CLARK FORKLIFT TMEM 10 thru 15S SERIES TMEM 127 Planned Maintenance and Adjustment Manual

Planned Maintenance & Adjustment Procedures

TM/EM 10 thru 15S SERIES TM/EM 127

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2nd Rev.

8ook No. PMA·500

ClARK

PM

Fig. 21190 EM127 AND TM127 SERIES TRUCKS EQUIPPED WITH CABLEFORM CONTROL MODELS 10/12/15S SPECIAL NOTICE TO ALL USERS OF THIS MANUAL If ••• in the process of using this manual for PM procedures, adjustments, references, etc ... you find that this manual can be improved in any way, put your ideas in writing and send them to: MARKETING TRAINING AND COMMUNICATIONS DEPT. CLARK EQUIPMENT COMPANY BATTLE CREEK, MICHIGAN (49016) We can't promise that your idea will be used, but it will be seriously considered. If you do submit any such ideas, please understand that Clark Equipment Company can use it without obligation.

Code: PM-500, AUG 80 REV

Cop) nghtcd Malen�l Intended for (.LJ\ltK dealer, onlv Oo nol ocll <1r di 1nliu1c

Page l

INDUSTRIAL TRUCK DIVISION

CUSTOMER SERVICES GROUP

PICTORIAL INDEX

BASIC GROUP NUMBERS 12.

13.

14.

16.

17/19.

20, 22, 23, ZS. 26.

29.

JO. 32.

34.

37.

38.

39.

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23

BATTERY SW ITCHES, ACCELERATING CONTROL ASSE118lY WIRING IIOTORS ( ElECTR ICAl) CONTACTORS/CONTROlS ORIVE -'-�LE BRAKES BRAKES WHEELS/TIRES STEERING LINKAGE STEER AXLE, PUI\P & LINES HYO. PUMP, SUII!' & FILTER HYDRAULIC VAlVE-S & LINKAGE TILT CYLINDER UPRIGHT & LIFT CYllHOER SHEET NET Al FRAME & COUNTERWEIGHT SHEET NETAl. OVERHEAD GUAAO. & SEAT

Cop)Tll,hl,xl Ma1cnal Intended for tU\RK d��k.-n ool\ · Du nnl �fl or di.trihu1c

Code: PM-500. REV NOV 80

CLARK

PM TABLE OF CONTENTS Page Page Page Pages

1 2 4 5-31

Illustration of Machine Pictorial Index Iruportant Listing of Cautions for SCR Trucks Planned Maintenance Procedures GROUP

SECTION

Lubrication Charts • • .

01

l

Main Pump Motor Micro-Switch Adjustment Parking and Service Brake Micro-Switch Adjustments •

13 13

1

4

16

1

Electric Truck Battery .

Steering Trunnion Micro-Switch Adjustments Electric Motor Maintenance • •

Cableform Troubleshooting - Periodic Checks

12

13

19

l

6 l

Cableform Troubleshooting - 2nd Level

19

2

Wheels and Tires

22

l

Drive Unit

20

1

Parking Brake Adjustment • • •

23 23

4

Check & Adjustment of Steering Cylinder & Trunnion .

26

l

Removal of Air From Brake System .

Pylon Release Lever Adjustment •

Steer Wheel Bearing Adjustment Power Steering System Pressure Check & Adjustment Hydraulic Filter & Sump Tank Maintenance .

Hydraulic System Pressure Checks . • . . .

Hydraulic Valve Flow Control Cartridges

Tilt Cylinder Adjustment . •

• • • .

Carriage Chain Adjustment

Tools Required For Upright Adjustment Blocking & Jacking Decals & Nameplate

Suggested Equipment for Electric Truck P.M. PM and Daily Inspection Forms

Lubrication Specifications • .

Component and Torque Specifications Knowing your Volt Ohm Meter

Code: PM-500, AUG 80 REV

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25

3

5

26 26

2

30

l

29

3

l

30

2

34

l

32 34

38 40

40 40 40 40 40

l

2 3 l

2 3

4

5 6

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INDUSTRIAL TRUCK DIVISION CUSTOMER SERVICES GROUP

I M P O R T A N T THE FOLLOWING IS A LIST OF 'CAUTIONS' CONNECTED WITH THE OPERATION AND MAINTENANCE OF TRUCKS EQUIPPED WITH SOLID STATE CONTROL DECALS AND NAME PLATES Do not operate your truck without warning decals or name plates.

Replace those that are damaged or lost by ordering from your Authorized Clark Dealer.

A solid PM program should incorporate a method of record keeping, which enables you to better determine PM schedules and to track maintenance costs per machine.

WELDING ON TRUCKS l. Make sure truck electrical systems have no grounds.

2. Disconnect truck battery.

3. Protect electrical wiring and components from weld splatter with shield.

If the above is not followed ••• damage can result to wiring and electrical components on a solid state controlled truck.

DO NOT STEAM CLEAN Do not steam clean a solid state controlled truck as excessive moisture will interfere with proper operation of the solid s·tate components.

CHECK POLARITY Battery polarity must be correct or the truck will not operate.

USE THE TRUCK BATTERY ONLY Do not use a motor generator unit such as ready power to move an/or check this truck as serious damage may occur.

ABOUT PLANNED MAINTENANCE Planned Maintenance Procedures is a basic step by step guide of inspections, minor adjustments, lubrication, oil changes and replacement of filters that are performed on a scheduled and systematic basis.

Page 4

The Planned Maintenance routine is based on 50 to 250 operating hours ••• with the interval being determined by operating conditions.

If PM is followed on a routine scheduled basis, need for repair, major adjustment and component replacement will be discovered automatically and such work will be done only as needed.

For instance, brake checks which are part of the PM will uncover the need for adjustments and/or repairs which may be required periodically. Who can say? The point is, this will be done only when needed and that's true for all systems and components. Thus in this program we are able to eliminate 500, 1000 and 2000 hour inspections and the things normally covered in these inspections will be done only when the PM uncovers the need for repairs.

THE OBJECTIVES OF PM ARE: 1. To reduce costly unscheduled downtime.

2. Reduce maintenance costs.

3. Increase vehicle productivity.

4. Above all, to increase personal safety of drivers and other personnel.

INSPECTION FORMS To insure that daily inspection and PM are properly performed, we recommend the use of inspection forms such as sample shown in GROUP 40, which may be purchased from your local CLARK dealer.

Cop�n11h1cd Mutmal ln1c-1Kkd for C:LJ\IU<, dealers univ· D<1 nol •di or di.rnbute

Code: PM-500, AUG 80 REV

CIARK

PM

ELECTRIC TRUCK P.M. PROCEDURES: A special coding system in the PM-control sheets permits the PM-man to describe the status ' of the fork lift truck exactly, without the necessity of too many words. When performing the maintenance tasks, the PM-man simply checks off on the control sheet, if a module is in good condition; possibly shows a fault; or requires urgent repair action. In case a module is faulty, or not secure, this has to be marked on the control sheet, and reported to the customer.

Fig. 12618

What does the PM for an electric fork lift truck consist of to make it complete? The best answer is to carry out a PM on the basis of knowledge and experience of PM personnel, service managers, engineers, and technical service people.

Flg. 12619 Before testing electrical parts, remove all pieces of jewelry (watches, rings, etc.).

Fig. 12704 VISUAL CHECK: 1.

First of all, have a quick look for oil leaks. In case there are leaks detected now, or in the course of the PM, the smaller ones may be corrected at once, and the serious ones reported on the control sheet, when extended repair is necessary.

Fig. 19436

Code: PM-500, AUG 80 REV

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Page 5

INDUSTRIAL TRUCK DIVISION CUSTOMER SERVICES GROUP

2.

Inspect all sheet metal, the frame, battery cover, overhead guard and supports. Check all wheels for unusual wear and remove all foreign particles. Check these items with last P.M. sheet, making note of any new damage.

I M P O R T A N T BATTERY MUST BE FULLY CHARGED BEFORE YOU DO THE ELECTRIC CHECKS.

Fig. 19942

OPERATIONAL TEST: 1.

Position yourself in operator's seat and check the adjustment. If adjustment is needed, use left hand and pull lever back towards seat.

Fig. 20278 2.

Turn key switch to the on position and listen for the steering servo pump· to run.

During riding test make note of any problem on P.M. check sheet.

Fig. 19541 3.

Now look at the instrument gauges. hour meter should be working.

The

Fig. 14015

. Page 6

Cop) nghtcd Malen�l Intended for (.LJ\ltK dealer, only Oo nol ocll <1r di tnliutc

Code: PM-500. AUG 80 REV

CLARK 4.

PM

Push on horn button to check the horn operation.

Fig. 23689 5.

Move tilt control lever a small amount forward and backward, from the neutral position. The pump motor must run, if not, the micro switch needs-adjustment.

See GROUP 13, Section 1.

Fig. 23690 6.

Check battery condition by holding the tilt lever in back tilt position so fluid bypasses for a few seconds. If the needle falls into the red area, the battery is low and must be charged before completing the electrical part of P.M.

Fig. 14013

7.

Push the lift lever to the lift position.

The pump motor should run. Pull the lever back until upright starts to lower.

See GROUP 13, Section l for adjustment procedure.

Fig. 23690

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ID!J!nd...d fo1 ( LARK tlcalc111 only

Code: PM-500, REV NOV 81 P • S .L.

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Page 7

INDUSTRIAL TRUCK DIVISION MARKETING TRAINING DEPT.

8.

With parking brake on, utove directional

lever forward. The drive motors should not run. If they do, the micro switch on the parking brake linkage is not adjusted cor­ rectly. See GROUP 13, Section 4 for adjust­ ment procedure.

Fig. 23689 9.

Release parking brake and check creep speed, accelerating, and maximum speeds while driving truck in a straight line in both directions. Listen for any noises from the drive unit. All speed changes should be smooth while increasing and de­ creasing speed.

Fig. 19437 10. While checking speed ranges, feel the ac­

celerator movement. It must use the same foot pressure throughout the pedal travel during acceleration, with no friction during deceleration.

Fig. 19939

Page 8

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PM-5 00, REV NOV 81 P. S • L.