screws.

6. Install bearings in top ends of outer arms and install these arms in top trunions on front frame.

Install roll pin in pin groove and drag link screw through upper part of front frame and arm assembly. Tighten screw until it bottoms. Repeat for opposite side.

Check fit of arm assembly. If loose, add shims to either side of bearings on upper end ofouter arm (Again, keep same number of shims on each side unless extra shim is required).

After shimming to remove any looseness, tighten drag link screw, then back screw off until hole in screw and groove in rear frame are aligned. Install roll pin to lock screw. Repeat for opposite side.

7. Install tilt cylinders on front frame by inserting spacers and pins through trunions and through cylinder base trunions.

Insert a rollpin through each pin to lock pins in place.

34-03 PANTOGRAPH INSTALLATION 1. Assemble outer arm to inner arm. Install bearings and thrust bearing in center of inner arm.

2. Push outer arm center stud through inner arm and install bearing and nut.

Nut will bottom out.

If outer arm has excessive sideways movement, shimming of inside bearing is required.

The outer arm should pivot freely with a very small amount of tightness when nut is tightened.

When adjustment is complete, back nut off until hole in shaft and groove in nut are first aligned and install roll pin to lock nut.

3. Install roller bearings on arm ends. One set is put on lower inside of inner arm assembly and other set is installed on outside lower end of outside armassemblies. Fasten rollers with caps and screws.

4. Install bearings in top ends of inner arms and install these arms in top trunions on rear frame.

Install roll pin in pin groove and drag link screw through upper part of rear frame and arm assembly. Tighten screw until it bottoms. Repeat for opposite side.

Check fit of arm assembly. If loose, add shims to either side of bearings on upper end of inner arm (Keep same number of shims on each side unless extra shim is required).

8. Position fork bar assembly on front frame and insert pivot pins through fork bar frame and through trunions on front frame. Lock these pins in place with roll pins.

9. Install load back rest using fasteners on each side of fork bar assembly.

10. Install reach cylinders by first installing pivot pins through the piston rod yokes and thru the trunions on inner frame assembly. Lock thes pins in place with roll pins.

Then complete installation of reach cylinders by moving cylinders until trunion holes in base of cylinders aligns with trunions on top of rear lift frame. Insert pivot pins and lock in place with roll pins.

11. Install solenoid selector valve on inner arm assembly. Install hydraulic lines to tilt cylinders and to reach cylinders. Make sure all fittings have been tightened and that lines are correctly routed.

12. Collapse reach assembly and chain front and rear frames together.

13. Install carriage rollers making sure the correct shims are in place.

14. Use a chain hoist to raise assembly and positon rollers in inner frame assembly.

SM538 34 - 07- 3

15. Install lift chains and tighten nuts. Make sure tension is correct.

16. Connect hydraulic lines to carriage assembly.

Make sure fittings are tight and that hoses are in correct position.

17. Remove chain hoist.

18. Connect battery and check all operations of upright control. Examine all fittings for leaks. Make sure all lines are routed correctly and that lines do not rub on moving parts.

19. Install cover over solenoid selector valve.

SM538 34 - 07- 4

GROUP 38 SECTION 02 MACHINE JACKING AND BLOCKING CONTENTS

NO.

RAISING DRIVE WHEELS BLOCKING THE UPRIGHT RAISING REAR OF TRUCK RAISING ENTIRE TRUCK RAISING TRUCK WITH A HOIST

38-01 38-02 38-03 38-04 38-05

CAUTION To perform these service recommended that you first:

procedures,

it is

Park truck on a hard, level and solid surface, such as a concrete floor with no gaps or breaks.

Put forks in vertical position and fully lower forks or attachment.

Put all controls in neutral and turn key switch to OFF position.

4 Raise hoist to lift rear of truck off floor. This action will raise drive wheel and caster assembly off floor.

Block frame to necessary height using solid hardwood blocking or steel jacks.

WARNING DEFECTIVE EQUIPMENT CAN CAUSE ACCIDENTS

All tools and lifting equipment must be in meet load capacity good condition, requirements and have OSHA labels when required. Tools with defects can have failures causing severe injury or death.

38-01

RAISING

DRIVE

WHEEL

1 Park truck safely.

2 Turn key switch ON. Turn key switch OFF. 3. Use a chain hoist and lifting chains with hooks that will safely catch rear of frame.

6 Check for safe clearance between drive wheel and floor.

7 Check for stable condition of truck. Be sure that the blocks are located securely under frame before operating drive or working on truck.

8 Lower drive wheel to floor and remove blocks by reversing above procedure.

38-02 LOAD BLOCKING

WHEEL

ACCESS

This procedure is used to safely provide clearance for removal of load wheels.

1. Park truck on a hard, level and solid surface, such as a concrete floor with no gaps or breaks.

2. Put forks in vertical position and fully lower forks or attachment.

3. Put all controls in neutral and turn key switch to OFF position.

SM538 38 - 02 - 1

4. Use overhead hoist and lift chains to lift turck.

Position lift chains around outrigger legs and fasten chain ends securely to prevent slippage.

5. Lift legs about four inches off floor and block securely with hardwood blocking.

4 Put blocks under side frame, at each sidejack.

Put (spread) blocks close to drive and stabilizing caster wheels for maximum stability.

38-03 RAISING REAR OF TRUCK 1 Park truck safely. See Page 1.

When convenient, first remove battery from truck to reduce weight. Drive truck onto shim plates to increase underclearance.

CAUTION - When jacking rear of truck, be sure upright is lowered fully and do not raise one side of truck more than about 2 inches higher than other, to avoid tipping truck over laterally.

2 Put jack(s) under rear frame near center of truck.

IMPORTANT - Be sure to put jack(s) squarely and fully under main structure of frame.

3 Carefully raise truck only as high as necessary to do maintenance work and not more than a maximum of 6 inches, total.

4 Put blocks under tmain frame, at each side of jack.

38-04

RAISING

ENTIRE

5 If using one jack, lower truck onto blocks and Repeat lifting move jack to opposite side. pcocedu re.

6 Put same size blocks under each side of truck so it will be level.

CAUTION - Before performing any maintenance work, check truck for stablr condition on blocking.

TRUCK

Refer to Specifications for truck weights.

1 Park truck safely. See Page 1.

When convenient, first remove battery from truck to reduce weight. Drive truck onto shim plates to increase underclearance.

CAUTION - When jacking side of truck, be sure upright is lowered fully and do not raise one side of the truck more than about 2 inches higher than other, to avoid tipping truck over laterally.

2 Put jack(s) under main frame near center of truck.

IMPORTANT - Be sure to put jack(s) squarely and fully under main structure of frame.

3 Carefully lift truck one side at a time,only as high as necessary to do maintenance work and not more than a maximum of 6 inches, total.

7 When maintenance work is completed, lower entire truck to floor by reversing lifting procedure.

Lower truck one side at a time, while carefully removing blocks. Check to be sure no tools or equipment are under truck or wheels.

NOTE - Depending on jack height, shims under tires may be needed for clearance to allow removal of jack.

38-05 HOIST

RAISING

TRUCK

WITH

A

When suitable equipment is available, truck may be raised by means of a hoist and wheel cradles placed under wheels.

SM!538 38-02-2

IMPORTANT - Lift only front or rear of truck at a time. Watch truck for signs of lateral instability. It may tip sideways. You may have to support or guide side of truck or overhead guard to prevent tipping.

1 Attach a hoist with chains of correct capacity.

2 To raise front of truck, use two chains hooked around outrigger arms. Lift truck up and place wheel cradles under front load wheels.

3 To raise rear of truck, use two chains with special formed hooks of steel plate which hook frame lower vertical member. Place hardwood blocks of equal height under frame near outside rear edge of frame.

SM538 38-02-3

GROUP 40 SECTION SPECIFICATIONS

UPRIGHT

SPEEDS:

01

- Nominal performance for UPR at cut-off MFH:

LIFT SPEEDS NS300 30 NS300 40 LOADED/EMPTY STD, HI-VIS HI-LO,TSU

41 38

36 33

LOWER SPEEDS LOADED/EMPTY STD, HI-VIS HI-LO,TSU LOADED ALLUPR EMPTY ALL UPR

68 56 70 85

68 56 70 85

CRITICAL

FASTENER

TORQUE

NP300 20 NP300 30

57 50 70 85

37 35

32 30

57 50 70 85

57 50 70 85

SPECIFICATIONS

TIGHTENING TORQUE, (DRY): ITEM

N-4

Oil filter Drive motor mtg bolts Drive unit mtg bolts Drive wheel lug nuts Caster assy. mtg. bolts Brake assy. mtg. bolts Steer handwheel retaining nut Torque gen. mtg. bolts Hydraulic valve mtg bolts Main hydraulic pump mtg. bolts Main hyd. pump motor mtg bolts Steer pump mtg. bolts Steer pump motor mtg. bolts Upright mtg. block bolts DOG to upr. mtg. bolts DOG leg mtg. bolts

11-13 20-25 70-80 447-610 224-305 19-22 21-23 19-22 34-38 32,5-36,5 20-25 21-23 21-23 289-325 340-380 21-23

Ibf.ft 8-9 15-19 52-59 300-450 165-225 14-16 16-18 14-16 25-28 24-27 15-19 16-18 16-18 220-240 250-280 16-18

NOTE: When checking tightness of major fasteners on new trucks, the values may be less than the recommended specification due to metal deformation and fastener stretch. This is a normal occurrence and does not indicate that the fasteners were not correctly tightened during assembly.

Tighten to recommended specifications.

SM538 40 - 01 - 1

NP300 40

LUBRICANT Transmission

SPECIFICATIONS Fluid TEXACO 8570 ATF, or Clark #962669 Automatic Transmission Fluid

Drive axle

Hydraulic

Fluid CLARK Specification MS-68 Hydraulic Oil, w/antiwear additives

Hydraulic Sump Normal application

CLARK Specification MS-226 Hydraulic Oil

Cold Storage Multi-purpose

grease

Axle ends, Wheel bearings

NLGI Grade No. 1, Lithium soap base grease, CLARK Specification MS-96 and MS-1 07B, or equivalent.

Steer linkage, Upright mast & carriage rollers, Trunnion bushings, Tilt cylinder rod ends, Brake pedal shaft

NLGI Grade No. 2, Lithium soap base grease, CLARK Specification MS-107C, or equivalent.

Chain

Lube CLARK #886399 Chain and Cable Lube, or equal

Upright lift chains Dry-film

lubricant Dow Corning Molykote 321 Bonded Lubricant; Graph-0-Kote #22; Molub-Alloy #369 Dry Lube, or equivalent.

Side shifter, Attachments, Clamp slides Low-Temperature Grease Cold storage general purpose grease Protective

spray

Low temperature grease, MIL-G-23827A, or equivalent

coating Clark #886784 Spray Coating

Wiring, terminals, switches after assembly Moistureproofing

spray

coating

Contactor panels, SCR cards

Clark #1801145 Spray Coating

Battery

Distilled water

service

SM538 40 - 01 - 2

CONTROL

CARD

SPECIFICATIONS

Current Limit Creep Speed Voltage By-Pass Contactor Time Delay

CURRENT

BATTERY

AMPS)

190-210 Amps 3-4 Volts 1.5-2.0 Sec.

DRAW

Drive Motor Pump Motor Pump Motor Pump Motor P/S MOTOR

GROUND

(IN

(Free Wheeling) (At By-Pass) (At By-Pass) (At By-Pass) (At By-Pass)

I._?

Lift Tilt

(25) (35-45)

TEST

All Trucks

20,000 Ohms (Min.)

CONTACTORS 1A and Pump Coil Resistance

300 Amps 22-35 Ohms

Forward / Reverse Coil Resistance

150 Amps 25-300hms

Power Steering Coil Resistance

50 Amps 50-58 Ohms

SM538 40 - 01 - 3

47-52 Amps 375 Amps 140 Amps 85 Amps 40 Amps

OPTION

NPlNS300C

SELECTOR VALVE

SPOOL VALVE __________________ DOUBLE

PILOT

a

TILT CYLINDER

I

i_:r____j 1 f-h

STEER

STEER

LIFT CYLINDER

VALVE VENT LINE FOR STANDARD

AND AUX. PUMP

SUMP

SM53840-03-1

UPRIGHTONLY

lsl

I

-

DRIVEMOTOR

I

JSENSORl .!

KEY SWITCH OSCCARD TERMINAL

VlDLEl

INTERNAL BOARD

”

6

,n ti A

+1 ‘.I

2 14

l3

III

1

TT3

T4

I

I

b

1

SPEED CONTROL

BRAKE SWITCH

I

H. M. S. TRANSDUCER

7

15 15

t

, PSTD

VALVE

SPOOL SWITCH

3A 1

7 REC

LINE DUMP SOLENOID

35

--it&--

36 &

37

----------*

_________-------__~*__m 19 REC

DUMP VALVE SOL ‘A

TILT SELECTOR

9B ---

L ._---------w-v--

OPTION 27__----_-_____

*#15

HM FILTER

42

4a’:,r HORN SWITCH

SM538 40 - 03 - 2

+

SOL.

SELECTOR

SOL.

J*,~’ 4

REC __-----

NP300D

WHEN THIS LINE IS PRESSURIZED THE AUX FUNCTIONS ARE AS FOLLOWS:

SIDE SHIFT CYLINDERS (OPTIONAL) I\

PANTOGRAPH - EXTEND CARRIAGE -TILT FORWARD

SPOOL VALVE CHECK AND DUMP

LIFT PUMP

TRIPLE STAGE UPRIGHT

:._.._.._.__.._.._.._.._.._.._.._.__..__...

7

T “L IT OU

:____________ __._______ .________________.__.

STEER VALVE

-P

STEER AND AUX. PUMP 1

A --

SUMP BREATHER

a

L

?

SUMP

SM53840-04-l

Al

A2 i______________________._

TILT WITH SIDE SHIFT (TWO FUNCTION)

NS300D

HEN THIS LINE IS PRESSURIZED E AUX FUNCTIONS ARE AS FOLLOWS:

SPOOL VALVE

SOLENOID VALVE __- _________---

,

LIFT PUMP

RELIEF XXK) PSI

L____ ... ... ...___ ______ ________________.

1 STEER VALVE

STEER AND AUX. PUMP

-P SUMP BREATHER

I

SUMP

SM53840-04-2

I 1

NP/NS

300D BAlTERY

NEG

Tl

1 REC

TZ

10

PS _

._

3

, PSTD

1

73

QpsDP

S. SHIFT

7A

TILT SOLENOIDS

._

,y

_

- -

Lt.1 __--________.___-____ --

--------.------

SIDE SHIFTER SOLENOIDS .-+-~ ____.______._____ -_- ___________ --_---________ -_ n-__~+__,,-__+-_-__-_____________~_~

42-25 HORN SWITCH

SM53840-04-3

SM538

INDEX PARAGRAPH

GROUP CONTENTS FOREWORD HOW TO USE THIS MANUAL PICTORIAL INDEX SAFETY AND OPERATIONAL CHECKS RECOMMENDED PLANNED MAINTENANCE AND LUBRICATION SCHEDULE SAFETY SIGNS AND MESSAGES USER SAFE MAINTENANCE PRACTICES PM Planned Maintenance Program General Visual Inspection Functional Tests Test Drive The Truck Air Cleaning Critical Fastener Torque Check Lubrication, Fluids and Filters 12 Battery Handling and Care BA-ITERY HANDLING BATTERY REMOVAL PROCEDURE BATTERY MAINTENANCE BAlTERY RECORDS FOR MAXINMUM BATTERY LIFE BATTERY INSTALLATION 13 Accelerator Control ACCELERATOR DESCRIPTION ACCELERATOR MAINTENANCE CONTROL REMOVAL HAND MASTER SWITCH DISASSEMBLY HAND MASTER SWITCH ASSEMBLY CONTROL INSTALLATION 16 Electric Motor general maintenance 1 6 Drive motor MOTOR DESCRIPTION MOTOR MAINTENANCE MOTOR REMOVAL MOTOR DISASSEMBLY MOTOR INSPECTION MOTOR ASSEMBLY MOTOR INSTALLATION 1 6 Lift Pump Motor MOTOR DESCRIPTION MOTOR MAINTENANCE MOTOR REMOVAL MOTOR DISASSEMBLY MOTOR INSPECTION MOTOR ASSEMBLY MOTOR INSTALLATION

SM538 INDEX 1

NO.

PAGE

ii . ..

III iv V vi vii . ..

VIII

PM-1 1 : 8 11 11 11 12-01-l 12-01 12-02 12-03 12-04 12-05 12-06 13-01-l 13-01 13-02 13-03 13-04 13-05 13-06 16-01-l 16-02-o 16-01 16-02 16-03 16-04 16-05 16-06 16-07 16-03-l 16-01 16-02 16-03 16-04 16-05 16-06 16-07

SM538 GROUP

tNDEX PARAGRAPH

1 6 Steer Pump Motor MOTOR DESCRIPTION MOTOR MAINTENANCE MOTOR REMOVAL MOTOR DISASSEMBLY MOTOR INSPECTION MOTOR ASSEMBLY MOTOR INSTALLATION 1 9 SCR Control ,Test, Equip., Proce.edures 1 9 SCR, Symptom Charts 1 9 Control Panel CONTROL PANEL DESCRIPTION CONTROL PANEL MAINTENANCE CONTROL TROUBLE-SHOOTING CONTROL PANEL REMOVAL CONTROL PANEL DISASSEMBLY CONTACTOR INSPECTION CONTROL PANEL ASSEMBLY CONTROL PANEL INSTALLATION 2 0 Drive Unit GENERAL DESCRIPTION DRIVE UNIT MAINTENANCE DRIVE UNIT REMOVAL DRIVE UNIT DISASSEMBLY DRIVE UNIT INSPECTION DRIVE UNIT ASSEMBLY DRIVE UNIT INSTALLATION 22 Wheels and Tires DRIVE TIRE SPECIFICATIONS DRIVE TIRE REPLACEMENT 23 Brake BRAKE DESCRIPTION BRAKE ADJUSTMENT PROCEDURE BRAKE REMOVAL BRAKE DISASSEMBLY BRAKE ASSEMBLY BRAKE INSTALLATION 25 Caster Adjustment CASTER DESCRIPTION CASTER REMOVAL CASTER SERVICE/ ADJUSTMENT 26 Steering System POWER STEERING SYSTEM TORQUE GENERATOR REMOVAL SHAFT/GEAR REMOVAL TORQUE GENERATOR DISASSEMBLY TORQUE GENERATOR INSPECTION TORQUE GENERATOR IASSEMBLY SHAFT/GEAR INSTALLATION TORQUE GENERATOR INSTALLATION

SM538 INDEX 2

NO.

PAGE 16-04-I

16-01 16-02 16-03 16-04 16-05 16-06 16-07 19-02-I 19-03-I 19-04-I 19-01 19-02 19-03 19-04 19-05 19-06 19-07 19-08 20-01-I 20-01 20-02 20-03 20-04 20-05 20-06 20-07 22-01-I 22-01 22-02 23-01-I 23-01 23-02 23-03 23-04 23-05 23-06 25-01-I 25-01 25-02 25-03 26-01-I 26-01 26-02 26-03 26-04 26-05 26-06 26-07 26-08

SM538

INDEX PARAGRAPH

GROUP 26 Power Steering Pump GENERAL DESCRIPTION RELIEF PRESSURE CHECK PUMP TROUBLESHOOTING PUMP REMOVAL PUMP DISASSEMBLY PUMP ASSEMBLY PUMP INSTALLATION 29 Hydraulic Lift Pump PUMP OVERVIEW PUMP MAINTENANCE PUMP REMOVAL PUMP DISASSEMBLY PUMP INSPECTION PUMP ASSEMBLY PUMP INSTALLATION 30 Main Hydraulic Valve GENERAL DESCRIPTION MAIN VALVE RELIEF PRESSURE CHECK AND ADJUSTMENT MAIN VALVE TESTING MAIN VALVE TROUBLESHOOTING MAIN VALVE REMOVAL MAIN VALVE DISASSEMBLY MAIN VALVE INSPECTION MAIN VALVE ASSEMBLY MAIN VALVE INSTALLATION 32 Tilt Cylinder Model C TILT CYLINDER ADJUSTMENT TILT CYLINDER REMOVAL TILT CYLINDER DISASSEMBLY TILT CYLINDER ASSEMBLY TILT CYLINDER INSTALLATION 3 2 Reach Cylinder Model C REACH CYLINDER ADJUSTMENT REACH CYLINDER REMOVAL REACH CYLINDER DISASSEMBLY REACH CYLINDER ASSEMBLY REACH CYLINDER INSTALLATION 3 2 Lift Cylinder Model D LIFT CYLINDER REMOVAL (STD UPR) LIFT CYLINDER DISASSEMBLY (STD) LIFT CYLINDER ASSEMBLY (STD) LIFT CYLINDER INSTALLATION (STD) LIFT CYLINDER REMOVAL (TSU UPR) LIFT CYLINDER DISASSEMBLY (TSU) LIFT CYLINDER ASSEMBLY (TSU) LIFT CYLINDER INSTALLATION (TSU) 3 2 Tilt Cylinder NP D TILT CYLINDER ADJUSTMENT TILT CYLINDER REMOVAL TILT CYLINDER DISASSEMBLY TILT CYLINDER ASSEMBLY TILT CYLINDER INSTALLATION

SM538 INDEX 3

NO.

PAGE 26-02-l

26-01 26-02 26-03 26-04 26-05 26-06 26-07 29-01-l 29-01 29-02 29-03 29-04 29-05 29-06 29-07 30-01-l 30-01 30-02 30-03 30-04 30-05 30-06 30-07 30-08 30-09 32-01-l 32-01 32-02 32-03 32-04 32-05 32-02-l 32-01 32-02 32-03 32-04 32-05 32-03-l 32-01 32-02 32-03 32-04 32-05 32-06 32-07 32-08 32-04-l 32-01 32-02 32-03 32-04 32-05

SM538

INDEX PARAGRAPH

GROUP 3 2 Tilt Cylinder NS D TILT CYLINDER ADJUSTMENT TILT CYLINDER REMOVAL TILT CYLINDER DISASSEMBLY TILT CYLINDER ASSEMBLY TILT CYLINDER INSTALLATION

NO.

PAGE 32-05-I

32-01 32-02 32-03 32-04 32-05

3 2 Reach Cylinder NP D REACH CYLINDER ADJUSTMENT REACH CYLINDER REMOVAL REACH CYLINDER DISASSEMBLY REACH CYLINDER ASSEMBLY REACH CYLINDER INSTALLATION 34 Upright Removal Model C UPRIGHT REMOVAL UPRIGHT INSTALLATION 3 4 Upright Maintenance Model C UPRIGHT MAINTENANCE (STD) ROLLER CHECK/ADJ. LIFT CHAIN CHECWADJ BLEEDING CYLINDERS UPRIGHT DOWNDRIFT TEST UPRIGHT DESCRIPTION (TSU) OPERATIONAL CHECKS (TSU) LATCH OPERATION (TSU) INTERMEDIATE RAILS (TSU) CARRIAGE CHAIN ADJ. (TSU) CHECKING ROLL PATTERN CHECKING CYLINDER SEALS LOAD TESTING LIFT CYLINDER DRIFT TEST TILT CYLINDER DRIFT TEST CARRIAGE REMOVAL ADJUSTING CARRIAGE ROLLERS CARRIAGE INSTALLATION UPRIGHT CLEARANCE (TSU) ROLLER SHIM INSTALLATION (TSU) 3 4 Upright Lift Cylinder Model C LIFT CYLINDER DESCRIPTION UPRIGHT MAINTENANCE STANDARD CYLINDER DISASSEMBLY STANDARD CYLINDER ASSEMBLY COMPOUND CYLINDER DISASSEMBLY CYLINDER PARTS INSPECTION COMPOUND CYLINDER ASSEMBLY 3 4 Pantograph Model C PANTOGRAPH REMOVAL PANTOGRAPH INSTALLATION 3 4 Upright Removal Model D UPRIGHT REMOVAL UPRIGHT INSTALLATION

SM538 INDEX 4

32-06-l 32-01 32-02 32-03 32-04 32-05 34-01-l 34-01 34-02 34-02-l 34-01 34-02 34-03 34-04 34-05 34-06 34-07 34-08 34-09 34-10 34-11 34-12 34-13 34-14 34-15 34-l 6 34-l 7 34-l 8 34-19 34-20 34-03-l 34-01 34-02 34-03 34-04 34-05 34-06 34-07 34-04-l 34-01 34-02 34-05-l 34-01 34-02

SM538

INDEX PARAGRAPH NO.

GROUP

34 Upright Maintenance Model D UPRIGHT MAINTENANCE ROLLER CHECK/ADJ. LIFT CHAIN CHECWADJ BLEEDING CYLINDERS UPRIGHT DOWNDRIFT TEST CHECKING ROLL PAlTERN CHECKING CYLINDER AND SEALS) LOAD TESTING LIFT CYLINDER DRIFT TEST TILT CYLINDER DRIFT TEST CARRIAGE REMOVAL ADJUSTING CARRIAGE ROLLERS CARRIAGE INSTALLATION 34 Pantograph NP D PANTOGRAPH REMOVAL PANTOGRAPH DISASSEMBLY PANTOGRAPH INSTALLATION 3 8 Machine Jacking & Blocking RAISING DRIVE WHEELS BLOCKING THE UPRIGHT RAISING REAR OF TRUCK RAISING ENTIRE TRUCK RAISING TRUCK WITH A HOIST 40 Truck Data, Specifications

SM538 INDEX 5

PAGE 34-06-l

34-01 34-02 34-03 34-04 34-05 34-06 34-07 34-08 34-09 34-10 34-l 1 34-12 34-13 34-07-l 34-01 34-02 34-03 38-02-l 38-01 38-02 38-03 38-04 38-05 40-02-l