CLARK ESM 12-25 Forklift Service Repair Manual

SM-556 ESM 12-25

SERVICE MANUAL SM556 GROUP CONTENTS PAGE Foreword How to Use this Manual Pictorial Index Safety and Operational Checks Recommended Planned Maintenance and Lubricatiin Schedule Safety Signs and Messages User Safe Maintenance Practices ii . .. III iv iv V vi vi GROUP PAGE PM Planned Maintenance Program ’ 12. . Battery Removal & Maintenance 13 Accetkator and Directional Control System 13 Main Pump Motor Switch Check and Adjustment 14 Electrical System and Components 16 Electric Motor General Maintenance 16 Drive Motor 16 Main Pump Motor 16 Steer Pump Motor 16 Drive Motor Overhaul 17 Drive Motor Cut-Cut Switch Check and Adjust 19 Control Panel 19 Control Panel Operation and Troubleshooting 20 Drive Axle 22 Cushion Wheels and Tires 22 Pneumatic Drive Tire and Wheel Maintenance 23 Hydraulic Brake System 23 Brake Master Cyiinder 23 Brake Slave Cylinder 23 Service Brake 25 Steering Gear 26 Steering Axle 26 Power Steering Pump 26 Steer Torque Generator 29 Main Hydraulic Pump 30 Main Hydraulic Valve 31 Hydraulic System 32 Tilt Cylinder 33 Selector Solenoid Valve 34 Upright 34 UprigM Removal 36 Counterweight 38 Machine Jacking & Blocking 39 Overhead Guard 39 Sheet Metal and Trim 40 Truck Data Plate and Decals 40 Truck Data and Specifications 40 Hydraulic and Electric Diagrams PM-1 12-01-l 13-01-f 13-02-l 14-01-l 16-01-l 16-02-l 16-03-l 16-04-l 16-23-l 17-01-l 19-01-l 19-02-l 20-01-l 22-01-l 22-02-l 23-01-l 23-02-l 23-03-l 23-04-l 25-01-l 26-01-l 26-02-l 26-03-l 29-01-l 30-01-l 31-01-l 32-01-l 33-01-l 34-01-l 34-9R-1 38-01-l 38-02-l 39-01-l 39-02-l 40-01-l 40-02-l 40-03-l SM556 i Rev Jan 90

FOREWORD Clark Equipment Company welcomes you to the growing group of professional people who own, operate and maintain Clark lift trucks. This manual wiil 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 Iii truck is a potential source of danger to the operator, and to other personnel working near it. The importance of maintaining your Iii truck in a safe operating condii by servicing it regularly and, when necessary, repairing it promptly cannot be emphasized too strongly. To assist you in keeping your fii 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, deaning, tubncatiin, 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. SM556 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 speciaf instructions; before doing anywork. Speciffcations 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 ofprinting. Clark Equipment Company reserves the right to make improvements and changes in specifications or design, without notice and without incurring obligation. Please check w2h your authorized CLARK dealer for information on possible updates or revisions. 0 Clark Equipment Company 1989 SM556 iii

PICTORIAL INDEX 5 6 1. Control Handle 2. Traction Control Panel 3. Lift Pump & Motor 4. Steer Pump & Motor 5. Service Brake 6. Drive Motors (2) 7. SumpTank 8. Battery 9. Steer Axle & Housing 1O.Steer Torque Generator 11. Brake Reservoir 12. Steer Control and Valve SAFETY AND OPERATIONAL CHECKS Daily Inspection - CMWV Checktruckforobvic__ __...__ . _-_. J S-10 hours ABCDE XIS damage and leaks 0 Q Check / clean battery terminals Check electrolyte level Check capacity, wamina plates. decal Check condition of ti, res and wheels and I II I I 0 I I I remove embedded objects Check wheel lug nuts bnand bolts tration and other warning devices Check steering operation Check brake operation . Check directional and speed control operation Check lift, tilt, ai _._ nd aux. operation Check upright, lift ch( ains and fasteners Check load backrest extension and forks V 0 0 SM556 iv

RECOMMENDED PLANNED MAINTENANCE and LUBRICATION SCHEDULE Recommended Planned Maintenance Interval A = 8-l 0 hours daily B = 50-250 hours or every month c= 450-500 hours or every 3 months D = 900-l 000 hours or every 6 months E = 2000 hours or every year

Safety Signs and Safety Messages User Safe Inspection Practices lmproperorcareless techniques cause accidents. Don’t take chances with incorrect or damaged equipment. READ and UNDERSTAND the procedures for safe driving 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 is required to clarify procedures or identify components pertaining to the truck. IMPORTANT This message is used when additional attention is required for proper operation or maintenance of the truck. A ! CAUTION This message is used as a reminder of safety practices which can result in personal injury if proper precautions are not taken. A WARNING This message is used when a hazard exists which can result in injury or death, if proper precautions are not taken. A DANGER This message is used when an extreme hazard exists which will result in death or serious injury if proper precautions are not taken. The following instructions have been prepared from current industry and government safety standards applicable to industrial truck operations and maintenance. They are listed hereforthe reference and safety of all workers during inspection / maintenance operations. When in doubt of any inspection / maintenance procedures, please contact your local CLARK dealer. 1.Powered industrial trucks can become hazardous if maintenance is neglected. Therefore, suitable maintenance facilities, trained personnel and procedures shall be provided. 2. Maintenance and inspection of all powered industrial trucks shall be done in conformance with the manufacturers recommendations. 3. A scheduled planned maintenance, lubrication and inspection system shall be followed. 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, 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 electrolyte level. Do not use open pans of fuel or flammable cleaning fluids for cleaning parts. 7.Before Starting To Work On Truck: a) Raise drive wheel free of floor or disconnect power source and use blocksorother 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. 8. Operation of the truck to check performance must be conducted in an authorized, safe, clear area.

9. Before Starting to Drive the Truck: a) Be in operating position. b) Turn on power. c) Check functioning of lift and tilt systems. d) Check directional and speed controls. e) Check steering. 9 Check brakes. g) Check warning devices. h) Check any load handling attachments. connections must be inspected and maintained in conformance with good practices. Special attention must be paid to the condition of electrical insulation. 17. To avoid injury to personnel or damage to the equipment, consult the manufacturers procedures in replacing contacts on any battery. 10. Before Leaving the Truck: a) Stop truck. b) Fully lower forks or attachment device. c) Allow directional control to return to neutral. d) Turn off the control / ignition switch. e) Chock wheels if truck must be left on an incline. 18. Industrial trucks must be kept in a clean condition to minimize fire hazards and help in the detection of loose or defective parts. 11. Brakes, steering mechanisms, control mechanisms, warning devices, lights, lift overload devices, guards and safety devices, lift, reach and rotation mechanisms, and frame members must be carefully and regularly inspected and maintained in a safe operating condition. 19. Modiiiations and additions that affect 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. ‘12. 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. 13. All hydraulic systems must be regularly inspected and maintained in conformance with good practices. 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. 20. 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 equipment. Parts, including tires, are to be installed per the manufacturers procedures. Always use genuine CLARK or CLARK - approved parts. ; 21. When removing tires, follow industry safety practiced. 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. SM556 vii 14. When working on hydraulic system, be sure the battery is disconnected and upright is in its fully lowered position, and hydraulic pressure relieved in hoses and tubing. 22. 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. /\ ! WARNING Always put blocks under the carriage and upright rails when necessary to work with upright in an elevated position. 15. The truck manufacturer’s capacity, operation and maintenance instruction plates, tags or decals must be maintained in legible condition. 16. Batteries, motors, controllers. limit switches, protective device, electrical conductors and

Planned Maintenance GROUP PM PLANNED MAINTENANCE Visual Inspection .............................................................................. 2 Functional Tests ................................................................................ 5 Test Drive The Truck ........................................................................ 7 Air Cleaning ..................................................................................... 9 Brake Adjustment ........................................................................... 10 Critical Fastener Torque Checks .................................................... 10 Lubrication, Fluids and Filters ....................................................... 10

Planned Maintenance PM - PLANNED MAINTENANCE PROGRAM A planned maintenance programof regular,routine inspections and lubrication is important for long life and trouble-free operation of your lift truck. Make and keep records of your inspections. Use these records to help establish the correCtPM intervals for your applicationand to indicate maintenancerequired to prevent major problems from occurring during operation. PM REPORT FORM Asan aid in performing and documenting your PM inspections, Clark has prepared an “ELECTRIC TRUCK PLANNEDMAIN- TENANCE REPORT”form. Copies of this form may be obtained from your authorizedCLARKdealer. We recommend that you use this form as a checklist and to make a record of your inspectionand truck condition. The periodic maintenanceprocedures outlined in this manual are intended to be used with the PM report form. They are arrangedin groupings of maintenance work that are done in a logical and efficient sequence. AcheckmarkorentryismadeonthePMReportFormwhenthePM is performed. Please note the special coding system for indicating the importance of needed repairs and/or adjustments. When you have finished the PM inspections, be sure to give a copy of the report to the designatedauthorityor the personresponsible 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. Disconnect battery from truck receptacle before working on electrical components. Always weaf safety glasses. Wear a safety (hard) hat in industrial plants and in special work areas where protection is necessary or required. IMPORTANT The ESM brakes are not self adjusting, but need to be periodically inspected and adjusted accordingly. If adjustments are not made as required, the slave cylinder can run out of stroke, and the springs will not apply the brakes. This condition will not be a sudden event, but will result in a gradual loss of braking capability. If the brakes begin to get “soft”, this is an indication that the slave cylinder may be “bottoming out” and the brakes have not been adjusted as needed. Checking the brake adjustment setting in addition to the driving test must be part of the Planned Maintenance program. When the covers are removed for air cleaning the travel controls, the brake arm positioning and lining wear must be in- A WARNING Failure to perform these checks and adjustments will cause a loss of brakes and may result in prop- erty damage, and/or severe or fatal bodily injury. HOW TO PERFORM THE PM PERIODIC INSPECTIONS AND MAINTENANCE VISUAL INSPECTION First, perform a visual inspection of the lift truck and its components. Walk around the truck and take note of any obvious damage and maintenance problems. Check for loose fasteners and fittings. Check to be sure all capacity, safety, and warning plates or decals are attached and legible. IMPORTANT NAMEPLATES & DECALS Do not operate a lift truck with damaged or missing decals and nameplates. Replace them immediately. They contain important information. Inspect the truck for signs of external leakage of transmission fluid, etc. Check for hydraulic oil leaks and loose fittings. DO NOT USE BARE HANDS TO CHECK OIL. Oil may be hot or under pressure. A WARNING HYDRAULIC FLUID PRESSURE Do not use your hands to check for hydraulic leakage. Fluid under pressure can penetrate your skin and cause serious injury.

CLARK ESM 12-25 Forklift Service Repair Manual

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