Service Manual SM -587 NPR-345 NPR-17 ~ NPR-20 Technical Pubicatons Lexington, KY 40507-1840,TABLE OF CONTENTS a 01 Planned Maintenance Procedures PM-1 thru 29 02 Lubrication Charts O1-1-1 03 Battery Service 12-1-1 lem Group No-Section No-Page No. 31 Hydraulic Control Valves & Solenoid: Control Valves, Remove & Replace30-1-1 32 Auxiliary Reach & Tilt Valve Overhaul 30-2-1 (04 Multi-Function Control Handle Switches 13-1-1 33 Lift Control Valve Overhaul 303-1 05 Electric Motor Service ~- General 162-1 34 Lowering Solenoid Valve 30-41 06 Traction Motor Service 163-1 35 Auxiliary Solenoid Valve 07 Pump Motors 165-1 (Reach & Tilt Control Valves) 30-5-1 08 Auxiliary/Steer Pump Motor Service 167-136 Reach & Tilt Selector (Solenoid) Valves 30-6-1 09 Contactor Service 1-1-1 37 Side Shifter Solenoid Control Valve 30-7-1 10 Electrical Sequence of Operation 19-21 39 Tilt Cylinder Overhaul 32-21 LL EV-T15 Solid State Control Status Code 19-3-1 39 Reach Cylinder Overhaul 32-31 12 Oscillator Card Settings and Tests «19-414 Upright & Pantograph Remove & Replace 13 Steering Control Adjustments (EV-TSPS)19-5-1 andRoller Shim Adjustments 34-1-1 14 Wiring Diagrams 19-6-1 41 Pantograph & Fork Carriage R&R 15 Directional, Lift & Lower Switches and and Roller Shim Adjustments 342-1 ‘Transducer Adjustment 19-7-1 42 Rail Lift Cylinder Overhaul 343-1 16 Periodic Electrical Checks 19-8-1 43 Free Lift Cylinder Overhaul 341 17 Oscillator Card, Remove & Replace 19-10-1_ 44 Lift Fork Inspection 345-1 18 solenoid Control Card Troubleshooting 10-16-1 45 Lift Chains 34-61 19 Axle Articulation Adjustment 20-1-1 46 Load Wheels 351-1 - 20 Drive Unit Overhaul 20-2-1 47 Specifications 401-1 21 Traction Wheel & Tire 221-1 48 Service Weights 40-21 22 Caster Wheel & Tire 22-2-1 49 Lubricants and Shop Supplies 40-3-1 23 Motor Brake 23-1-1 24 Caster Brake 3-2-1 NOTE 25 Brake Bleeding Procedure 233-1 Pictorial Indexes are providedon 26 Brake Pedal Adjustment 23-41 the following four pages. 27 Hydraulic Pressure Checks 26-11 Indes Page6/7 28 Hydraulic Sump Tank, Filter and Strainer(s), Service 2-1-1 29 Hydraulic Schematic 2-2-1 30 Hydraulic Pump Overhaul 29-41 ‘SM-587 Table of Contents - 1 Dec 94INDEX Pictorial Index Pictorial Index #1 NPR-345 Dec94 Index-2 ‘SM-587Pictorial Index INDEX Index 1 of 2 Pictorial Index Contents, "PM" Planned Maintenance Procedures .. "PM" Caster Brake: Adjusting for Lining Wear, When to Replace Brake Linings Motor Brake: Adjusting for Lining Wear, When to Replace Brake Linings Group. 1 Lubrication Chan and Instructions. 12 Battery Service Instruction 13 Multi-Function Control Handle Switches 16 Electric Motor Service ~ General. 16 Traction Motor Service 16-2-01 thru 09 16-3-01 tha 11 16 Pump Motors 24 & 36 Vol 16-5-01 thru 11 16 Awniliary/Steer Pump Motor Service. 16-7-01 thru 12 17 Contactors, Control Panel... 19 Electrical Sequence of Operation. 19-2-01 thru 51 19 Instructions - Starus Codes for EV-T15 Control. 19 Oscillator Card Settings. 19 Steering Control Adjustments. 19 Wiring Diagrams .. 19 F&R Switches, Up & Down Switches, Transducer Aqjl ..19-7-01 thru 10 19 Periodic Electrical Checks 19-8-01 tha 16 19 Oscillator Card Remove & Replace . 19-10-01 thru 04 19Solenoid Control Card Trouble Shooting .. 19-16-01 thru 06 20 Axle Articulation Adjustment 20 Drive Unit Disassembly & Reassembl 20-2-01 thra 19 22 Wheel & Tire, Traction 22-1-01 thru 03 22 Wheel & Tire, Caster 22-2-01 thna 04 23 Brake, Traction Motor. 23-1-01 thru 08 23 Brake, Caster ... 23-2-01 tha 09 23 Bleeding Procedure, Brake. 23-3-01 thra 02 23 Brake Pedal and Cylinder(s) Check & Adjustment 23-4-01 tha 02 ‘SM-587 Index-3 Dec odINDEX Hydraulic Schematic > Pictorial Index Pictorial Index #2 NPR-345 WA Crate q 19 Wiring Schematic lh Dec as Index4 ‘SM-587 hes nisPictorial Index INDEX Index 2 of 2 Pictorial Index Contents Group .. — Group-Section-Page 26 Pressure Check & Adjustment Steering, Auxiliary, Reach & Tilt, and Side Shift Uf so equipped) 29 Hydraulic Sump Tank, Filter and Strainer Service 29 Hydraulic Schematic Diagram 29 Hydraulic Pump Overhaul. 30 Hydraulic Control Valves and Solenoid Control Valves, Remove & Replace 30 Auxiliary, Reach/Tilt Control Valve Service .. 30 Lift Control Valve Service Procedures .:. 30 Lowering Solenoid Valve Service Procedures 30 Auxiliary Solenoid Valve (ReaclyTilt Control) . 30 Reach & Tilt Selector Valve Service Procedures .. 32 Tilt Cylinder Overhaul Procedures .. 32 Reach Cylinder Overhaul Procedures .. 34 Upright, Pantograph Remove & Replace Procedures and Roller Shim Check & Adjustment Procedures. 34 Pantograph & Fork Carriage Service Procedure 34 Lift Cylinder, Rail - Overhaul Procedures 34 Lift Cylinder, Free Lift - Overhaul Procedures 34 Lift Fork Inspection 34 Lift Chain Inspection, Lubrication and Specifications. 35 Load Wheel Service Procedures .. 40 NPR-345 Specification Listing. 40 Service Weights 40 Lubricants and Shop Supplies ‘SM-587 Index-5 Decs4INDEX Se Item Group No:SectionNo-PageNo, Item No-Section No-Page No Axle Motors Articulation Adjustment 20-1-1 General 16-2-1 Battery ‘Traction 16-3-1 Remove & Replace 12-1-1 Auxiliary/Steer Pump 16-7-1 Service 1-1 Pantograph & Fork Carriage Brakes Remove & Replace 34-2-1 Motor 23-1-1 Roller Shim Adjustments 34-2-1 Caster 23-2-1 Lift Fork Inspection 34-5-1 Bleeding 23-3-1 Periodic Electrical Checks 19-8-1 Pedal Adjustment 23-41 Cable & Wire Routing 19-8-1 Master Cylinder 23-4-1 Planned Maintenance Procedures PM-1 thru 29 Caster Service Checks PM-17 Caster Special Socket Adapter PM-24 Control Panel Pressure Checks Contactors. 17-1-1 Steering 26-1-1 Oscillator Card, Lift Circuit 26-1-1 Remove & Replace 19-10-1 Auxiliary Reach & Tilt 26-1-1 ‘Cylinders Pump Overhaul 29-4-1 ‘Tilt Cylinder Overhaul 32-21 ‘Sequence of Operation Reach Cylinder Overhaul 32-3-1 Electrical 19-2-1 Rail Lift Cylinder Overhaul 34-3-1 Solid State Control Free Lift Cylinder Overhaul 34-4-1 Status Codes (EV-T15) 19-3-1 Diagrams Oscillator Card Settings/Tests 19-4-1 Electrical 19-6-1 Steering Adjustments ‘Hydraulic 29-2-1 (EV-TSPS) 19-5-1 Drive Unit Switches Overhaul 20-2-1 Directional, Lift & Lower 19-7-1 Lift Chains Multi-Function Control Handle 13-1-1 Inspection 34-62 Transducer Adjustment 19-7-1 Lubrication 34-6-6 Remove & Replace 34-66 Lubrication Charts & Specifications O1-1-1 Dec 94 Index - 6 ‘SM-587INDEX Upright & Pantograph Lift Chains 34-Manual Insert Remove & Replace 34-14 Roller Shim Adjustments 34-1-1 Valves Remove & Replace 30-1-1 Auxiliary Reach & Tilt 30-2-1 Lift Conwol 303-1 ‘Lowering Solenoid 30-41 Auxiliary Solenoid Valve (Reach & Til) 30-51 Reach & Tilt Selector 30-6-1 Side Shifter Solenoid Control _30-7-1 Specifications 40-11 Service Weights 40-21 Lubricants and Shop Supplies 40-3-1 Sump Tank Fluid Level 29-1-1 Filter and Srainer(s) 9-1-1 Wheel & Tire Traction ~ 22-1-1 Caster 221 Load 35-1-1 SM-587 Index- 7 Dec 94Cautions The followingiisa listof "CAUTIONS" connected with the operation and maintenance of trucks equipped with Solid State Control Panels. Safety Signs and Safety Messages ‘SAFETY SIGNS and MESSAGES are placed in this manual and also on the truck to provide instructions and toidentify specific areas where potential hazards existand special precautions mustbe taken. Be sure youknow and understand the meaning of these instructions, signs and messages. Damage to the truck or serious injury toyou or otherpersonsmay resultif these messages are not followed. If warming decals are damaged they must bbe replaced. Contact your Clark dealer for replacements. 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 messageis 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. 7 GS cauTion —Thismessageisused asa reminder of safery practices which can result in personal injury if proper precautions are not taken. AL warnwa This message is used when a hazard exists which ean result in serious personal injury or death, if proper precautions are not taken. A bancer ‘This message is used when an extreme hazard exists. ZS WELDING ON TRUCKS 1, Make sure the truck has no grounds. 2 Disconnect truck battery. 3. Protect electrical wiring and components from weld spatter with ashield, 4. Ventilate battery or remove battery from truck. Iftheaboveisnot followed, damagecan result to wiring and electrical components on a solid state control truck. SM-587 i Dec 94,CAUTIONS Pll ane AS DO NOT STEAM CLEAN ‘Donotsteam cleana solid state controlled truck as excessive moisture will interfere with proper operation of the solid state components. Solid: putting truck into service. ‘State Controls should be cleaned at regular intervals. Blowing dir off with an airhose (that is restricted to 30 psi (207 kPal) periodically will, for the most part, eliminate any serious cleaning problems. Should the need arise fora more thoroughcleaning, water may behosed over the control and if necessary a mild detergent applied such as that used in washing dishes in our home, The detergent should be rinsed off and the controls must be thoroughly air dried before Periodic cleaning, such as those mentioned above, should preclude the need for using a degreaser. However, if a degreaser is used we recommend the following: Only approved solvents should be used to clean Solid State Control Components. Use Clark #1801146 Degreaser, or the equivalent to MS-180 Freon TF Degreaser and Cleaner. QS CHECK POLARITY Battery Polarity must be comect or the truck will not operate. ZN USE TRUCK BATTERY ONLY Do not use a motor generator unit such as "ready power" ora battery charger tomove and/or check this truck as serious damage may occur IMPORTANT SAFETY NOTICE Read andunderstandall ae ee and Warnings before performing repairs on lift truc! Appropriate service methodsand properrepair proce- dures are essential to the safe, reliable operation of ‘industrial trucks as well as the personal safety of the individual doing the work. This Service Manual provides general directions foraccomplishingservice and repair work with tested, effective techniques. Following them will help assure successful repairand reliable truck operation. ‘There are numerous variations in procedures, tech- niques, tools and parts for servicing induswial trucks, as well asin the skill ofthe individual doing the work. ‘This manual cannot possibly anticipate all such varia- tions and provide advice or precautions as to each. ‘Accordingly, anyone departing from the instructions provided in this manual through procedures used or choice of tools, materials, and parts may jeopardize his or her personal safety andor the safety of the vehicle user. ‘Improperorcarelesstechniquescause accidents. Don't take chances with incorrect or damaged equipment. Read and understand the procedures for safe opera- tion and maintenance outlined in this manual, Drive and work safely and follow the safety signs and their messages displayed in the work area, on the truck and in this manual, Dec 94Cautions GENERAL PRECAUTIONS ‘The following list contains general precautions that should be followed when working ona lift ruck. + Service Electric Truck Batteriesina well-venti- lated area to avoid the danger of lighting explo- sive gases, clear of pedestrians and with ad- equate overhead clearance and on a flat, evel surface. + Always wear safety glasses for eye protection. + Remove rings, watches, loose jewelry and open clothing before working on a vehicle, to avoid serious injury. + Do not smoke while working on a vehicle. + Putpowerkey switch inthe OFF position, unless otherwise required by the procedure. Set the parking brake. Place chocks to the front and rear surfaces of the tires to provide further restraint from inadvertent vehicle movement. ‘Use safety stands or blocks whenever a proce- ure requires you to be under the vehicle. Follow the Safety Instructions outlinedin Group 12, "Handling Storage Batteries Always Discharge the Capacitors prior to work- ingon around electrical components. Referto the instructions outlined in Group 19, "Dis- charging Capacitors". QS caution Avoid contact with Battery Acid. The battery contains corrosive acid which can cause injury. Follow the instructions outlined in Group 12 "Handling ‘SM.587 and those instructions received with your battery and Dec a4Foreword Forewore This Service Publication provides information covering normal service, maintenance and repair of the Clark industrial lift tracks noted on the cover. It hhas been specifically prepared to help owners and service personnel maintain these trucks in efficient and safe operating condition. ‘This manualisintended foruse by persons who are trained and authorized to do lift truck mainte- nance. It is designed to provide essential information ‘about the correct and safe service maintenance and repair of the truck by trained mechanics or service technicians. ‘The information is organized by use of the Basic Group Numbering System used in the ‘Master Parts Book and the Customer Parts Manuals. ‘The manual includes: : PM. Planned Maintenance Procedures including precautions and safe maintenance recommendations. 01-40 Service specifications, adjust- ments, maintenance and overhaul procedures including lubrication charts, recommended lubricants and service weights, etc. General and detailed service and repair procedures are outlined (as required) for each component or subsystem. Some procedures include explanations that are common to several components or subsystems. ‘The Pictorial Index lists components or systems by Basic Group Number of Major Parts. Additional ‘content listings are placed at the beginning of each Section in the manual. The Table of Contents list the pages in this manual. Procedures have been made easier touseby providing specific steps only when necessary and general instructions required to explain the activity, component, assembly, or process being worked on. ‘The technician is expected to include obvious addi- tional steps of standard procedure forremoval, disas- sembly, cleaning, inspection, reassembly, installa tion, etc, as needed. ‘Tobebetter prepared todothenecessary service ‘work, take time to completely read the entire proce- ure, including any special instructions, before start- ing any work. ‘The technician is cautioned and expected tO. ... before beginning to work. “Take time to completely read (entire) procedures, including any special instructions. ABOUT PLANNED MAINTENANCE The Planned Maintenance Procedures located in the front ofthis manual provide abasic sep by step guide which should be followed in servicing the vehicle. Adjustment Procedures, Specifications, Lubrication Guides, Overhaul Procedures and other data are found in the rear of this manual listed under Group and Section Numbers. Refer to the index. Regular, correct maintenance and care of industrial trucks is not only important for long and efficient truck life but tis essential for safe operation. ‘The importance of proper maintenance through planned service, inspection and qualified repairs can- not be emphasized too strongly. Preventive mainte- nance instructions are provided for reference in set- ting-up and conducting a recommended periodic Planned Maintenance (PM) program. NOTICE “The descriptions and specifications included in this manual were in effect at the time of printing. Clark reserves the right io discontinue modelsatany time, ormakeimprovements and changes in specifications or design without notice and without incurring obligation. Specifications, torques, pressures, measurements, adjustments, ilustrations and other items may change at any time. Contact your authorized CLARK dealer for information on possible updates or revisions. Dec 94 ‘SM-587Foreword An effective PM program should incorporate ‘wo basic phases: 1. Aninspection performed by the driver ormain- tenance man at the beginning of each shift. This isa quick visual check for obvious damage and Jeaksandafunctionaltest...acheckoffluids and water levels, lights ifso equipped), instruments and warning devices. 2. The Planned Maintenance routine is based on 50 to 250 operating hours ... with the interval being determined by operating conditions. Records will tell you how often PM should be done. + [fan operation is clean and not strenuous, a PM the PM interval may have to be reduced. If the PM is faithfully followed, needs for repair, major adjustment and component replace- ment will be discovered and such work can be scheduled eliminating unnecessary downtime and cost. For instance, brake checks which are part of the PM will uncover the need for adjustments and/or repairs which may be required periodically. The objectives of PM are: 1. Toreduce costly unscheduled downtime. 2. Reduce maintenance costs. 3, Increase vehicle productivity. 4, Increase personal safety of drivers and other personnel. Inspection Forms ‘To insure that the daily inspection and PM are prop- erly performed, we recommended the use of inspec- tion forms. Such forms not only provide a guide for the inspections and maintenance requirements for each vehicle, they willassist you in determining when toschedule a vehicle for major repairs. Consequently theserepairscan bedone without the disruptive effect of unscheduled down time. NOTE Refer to the Operator's Manual, located on the truck, for additional information on the operation, care. and maintenance of your truck. Contact your authorized Clark dealer for more information on maintenance and repair of these trucks. ‘SM-587 Dec oswePlanned Maintenance Procedures The Planned Maintenance Procedures | Outlined on the following pages are organized in| | five basic catagories. They are: 1. Walk Around Visual Inspection. }] 2. Operational Tests. [> Cleaning. | | 4. Checks and Minor Adjustments. | 5. Lubrication. | Each catagory is preceded with a summary of the’ inspections, checks, tests, etc., that should be per- formed in each catagory. P.M. CHECK SHEET ‘A special coding system on the P.M. Check sheet allows trick condition tobe reported with aminimum number of words. As the PM. is performed, a mark should be made in the appropriate box of the compo- nent being checked. + (\) indicates the particular truck component or system has been checked. + () indicates the componentor systems in need of a minor adjustment or service (not partof the normal P.M.) thet should be taken care of in the near future. + @) indicates there is a potential problem that couldresultin damage to acomponent orsystem and requires attention. ‘Thenature of problems found duringaP.M. shouldbe noted in the "comments" portion of the check sheet. ‘Whenever a system or componentis faulty or unsafe, itmustbe noted on the check sheet andreported to the designated authority at the conclusion of the PM. PAll.Check Shest Sample 1. Visual Inspection 2. Operational Tests Code + (s)indicates the need for urgent repair orreplace d= ox ‘ment of a component or system and the tuck OK X= Adjust (Not Pam should be shut down as possible property dam- Potential [= Repair or Replace ‘age or personel injury may result. TERE] Ss = Requires Shop Repair SM-587 oe eeltenance Procedures Walk Around Visual Inspection summary + Visible frame damage. + Tire Wear andor lodged foreign objects in tire wead andor badly damaged side walls. + Overhead Guard for security of mounting (loose or missing fasteners) and damage. Fi + Visible fluid leaks. + Presence and condition of covers, pads, floor mat, decals and truck data plate. + Safety Screen and/or Glass for security of mounting and damage. + Visible signs of wear and/or damage to upright. + Load Back Rest for security of mounting and damage. + Check that "ground chain link” is touching the floor. ‘ Visual Inspection 1. Inspect Batterv Plug & Truck Receptacle Battery Plug + Disconnect battery from truck. Pull back on the battery disconnectlever located at theright front comer of the console. ‘+ Inspect the spring loaded terminals in the truck battery receptacle and check the battery plug terminals. Bumed or pitted terminals should be noted on the P.M. check sheet. Disconnect Battery and check Spring Loaded Terminals Deco4 PM-2 ‘SM-587Planned Maintenance Procedures 2 Check for Obvious Oil Leaks and general, ition of Frame & O G + Makea quick overall inspection for oil leaks. If oil leaks are found, at this time, or later in the PM, fix the minorleaks and report onthe check sheet any leaks which will require major repair. 3. Check condition of covers, pads and floor mat. + Inspect name plates, warming decals and truck date plate for damage and to be sure none are missing. Be sure warning and instructional de- cals are readable, 4. Check safety screen and/or glass for security of ‘mounting and damage. + Check overhead guard for damage and security of mounting. Be sure the legs of the overhead guard are mounted securely and are not dam- aged, cracked or bent. 5. Battery Retainers + Check battery retainers for damage. Make cer- tain retainers are locked in position at each end of the battery compartment. ‘Check for Obvious Leakage | Retainer Ss S587 PMS Dec 94Planned Maintenance Procedures 6. Inspect Wheels & Tires * Check for obvious damage to tires on the load, caster and drive wheels. + Look for excessive tire wear, cuts, breaks, "chunking" or bond failure between the tires and wheels. ‘Remove objects that are embedded in the tire. + Make sure grease fittings are not damaged and none are missing. + Be sure drive wheel fasteners are secure and none are missing. If they are loose, torque them to specifications. Fasteners must be tightened using a diagonal sequence as shown below (let- tered A through G). Retorque drive wheel fasteners ON after the first200 hours of opera- Caster Wheel Wheel & Tire tion, Fastener Tightening Sequence TORQUE FASTENERS TO: 124-139 LB. FT. (168 - 188 NeM) ‘SM-587Planned Maintenance Procedures ‘+ Check Mullti-Function control for freedom of operation. + Check battery connection. + Check hom. + Check key switch and dash display. + Check upright operation. Operational Test Summary + Check speed limit switch operation. Check brakes. + Check hour meter. + Check steering. + Check control plugging. + Check acceleration, Operational Tests a Check NOTE Battery connector should be disconnectedandkey switch mumed OFF before making these checks. Inspect multi-function control handle for free- dom of operation. Move control to the full forward and rearward positions. Then move it into the full left and full right positions. The control must operate freely without binding and spring retum to neutral. + Connect battery. Move control through all functions checking for free- dom of movernenet. ES Check the Multi-Function Control for Freedomofmovement. Control shouldspring return to neutral from any actuated position without —_ 2 o! ‘SM587 Dec osPlanned Maintenance Procedures b. Check hom to be sure it operates. c. Tum key switch ON. Check the Diagnostic Display & Key Switch + Digital readoutshould display "8888" for about ‘one second after you tum the key switch ON. This indicates that the digital readout is okay. then, either the battery symbol or the wrench ‘symbol light should come ON. + Battery Symbol: When the battery symbol light comes on, the digital readout shows the percent- age of usable remaining battery charge. lf the readout registers 19 or less, the readout will flash. should be + Fault Codes: Codes -01 through -03, -06 and -08 are usually operator fault codes, and can be corrected by the operator as explained in Group 19, Section 3. A momentary display of status code -99 indicates that the truck hours exceed the preprogramed maintenance reminder hours and the functions must bereset after completing the P.M. . Check the hour meter. Tum the key switch to Wrench Symbol: If this light comes on, a status code will appear on the digital readout. The status code may indicate an easily correctable “operator fault” or it may: ‘indicate that the truck serviced. Digital Readout the OFF position. The hourglass symbol light Battery Symbol should come on. The hours registered on the ‘ruck should appear on the digital readout for about four seconds. Record this hour meter reading on the PM check sheet. Sa Hourglass Symbol Wrench'Symbol Dec 94) PM-6 ‘SM-587theck Hydrauli ‘After making sure youhave overheadclearance, ¢gently pull back on the Multi-Function Control. ‘The pumpmotor should tum on and the carriage should begin to elevate. Release the control. It should retum toneutral without binding and the pump motor should tun off. The control should not bind when moving it any position. Elevate the upright tomaximum forkheight. As theuprightraises, watch for mechanical binding of rails, rollers and damage to hoses and lift chains. Lower the upright to full down position. As the uprightlowers, watch formechanical binding of rails, rollers and damage to hose and liftchains. Watch the upright to make sure itoperatessmoothly between the free lift and rail lift stages. Holdin one button ata time and check tilteach and side shift Gf applicable) forproper operation andrange. Forks should tltevenly and smoothly. Pantograph should reach and rewract smoothly without hesitation, Fork Side Shift operation should be smooth without binding. Note any excessive "slop" or “noise” in the upright that may indicate roller damage orroller reshimming is required. Record any malfunction and/or damage on the PM. Check List. = Check Brakes After checking that you have a clear travel path ahead, move the truck forward at a slow speed. Slowly lift foot from brake pedal. Drive motor should cut off before the brakes apply. Move truck in reverse at a slow rate of speed. Slowly lift foot from pedal, themotorshould cut off before the brakes apply. [operations not satisfactory .. do not operate the truck. Report condition to designated au- thority. Planned Maintenance Procedures Reach Control Tilt Controt Side Shift Control (Optional) Multi-Function Control Handle “Switch Buttons" SM-587 Dec osPlanned Maintenance Procedures h. Check Steering + While moving the truck ata slow rate of speed. ina forward direction of travel, tum hand wheel slowly both clockwise and counterclockwise while listening for unusual steering noise. The steering should be smooth without hesitation. ‘Next, tum the hand wheel rapidly in both direc- tions. Note on P.M. Check Listif steering locks momentarily. This may indicate a malfunction in the hydraulic steering system. 4, Check Controlled Piussing (Brak + Operate truck at a slow speed in a forward direction of travel. Reverse direction of travel. ‘The truck should slow down to a smooth con- trolled stop, and accelerate normally in the op- posite direction. Lfpluggingiis as specified, thenrepeatthe proce- dure at high speed. The truck should come toa smooth controlled stop in approximately 20- feet (6.10mm) with Multi-Function Control in maximum travel position. + Repeat the procedure at high speed with the Multi-Function Control moved in reverse direc- tion half way. Ifplugging (braking) is nots specified, refer to the adjustment instructions in Group 19 of this manual. Report condition to designated author- ity. k Acceleration + Now, after checking tosee that you have a clear path ahead, drive the truck in a straight line at a high rate of speed in a forward direction of travel. Listen for unusual drive train noise. Stop ruck. ‘+ Check acceleration from a stand still condition to top travel speed. Acceleration should be smooth without hesitation. D> -Look in the Direction of Travel 9 Now, afier checking to s¢e that youhaveaclear path behind, drive the truck in reverse. Check acceleration from stand still condition through toptravel speed. Accelerationshouldbesmooth, Report condition on PM Check List. Check Speed Limit Switch Operati ‘After checking for overhead clearance, elevate upright until the intermediate rail operates the speed limit switch attached to the outer rail assembly. Drive tuck forward in a straight line of travel with the control held in top speed position. Deco4 PM-8 ‘SM-587Planned Maintenance Procedures CLEANING i Cleaning Summary + Battery Compartment. + Caster Wheel and Brake. + Lower Compartment. + Hydraulic Compartment. + Drive Motor and Steer Motor. + Pump Motor. | + Brake Components. + Control Compartment, + Axle Mounting. + Upright and Pantograph. | IMPORTANT. Do not clean electrical components with steam. Only approved solvents should be used to clean Solid State components. Scheduled cleaning (as outlined) should preclude theneed for using a degreaser. Not all degreasers are acceptable. Ifa degreaser is to be used, we recommend Clark #1801146 degreaser or the equivalent to MS-180 Freon TF degreaser and cleaner. A warninc cleaning with compressed ait + Wear eye protection and protective clothing when cleaning or drying with air pressure. + Reduce air pressure to 30 PSI (207 kPa). Debris removed with air pressure can cause injury. Normal Cleaning Blowing dirt off with an air hose periodically will, for the most par, eliminate any serious cleaning problems. ‘Should the need arise fora more thorough cleaning, water may be hosed over the control and if necessary amild detergent applied such as that used in washing dishes in the home. This detergent should be rinsed off and the ‘control dried with an air hose. The control must be thoroughly dry before putting the truck back into service. Cisening the components of the truck Is a vital part of the P.M. process. Keeping the components clean will increase thelr services Iife and aseure trouble tres truck operation. ‘SM-587 PM-9 Dec 94Planned Maintenance Procedures a Remove Battery + Disconnect battery from truck receptacle. + Remove battery retainers and inspect them for damage. + Remove battery from truck. Refer to Group 12 for removal and safety instructions. + Clean off deposits of corrosion on the battery. + Check battery cables for fraying and damage. A frayed or damaged cable can cause a short. Report condition on P.M. Check List. Battery Cap A WARNING IThe battery contains corrosive acid whict ‘can cause injury. If acid contacts your eye: orskin, flush immediately with water and get medical assistance. Do not smoke or allow open #4) flame near the batery. lt Explosive. gas is always. present around batteries. Cap Vents Must Be Open At All Times + Check battery vents for obstruction..The cap vents must be open atall times. Ifany are found tobe plugged, they may be washed ina solution of baking soda and water. b. Access Internal Components + Remove fasteners securing front console cover tommck, Slip boot off cover lip and tuck bottom of boot into cover hole. (Carefully lift cover a litle forward and upward until the cover is free of the control. ‘Remove console cover from truck. + Remove fasteners securing the side coverto the truck. Lift cover off tuck. + Remove fasteners securing floor plate to truck. Lift floor plate upward and over the brake pedal. + Open Access Door. Loosen door fasteners until the dooris free to open exposing internal com- ponents, S Side Cover Dec 94 PM-10 ‘SM587c. Discharge the Capacitors + Be sure the batery is unplugged. + Discharge capacitors using a 100 ohm, 10 watt resistor connected berween the Positive and Negative power terminals on the Transistor Control. Holdthe resistor in place for? seconds before removing. ZS CAUTION Using a shorting device withouta "resistorload" could cause damage to the control. & WARNING Discharging the capacitors without using specified resistor could cause serious Injury to yourself and bystanders, A Warning + Wear eye protection and protective clothing ‘when cleaning or drying with air pressure. + Reduce air pressure to 30 PSI (207 kPa). Debris removed with air pressure can cause injury. d. AirClean + Using clean, dry air, and a nozzle extension on the air compressor hose, air clean tuck and components. e. Air Clean Battery Compartment + Blow off rollers and roller wells. + Inspectrollers for damage. Replace any that are unfit for further service. + Be’sure battery retainers arenot damaged and fit properly in their respective grooves. £. Air Clean Lower Compartment + Completely air clean the compartment. Blow off the steer control, steer pump & motor, drive motor, brake, cylinder and reservoir. Battery Roller Battery Retainer: Pump Motor Steer Shaft ‘SM-587 PM=11Planned Maintenance Procedures + Checkcondition of the steering slip shaftandthe universal joints. Clean area around the grease fittings. Check their condition and be sure none are missing. + Checkcomponentsforsecurity ofmountingand ‘general condition. AicClean Drive Uni + Blow off the drive unit. Be sureall dirtand dust, is removed around the level and drain plugs. Drive Motor and Steer Motor + If the motors are equipped with brush covers, remove the covers. + Remove the brushes and inspect them for wear. Refertothe Brush Inspection Chartin Group 16, + Inspect commutator bars for "bridging" dust or copper material while slowly rotating the brake drum. If bridging exists, gently remove the bridging dust using a sharp pointed tool such as a scribe or ground off hacksaw blade, Air clean the commutator after removing bridges. + Reinstall brushes and brush covers (if appli- cable). + Recoricommutatorcondition and brush lengths on the PM. Check List. Make certain that all dust is removed from both the outside and inside of the motor. Blow off Motors Dec 94 PM-12 ‘SM-587‘SM-587 Planned Maintenance Procedures HK Group 01 4 Motor Brake Slave Cylinders v Air Clean All Brake Lines, Fit- tings, Master Cylinders, Brake Pedal, Linkage and the Axle. [— Brake Line Retainers (Bracket and Fastener) Brake Master Referto Brake Pedal Group 01 —_ | Cylinders | Brake Components + Air clean master cylinders located beneath the ‘brake pedal. Blow off the brake lines in the operators compartment. + Check brake cylinders, lines and fittings for damage and leakage. Be certain the brake line retainer brackets are in place and tightened securely. Tighten all fasteners and replace any that are damaged or missing. If thereisleakage atthe connections, tightenthe fittings. If leakage still exists, replace damaged || parts. If brake cylinder leakage exists, report condition to designated authority, PMH-13 Dec oaPlanned Maintenance Procedures Flush Type Grease Fitting (accessible through opening in frame "doghouse”) ‘Axle Mounting Block (with Bushing) Axle -to- Frame Retainment Bolt h. Axle Mounting + Be sure the axle to frame retainment bolts are in place and tightened se- curely. + Each axle mounting block is equipp- Access Hole(S) = ed with one bushing and a flush type grease fitting. The grease fitting is accessible through an opening in the topside of the axle weldmentor "dog- Truck Frame house" located just beneath the opera- torscompartmentfloor. Cleanthearea around the fitting and wipe the fittings clean. Be certain they are in good condition, Dec 94 PM-14 ‘SM-587 meej. Air-Clean Caster Wheel & Brake + Blow off the caster wheel assembly. ‘+ Checkforobviousdamageand security ofmount- ing. + Check caster wheel for loose wheel bearings. + Airclean the cover located on the back side of the caster wheel and check it for damage. + Remove the cover and air clean the caster brake cylinder, spring and linkage. + Inspect brake cylinder and lines for leakage. + Checkthe brake spring, linkage and cylinder for damage and security of mounting. Kk. Check Brake Spring Length + Measure the distance between the inside of one ‘washer to the inside of the opposite washer (as shown here). If spring length is notas specified, an adjustment must be made. + Using wrench, turn nut (1) against washer until 2-1/4" (67.2mm) can be measured berween in- side of one washer to the inside of opposite washer. + After obtaining correct spring adjustment, use a second wrench and tighten jam nut (2) against nut (1) without disturbing spring adjustment. Be sure to Lubricate linkage. Refer to Group 01. Planned Maintenance Procedures PM-15, Dec s4Planned Maintenance Procedures Adjusting for Lining Wear Rey Brake Linin: As brake linings wear, the brake arm will move inwardtoward the caster" weldment". When thearm is within 3/16 of an inch from this weldment, move arm I-spline away from weldment. Refer to Group 23, Section 2 for CCheckand AdjustmentProcedures. IMPORTANT: This adjustment may be made a maximum of four (4) times. When the brake arm reaches the 3/16” measurement a fifth time, install new brake linings. Brake Pedal Up-Height should be checked after installing new brake linings. Referto Group23, Section 410 the Checkand AdjustmentProcedures. Lining Wear Check + Now install the cover onto the caster assembly being certain the fasteners are tightened se- curely. Never place truck into service with the cover missing. Itshould be installed at all times. + Check the brake line for damage and security of mounting. + Check to be sure lock ring is not missing or damaged. + Make certain retainer plate is properly located against the brake line fitting. “+ Make certain theretsiner plateis tightly secured tothe axle frame. Brake Line Fitting Dec 94 PM-16 ‘SM-587Planned Maintenance Procedures . (Stabilizer) i Trunni ring: a Chamfer : 7 ee + Try to move the caster assembly up To Face Upward down and check for side to side movement. If the bearings appear to be loose, they should be inspected for damage and proper fashers adjustment (Refer to Group 01 for lubrica- and tionspecifications.) If bearings appeartobe Bearing fit for further service, then adjust the pivot (union) bearings as outlined here. ‘Adjustment + Unlock bearing lock nut. IMPORTANT Lock Nut Be sure the lock nut is installed with the ia «t oe chamfer side (UP) away from bearing. + Using a torque wrench, torque nut to 30 ow Thrust Washer EN + Next,rotatecasterassembly atleast two 2) ~ ——— 2) jearing Cone ae Beating Cup The above procedure must be repeated until bearing preload is stabilized (you jE Axle cannolonger turn the nut)at the 30 Ib.ft. S Frame torque. Oncethishasbeen accomplished, tighten the lock nut (donot back off nut) to the next available locking tab. Lock the nut in place with washer locking tab. NOTE Outer _ Check, adjust and lubricate Thrust Bearing axle trunnion bearings every "P.M.". Refer to Lubrication Caster in Group 01. Mounting Spindle P ‘SM-587 PM-17 Dec 94Planned Maintenance Procedures ‘Hydraulic Compartment + Blow off the valves, pump and motor. hom, and steering sensor. Air clean the complete compartment. ‘+ Blow off the filter, sump tank and hydraulic ines. + Be sure area around the sump breather fll cap is clean, + Clean area around the fluid level indicator. ‘+ Visually inspect hydraulic hoses and clamps for damage, leakage and security of mounting. Tighten loose clamps and/or fittings. Note any damage on the PM. Check List. Pump & Motor Assembi mo SP Hydraulic Valve & Lines + Ifthe motor is equipped with a brush cover, remove the cover. + Remove the brushes and inspect them for wear. Refer to the Brush Inspection Chart in Group 16. + Inspectcommutatorbars for “bridging” dust (copper material) while slowly rotating armature. I bridging exists, gently remove the bridging dust using a sharp pointed tool such asa scribe or ground off hacksaw blade, Air clean the commutator after removing bridges. + Reinstall brushes and brush cover (if applicable). ‘+ Record commutator condition and brush lengths on the P.M. Check List, Make certain that all dust is removed from both the outside and inside of the motor. Blow off Motor Deco4 PM-18 ‘SM-587Planned Maintenance Procedures Contactors SA Soleo Control Card Air Clean Electrical Control Panels Traction and Control pe Control Card . Handle a “ & WARNING When clean with compressed air: Wear eye protection and protective clothing when cleaning or drying with air pressure Reduce air pressure to 30 PSI (207kPa). Debris removedwith air pressure can cause injury. Electrical Controls Compartment + Completely air clean the compartment floor. + Blow off the contactor panel, contactor tips wiring and cables. Harness + Blow off the control cards, capacitors and thd steer control box. ‘Transducer + Air clean the Multi-Function Control Handle] switches, transducer, wiring, switches and har- ness. SM587 PM-19 Dec osPlanned Maintenance Procedures Upright + Blow off the safety screen (or glass), upright . chains, lift cylinders and carriage. + Check screen/shield for security of mounting. + Airclean the packing glands on all cylinders. + Airclean the pantograph, valves and piping. + Airclean the cylinders and piston rods. + Blow off the piston rods. + Check rods and glands for obvious damage, nicks, marring, scratches that might damage the cylinderpackings. Check condition ofhydraulic plumbing and connections. Tighten connec- tions ifloose. Ifthe cylinders are leaking orrods are damaged note condition on the PM. Check List. + Check lift chains for damage. + Check the chain anchor pins (7), Be sure the cotter pins (6) are in place and not damaged. + Examine the hydraulic plumbing and connec- tions (5). Tighten loose connections. + Check rods and glands for obvious damage, nicks, marring, scratches that might damage the cylinderpackings. Checkcondition ofhydraulic plumbing and connections. Tighten connec- tions ifloose. Ifthe cylinders are leaking orrods are damaged note condition on the P.M. Check List. + Checkthehamesshold-downclamps (4), brack- ets (2), and connectors (3) for security of mount- ing and damage. + Note condition on P.M. Check List. . Fastener Bracket Connector . Clamp Fitting Cotter Pin Chain Anchor Pin AAwa YP Dec 94 € nePlanned Maintenance Procedures + Inspect condition of fork retainment pins. + Check the fork mounting bar to be sure itis properly located. Be certain the snap ring and retainment pins are in place and in good condi- <— Retainment Pin tion. S Fork Retainment Pin pf 6 3<— snap Ring Check the liftforks forcracks, breaks and exces- sive wear. Neither fork tip should be more than 1/4 of an inch higher or lower than the other. SM587 PM-21 Dec 94Planned Maintenance Procedures Checks & Minor Adjustments Anchor Cotter Pin Heads must be to the inside of the upright. IMPORTANT Outer Rall Assembly Intermediate Rail Assembly Inner Upright Lift Chains ‘Triple-stage uprights use two chain sets (refer to illustration above); one set for carriage free lift and one set for inner rail lft. Adjustment Chain Anchors (A), located at the back of the Free Lift Cylinder are used to adjust, the carriage lift chains. These chains attach to chain anchors atthe base of the lift carriage. The carriage chain anchors are not adjustable. Adjustment Chain Anchors (B), located at the back of the Outer Rail Assembly are used to adjust Inner Rail Lift Chains attached to chain anchors at the base of the Inner Rail Assembly (see above). The Inner Rail Lift Chains are routed over Sheaves (C) attached to the Intermediate Rail Assembly. Asthe Rail Lift Cylindersextend the Intermediate Rail elevates thus the lift chains routed over Sheaves (C) elevate the Inner Rail Assembly. AIILiftChainsmustbe adjustedtoproperlength ‘and equal tension as outlined on the following pages. Dec oa PM-22, ‘SM-587Planned Maintenance Procedures QS CAUTION Never tighten Chain Anchor against weldment. To do so will result in chain camage. Chain Anchors must be free to in their mounting holes at all times. Maintain Freedom of Movement All Chain Anchors must be free allowing their Spherical Bushings to self align in the machined surtace of their anchor weldments. This helps Prevent chain “twist” and excessive chain stress that eventually results in chain damage. Chain Lubrication ‘The most important consideration in field mainte- nance of lift chains is lubrication. Hard-working, heavily-loaded chains cannot give acceptable wear life without periodic lubrication. As with all bearing surfaces, the joint-wearing surfaces needa layer of oil between mating parts to prevent wear. Keeping a layer of oil on all chain surfaces will: + Keep joint wear (chain wear) to a minimum. + Prevent or reduce the rate of corrosion. + Reduce the chance of pin tuning, + Keep tight joint in chains to a minium number. + Help give smooth, quiet chain action. + Lower the chain tension by reducing internal friction in the chain, Use Clark Chain and Cable Lubricant, part number 886399, for lubrication of chains. Heavy motor oils also a very good lubricant. The lubricant will pen- trate into the chain joint to prevent wear. Applying lubricantto extemal surfaces will preventrust, butthe lubricant must flow into the bearing surfaces for maximum chain life. SM587 PM-23 The frequency of lubrication will change with the operation conditions and the environment. The best lubrication time is during each P.M. (50-250 hours or four weeks maximum actual truck operating time). ‘Trucks that are parked outdoors or in very severe service may need lubrication more often to keep a layer of oil on all chain surfaces. In diy operating conditions, lubricated chains will, gather dirt. Even under these conditions, chain life will be increased by periodic lubrication, Joints geta, "paste" of oil and dirt, butjoint wear will still be much Jess than if the chain is permitted to operate dry with metal-to-metal contact between pins and plates (pin, and bushing in roller chain). In dirty operating conditions, leaf chain can be more easily lubricated than roller and rollerless chain. The plates in leaf chain give more paths for the lubricant, toreach the pin, Atevery P.M. orfour week intervals, clean the chains in a Stoddard type cleaning solvent to remove dirt. Lubricate immediately after the chain is dry. Steam. cleaningisnotrecommended because some clean- ing solutions contain chemicals which can cause linkplates to crack, DecoaPlanned Maintenance Procedures Lift Chain Adjustment Step 1: Adjustment Check + With the upright fully lowered, check to see if the inner rails protrude 1/8 inch above the inter- mediate rails (both sides). + Ifthey do, check tension of both chains on the longest span. Chain tension should be the same. Ifthe above checks are as specified, the Inner Rail Chains do not require adjustment. Check the carriage chains as outlined on the following age. If any one of the above checks are not as speci- fied, adjustthe chains as instructed on this page. Step .djustment Procedure 1, Loosen jam nut on each chain anchor. 2. Rotate chaisi adjustor nut on each chain anchor the same number of tums to position the Inner Rail 1/8-inch above the Intermediate Rail. 3. After completing adjustment, check for equal chain tension... they should be the same. If not, make a minor adjustment to the chain that has the least tension. 4, Finger tighten jam nuts against chain adjustor nuts. Make sure the chains are not twisted and torque jam nuts as instructed in illustration be- low. Again, check to be sure chains are straight and not twisted. Step 1 Chain Tension should be the samé for each chain, You can "feel" chain tension by pushing ‘on each chain by hand. + Spherical Bushing + Chain Adjustor Nut }« Jam Nut <> Tor ecifications Using two wrenches, a torque wrench on the Jam Nut and a second wrench to hold the Chain ‘Adjustor Nut, (A third wrench on the chain anchor is helpful) ... Torque Jam Nut to: 100 - 200 Nem (74 - 148 Ib.tt.) Dec 94 PM-24 ‘SM-587Planned Maintenance Procedures Carriage Chains Step 3: Adjustment Check + With the upright fully lowered and the panto- ‘graph fully retracted, check to see if there is 1/2- inch clearance between the heelof the forks and the floor, see insert below. Check both forks. Hiclearanceisas specified, check tension ofboth chainson thelongestspan. Chain tension should be the same. + Ifthe above checks are as specified, follow the carriage instructions outlined in Step 5 on the next page. + Ifany one of the above checks are not as speci- fied, adjust the chains a instructed on this page and then continue to Step 6 on the next page. Step 4: Adjustment Procedure 1. Loosen jam nut on each chain anchor. 2. Rotate chain adjustor nut on each chain anchor the same number of tums until there is 1/2-inch clearance between forks and floor, see illustra- tion insert below. 3. Once the 1/2-inch clearance has been accom- plished, check for equal chain tension ... they should be the same. Ifnot, make a minor adjust- ‘ment to the chain that has the least tension. 4, Finger tighten jam nuts against chain adjustor nuts . Make sure the chains are not twisted and then torque the nuts as instructed in the iustra- tion below. Again, check to be sure chains are straight and not twisted. inch block ‘Chain Anchor 5)< Spherical Bushing |} Chain Adjustor Nut 1 Jam Nut <> Torque Specifications Lift Chains connect to Pantograph Carriage. Using two wrenches, a torque wrench ‘on the Jam Nut and a second wrench hold the Chain Adjustor Nut, (A third wrench on the chain anchor is helpful) ... Torque Jam Nut to: 100 - 200 Nem (74-148 lb-ft.) SM-587 Dec osPlanned Maintenance Procedures Carriage Stop - to - Upright Stop Step 5: Adjustment Check ZS CAUTION Make sure there Is adequate overhead clearance. + Elevate upright to maximum fork height. + Check to sce if there is clearance between the "stop" weldmenton the Inner Rail and the "stop" ‘weldment on the Pantograph Carriage. For loca- tion of these stops, see illustration below. There mustbesomeclearance...approximately 15mm (59 inch) .. between these stops. + Ifthe carriage stop contacts the rail stop, adjust cchain anchors as outlined in next column . IMPORTANT ‘The carriage stop must not be allowed to contact the upright rail stop under any circumstances during normal operation. Step 6: Adjustment Procedure + Loosen jam nut on each chain anchor. + Rotate chain adjustor nuton each chain anchor the same number of tums until theres 1/8-inch clearance between these stops. Adjust no more than necessary to provide this clearance. + Now, torque jam nuts as previously described. ‘Again, check to be sure chains are straight and not twisted. fork height. Step 8 Carriage Stops: Carriage stops must not make contact when upright is elevated to maximum. Chain Anchor < Spherical Bushing } Chain Adjustor Nut < Jam Nut <————> Tor Pantograph Carriage i Using two wrenches, a torque wrench ‘on the Jam Nut and a second wrench to hold the Chain Adjustor Nut, (A third wrench on the chain anchor is helpful)... Torque Jam Nut to: 100 + 200 Nem (74 - 148 lb. Dec 94 PM-26 ‘SM-587EV-TIS - _ AB,Y and Z Plugs (OSC or Traction Control Card) EV-TSPS - ‘PL4Ping DashDisplayPlug - += PL-DP Plug Key Switch Terminals - Wire Spades 10 & 10C and 12 & 128 ‘Hom Terminals - Wire Terminals 13 (or 13B) and 26 Relay Terminals (for optional equipment only) Check Contactor Tips for the following: Cleanliness ‘Wear Metal transfer between stationary and movable tips eck Harness/Cable/Fuse Check for frayed/broken cable strands at temni- nal crimp, see below. Badly Damaged Casing Cable unfit for farther service. Cables having damage as shown above should be removed immediately and replaced with new. Be certain the replacement cable is the exact same length, size and has the proper connector. Make absolutely cermain the cable endiisproperly crimped andits connection prop- erly torqued during installation. Every cable and wiring harness on this truckis manufactured to an exact specification. A shorter cable or harness will not fi If either a harness or cable is routed improperly, it will not ft. Electrical shorts and damaged compo- nents may result if the replacement part is the wrong one, or if itis routed incorrectly. + Check for oxidation (white/blue) and discolora- tion of cable edge on terminal barrel end. This reflects high resistance joint. Repsirable Small Cuts * Cables having small cuts may be repaired with electrical tape. 4. Check for Grounds + Metershould register 20,000 ohmsor greater when measured between truck frame and any battery connector terminal. + Metershould register 20,000 ohmsor greater when measured between any EV-T15 control power terminal and truck frame. + Metershould register 20,000 ohmsor greater when measured between any EV-TSPS control power terminal and truck frame. 5. Brake Inspection + Every P.M. check for brake lining wear and adjust, if necessary. Refer to next page. ‘SM-587 PM-27 DecaaPlanned Maintenance Procedures Spring Lenathy Increases [-Pressure-| pring | Brake Cylinder Let Notice: As Brake Linings Wear: + Brake Arm & Rod move inward. + Pressure Spring Length increases. To Adjust for Lining Wear: “loosen nut (1), as shown. Do Not Disturb! Nuts are used only at time of new lining installation. Refer to Group 23. + Rotate Nut (2) inwar rd against the brake arm and continue to tighten (This moves the actuating rod outward compressing. the spring.) nut until ... 1» Specified spring length obtained. is + Hand tighten nut (1) against brake arm without rotating the rod. + Using two wrenches, tighten nut (1) while. hold- ing nut (2) to secure adjust te ment. Make certain..nuts are tight without disturb- ing the spring “preload” adjustment. INSTALL NEW BRAKE LININGS when the brake arm moves to within 1/8- inch of the boot. Dec 94 PM-28 ‘SM-587Planned Maintenance Procedures Every 1,000 Operating Hours Check and Adjust the Following: + Forward & Reverses Switches + Lift & Lower Switches + Transducer Multi-Function Control Handle NOTE RefertoGroup 19, Section Tofthismannalforspecific Forward Switch procedures. Reverse Switch Up/Down Switches © Lubrication 6 Upright & Pantograph on iL - | <——— Hose Sheaves and fluids, | | | <— Litt Chains Breather - Control Handle Gears & Spring } Hydraulic Filter Steer Shaft & U-Joints ‘Sump Tank & Strainer: Brake Reservoir Motor Brake Linkage Drive Unit Pivot Bearing Drive Unit Crankcase Drive Unit Wheel Bearings Caster Pivot Bearings ‘Load Wheel hy Rocker Pivot Caster Axie Bearings Caster Brake Linkage Brake Pedal Pivot Load Wheels. Steering Gears: ‘Axle Pivot Blocks ‘SM.587 PM-28 Decs4GROUP 01 CLARK, ty" Section 1 Lubrication Chart & Illustrations NPR-345 Page 2 A Dec 94 ont ‘SM-587GROUP 01 Lubrication Lubrication Chart Key Li&L2 ‘A multi-purpose grease of refined mineral oil NLGI #1 Grade blended with a lithium soap thickener or equal Clark: ee General Purpose Grease containing enti-wear, ant-tustand anti-oxidants NLGI #2 Grade ae Sate et pa Clark Spec. MS-107C : La ‘A multi-purpose grease of refined mineral oil NLGI#2 Grade General Purpose Grease Denise wits tain keer ore) (Clark Spec. MS-107D with EP and Moly additives, eens ese mly adiives Asmooth high quality grease of refined mineral Cold Storage oil base with a lithium soap thickener or equal Applications Lom ere ae ‘compounded with corrosion and oxidation in- MIL-G-23827A hibtors and containing 1 03% moly (molybde- rum disulfids) NLGI#2. L5 Drive Unit Crankcase: Drain when oil is at operating temperature. Le Chain & Cable Lubricant Car Bag No, S8SS85, Use only high quay bya uid with Zine L7 pea ae or equivalent Anti-Wear additive which meets the requirements of ASTM D-2882 pump wear Lease of 6 one gal. CAMS se wih 50 mg total weightloss maximum per Hydraulic Fluid (Clark Spec. MS-68. A straw colored hydraulic fluid composed of a Royco 717 bend of highly refined hydrofined mineral oils Cold Storage or equivalent and additives to impart resistance to oxidation, Applications MILFA711 a and a and to afford eae lu A ‘ricity andimproved viscesity-temperauuechar- Hydraulic Fluid acteristics. Fluid must meet MIL-F-17111. ‘Brake Fluid, Grade DOT 3, as specified by Ls pole ‘Federal Motor Vehicle Safety StandardNo. 116. Lo ‘Acheson Gredag 2230 . speatins ae cre aeay Paste silly Formulated (acy) grease with ex special Grease Texaco Texclad 2 cellent adherence capabilites. or equivalent Dec 94 01-1-2 ‘SM-587Lubrication Chart GROUP 01 ~ Kei Pa ‘Lube jLube 8! OPERATING HOURS (See Key Below) (Thai Lubrication Chart Description | adie, [moo — a TES aT aa | A ‘AXLE PIVOTS 7 4 tT B BRAKE PEDAL PIVOTS: 6 ut x_T - G|BRAKE RESERVOR cot TB. x DT CASTER AXLE 7 TP { E CASTER PIVOT iT a tT F ‘CONTROL HANDLE GEARS: 1 ut ct Go TCONTROL HANDLE SPRING 7 tr £ H DOOR HINGES 2 13-1419 x T T [RIVE UNTT- OL LEVEL i is XO é STICORIVE UNIT- PIVOT i ii Z t [HYDRAULIC BREATHER GAP i i [7 RYORAULIG FILTER 7 a M HYDRAULIC RESERVOIR | nae! aaa c [HYDRAULIC STRAINER, I E (| LOADWHEEL BEARINGS aes P ROCKER PLATE PIVOT 14 BD rig G[“PANTOGRAPH ARM POT 2H x R_[_ REAGH CYLINDER PIVOTS ao x S[COUTER ARWS 2 x TICINNER ARWS a x UALS ao XT [STEERING GEAR FORWARD) —[—1 th = STEERING GEAR (REVERSE) 7 tr x i WI STEERING SHAFT saaleaeL T X—[- UPRIGHT CHANNELS eee Natg]_[-—4—] 13 x i YTCUPRIGHT GHAINS ra x Zz “SECONDARY HOSE SHEAVES- 2 Li x L it Lubrication Chart Lube Key Chart on Page 2 [78 e LY D ies caster Brake Linkage: Lubricate with engine oil at every PM Brake Inspection. Change Note Clean Lubricate length of ris at point of roller Contact” fst PM. only on new trucks. Lubricate Pack Check ‘As Required Lubricate each time a Load Wheel is replaced or squeaking occurs. Pack each time the Caster Wheel is replaced. ‘SM-587 01-1-3 Dec a4GROUP 01 Lubrication - Cold Storage & Standard Applications Every P.M. (250 operating hours maximum) Corrosion Protection Mechanical Paste Lubricant Using Clark PartNo.280220S apply tothefollow- [Apply to electrical ingPower Cableand Serew-Ontypewireconnec- _|connectionsany time tions: they are discon- AllPower Cable Connections ected, Nove: Resp : ‘plybeforemakingthe + All Motor Cable Connections. connection, + All Control Panel Cable Connections. one ae + All Card retainer screws. + Motor Ground Wire (both ends), see below. + Reverse Alarm (if so equipped). + Strobe Light Connections (if so equipped). Ground Wire Deces 1-4 SM-587Lubrication - Cold Storage & Standard Applications GROUP 01 Every P.M. (250 operating hours maximum) Corrosion Protection lechanical Lubricant Using Clark PartNo. 1803827spray the following: jen Ne + Contactor Panel. coe ore + Drive Control (EV-TI5). Part Numbers: + Steer Conzeol EV-TSPS). ” 1803827.& 2802295. + PLand DP plug connections. ety oles IMPORTANT Jconnections anytime Avoid direct spraying on contactor tips. they are discon- + Power Cable Connections. A CAUTION Do not spray motor brushes and commutator. Cover all motor openings prior to spraying. + Wire Terminal Screws including the follow. ing: + Control Card (1) and Control Card (2). + Brake Switch terminals. + Steer Interlock Switch on contactor panel. + Speed Limit Switch mounted on outer rail tie bar. Switch cover mustbe removedfor access 10 screw terminals. . ine shoul: ve + Horn terminals + Key Switch terminals. + Heater Thermostat (Cold Storage). Thermo stat located on contactor panel. Electrical Options (Spray all connections). + Forward Pointing Head Lights (terminals). + Suobe Light (terminals) + Reverse Alarm terminals (if applicable). + Any and all switches used on the option(s). ‘SM-587 1-1-5 Dec 94GROUP 01 Lubrication - Cold Storage COLD STORAGE LUBRICATION Every P.M. (250 operating hours maximum) Apply Anti-Corrosion Spray Clark Part No, 2794748 to the following: + Reach and Tilt Cylinder Rod Ends (spray threaded area only). See below. + Motor brake adjustment linkages, springsand bleeder screw (donotspray directly into the bleeder screw). See below. on Cylinder Rod Ends + Dowel Pin Retainers on panto- ‘graph. There are nine (9) pins tora. + Caster brake adjustment linkages, springsand bleeder screw (donotspray directly into the bleeder screw). See above. Dec 94 1-1-6 ‘SM-587 “ 8 peLubrication - Cold Storage GROUP 01 COLD STORAGE LUBRICATION Hydraulic Sump Tank ‘Specifications: Use Hydraulic Fluid which meets MIL-F-17111. (Royco 717 or equivalent) + A straw colored hydraulic fluid composed of a blend of highly refined hydrofined mineral oils and additives to impart resistance to oxidation, corrosion, and rusting and to afford greater lubricity and improved viscosity-temperature characteristics, Grease Fittings ‘Specifications: Usean extreme low temperature aircraft quality grease meeting MIL-G-23827A, or equivalent product. Temperature range: -100 to +250°F. Refer to Lubrication Chart on Page 3 for remainder of instructions and time intervals. ‘SM-587 1-1-7 Dec oanemCLARK tonany ns GROUP 12 SECTION 1 Battery Contents Battery Service Area ‘Handling Storage Batteries Battery Removal & Installation Battery Maintenance. Battery Installation Battery Records ———EEEEe—————E————— BATTERY SERVICE AREA Remove all jewelery before working on the truck SM587 ett Dec a4GROUP 12 BATTERY A warNiNG SULFURIC ACID THE BATTERY CONTAINS CORROSIVE ACID WHICH CAN CAUSE INJURY. IF ACID CONTACTS YOUR EYES OR SKIN, FLUSH IMMEDIATELY WITH WATER AND GET MEDICAL ASSISTANCE. AWARNING Disconnect battery before handling electrical components. Polarity must be correct to prevent damage. A WARNING Electric truck batteries are heavy and awkward to handle. On charge, they give off hydrogen and oxygen which, in certain concentrations, are explosive. Electric truck batteries are also costly, so before you remove, service, or install a truck battery, consult BATTERY MANUFACTURER, for more recommenda- tions and instructions on handling and charging batteries. Care- {ully ead and follow recommendations and instructions. Decs4 121-2 ‘SM-587BATTERY GROUP 12 BATTERY HANDLING Fire Extinguishey Change orservicebatteriesonly inan area designated ¥ for this purpose. + Be sure this area has provisions to flush and Seavice © neutralize acid spillage. + Be certain the area has proper ventilation to ventilate fumes from gassing batteries. + Check to see that there is fire protection. Fire extinguishers should be properly maintained and located in designated areas. A DANGER Explosive gas is always present around batteries, especially when they are being charged. The fol- lowing should be adhered to. + Nosmoking shall be allowed in the charging area. + Battery electrolyte shall never be checked with an open flame. Kd; + Open flame, sparks, or electric arcs shall never be allowed in the battery charging area, Persons maintaining storage batteries must wear pro- tective clothing such as: + Face and head shields + Long shirt sleeves. + Gaunlet gloves. A WARNING ~ SULFURIC ACID ‘THE BATTERY CONTAINS CORROSIVE ACID WHICH CAN CAUSE INJURY. IF ACID CONTACTS YOUR EYES OR SKIN, FLUSH IMMEDIATELY WITH WATER AND GET MEDICAL ASSISTANCE. ‘M587 241-3 Decs4GROUP 12 BATTERY we Be sure the battery service area is equipped with ‘Overhoas Holst material handling equipment designed for the pur- pose of removing and replacing batteries, such as a conveyer or overhead hoist equipped with safety hooks + When using an overhead hoist, be sure to use an insulated spreader bar or similar lifting device. Safety Hook To prevent side forces from damaging the bat- etd tery, the distance between the lifting hooks (of the spreader bar) must be adjusted to the same dimension as between the battery lifting eyes. \iteg ‘Make sure the lifting hooks are the correct size to fit the lifting eyes of the battery. + Be sure the hoist is equipped with a chain “naulatod Spreader Bar sy N mi sahd container to accumulate excess lifting chain. ‘When this is not possible, be sure the battery is covered as shown below. “Typical ltuswaton Plywood + Ifthe battery does not have a cover of its own, j cover it with a non-conductive material such as (Non-Conductive Cover) plywood. ‘pica ituseaton + Never lay tools or other metal objects on a ee battery. Metal objects contacting battery termi- nals will cause short circuits. The shorted cir- cuits could ignite battery fumes and cause the battery to explode. Dec94 124 ‘SM-587BATTERY GROUP 12 Battery Removal 1 5. Move truck to the designated battery service area, Tum key switch OFF and disconnect battery. ‘Remove battery retainer plate. ‘The battery must be pushed out of the compart ‘ment. A recommended method of handling the banteryistouse a platform equipped withrollers similar tothe one shown in opposite illustration. If the battery to be handled is uncovered, cover battery with a non-conducting material (plywood, heavy cardboard, etc.) prior to re- moval from truck. NOTE Do not wash battery in truck. Once the battery is out of the truck, a lifting device equipped with an insulated spreader bar and safety hook(s) can be used to transport battery. Be sure battery is covered prior to attaching lifting device. Anoverhead hoist (ofsufficientlifting capacity, refer to "Weights" in Group 40) should be used to lift battery. The safety hooks of the insulated spreader bar should be attached to the lifting eyes provided in the battery casing. Key Switch Off Battery Disconnected Removing Battery Transporting Battery Chain Container Uncovered Batteries: Plywood or Heavy Cardboard 124-5 Dec osGROUP 12 BATTERY Battery Vents + WhenCharging Batteries: The ventcapsmust bekeptin place to avoid electrolyte spray. Care must be taken to assure that vent caps are fune- tioning. The cap vents must be open to allow the battery to breath, The battery cover must be removed/opened to dissipate heat and explosive gas, +. When Cleaning Batteries: The vents must be tightly in place. Battery Cleaning ‘The easiest and most satisfactory method of cleaning a battery is to wash it with a low pressure cold water spray. The battery top can also be washed with a baking soda solution and rinsed with clear water. + Check to be sure all vent caps are tight before washing the battery. + Filla bucket with cold water while adding a box ‘of baking soda to the pail. Stir the solution until dissolved. It is advisable to have this solution around the battery service area at all times. + After washing battery, thoroughly rinse with clear cold water. Battery Charging Followtheinstructions supplied by the Baery Charger Vendor. Battery Electrolyte + Always use a carboy tilter or siphon when. handling banery electrolyte. + When mixing electrolyte, always pour acid into water ~ never pour water into acid. Pouring water into acid will cause adangerous chemical action, Vents Open Vent Caps must be free of obstruction and in good condition, a 0 IMPORTANT Battery top should be clean and tree of eracks or breaks. Battery terminals must be clean and solidly mounted. ‘Damaged batteries should be repair or replaced. Consult your battery vendor. Battery Maintenance ‘Toobtainmaximum performance and battery life, the instructions supplied by your Battery Vendor should be adhered to. Deco4 2-8 ‘SM-587BATTERY GROUP 12 Clean Battery Compartment + Using baking soda and water solution, clean the walls and floor of the compartment. Rinse with clear water. & warning Wear eye protection and protectiveclothingwhendrying with air pressure. Reduce alr pressure to 30 PSI (207 kPa). Debris removed with air pressure can cause injury. + Blow off the compartment walls and floor with an air hose. Allow to air dry. REPLACEMENT BATTERIES Cautionshouldbeexercisedto use a battery properly sized to the dimensions of the battery compartment. Batteries too small can shift and cause damage tothe truckor injury to the operator or bystanders. For the NPR 17 a minimum battery size of 38.69 x 13,00x 31.50 inches (982,7x 330,2.x 800,1 mm) and minimum weightof 1185 lbs. (537,5kg)isrequired. For the NPR 22 a minimum battery size of 38.69 x 15.75x31.50inches (982,7 x 400,0x 800,1 mm) and aminimum weightof 1400 bs. (635,0kg)istequired. Install Battery If the batery is uncovered, cover the battery with a non-conducting material (.c.. plywood, heavy card- board, exe.) prior to installation. + Push battery into battery compartment, + Install battery retainer. + Remove non-conductive material from battery. + Connect battery to truck. Clean Battery Compartment Bag Seca 8 ‘Wate Sour | ‘SM-587 121-7GROUP 12 BATTERY woe KEEPING BATTERY RECORDS Records should be kept to get the best service out of ‘your battery and truck. These records should contain: + Test Date, Each test should be dated for farare reference and comparison. + Specific Gravity and Temperature readings. Each battery cell should be checked and re- corded before and after charging. The specific ‘gravity reading of the electrolyte should not be Jess than 1.260. If below 1.250, the battery should be recharged and tested. + Variation between each cell tested. The varia- tion in specific gravity reading between cells should not be greater than 15 points (015). If readings are greater, this indicates there are defective cells. Thepilotcell shouldbe changedoccasionally to distribute any electrolyte loss over the battery when taking readings. + Load Voltage Tests should be performed and recorded indicating the condition of a battery while itis performing work. + Actual Operatinghoursofthebattery.Record the actual time the battery is in use before putting it on charge... + Charging Time.Keepan accuraterecordofthe actual time the battery is on charge. After each charge, check to see’ if the battery is fully charged. Test the battery before placing itback into service. Record these results. + Visually Inspect for loose terminal connec- tions or posts, a cracked case, or damaged cell ‘vent caps and excessive corrosion. This data should be noted to help ascertain work environ- ment and possible trouble areas. For further information, refer to Group 19, Section 4 inthis manual. ‘Check with your local battery supplier for complete battery maintenance procedures and their expertise. BATTERIES Industrial Batteries are used to supply the electrical power to operate an Electric Industrial Truck. Their voltage depends on the number of individual cells theycontain, There are approximately 2 volts foreach cell in the commonly used lead-acid type battery. Batteries normally range from 6 volts to 72 volts. ‘Their capacity varies depending on the application. Only use batteries that comply withfactory specifica- sions as to size and capacity and weight. HOW TO GET MAXIMUM LIFE OUT OF YOUR BATTERY + Do not add acid to a battery. Only qualified Battery Representatives should determine ifthis is necessary. + When lifting a battery, use a lifting device designed for this purpose * Check the electrolyte level before placing a battery on charge. Add water, ifrequired, before charging the battery. The electrolyte level in a battery should be slightly below the lower lip of the filling hole vent. Do not over fill. Over flushing causes loss of electrolyte. + Keep the battery clean, dry and in good condi- tion. + Keepmetal objects and tools away from the top of the battery. Short circuits will cause battery damage and could ignite battery fumes, explod- ing the battery. ‘+ Maintain good battery cable connections. + Check power cables and wiring for damage. ‘+ Donotover charge a battery. + Donot under charge a battery. + Follow the instructions provided by your supplier(s) of the battery and battery ‘charging equipment. + Maintain accurate battery records. If battery troubles occur, these records will help you and your battery representative determine the nature of the problem. Dec94 121-8 ‘SM-587CLARK tiny GROUP 13 Section 1 Multi-Function Control Handle Switches Contents Reach, Tilt and Auxiliary Switches, Remove and Replace. Lift and Lower Switches, Remove and Replace ... Fastener (Heel Side) \ Fastener (Switch Side) =>-g=—=>- $O-10 e Transduc Ze ft on LifvLower BQ 'SO-8 Switch py PT ‘SM-587 1344 Dec 94GROUP 13 Reach, Tilt & Aux. Switches REACH, TILT AND AUXILIARY SWITCHES Switch Remove & Replace ‘These switches (1) are located in a separate housing within the control handle. The handle grip has two halves (switch side and heel side). ‘Switch Removal L 2, Remove inner fasteners (4 & 5). 3. Pull hamess wires free of their retainer slots in 5. Remove wires from switch connections. |. Connect wires to the new switch and install Fastener >) (Heel Side) isc? Remove fasteners (2.& 3), see opposite illustra- tion. handle (heel side). Remove switch housing (6) from handle. Provide some wire slack in the housing before removing a switch. Pall switch from housing. switch kit plac housing. Multi-Function Control Carefully pull wires "taugt" butnot so tight as to cause damage to the connections. Place housing ..usinga blunt" instrument soasnottodamage into handle (heel side). wire insulation. .. Carefully push wires into their retainer slots... 4. Assemble handle being certain to tighten fasten- cers (2) thru (3) securely. IMPORTANT Connector Plugs and Receptacles are permanently labeled with the proper PL (Plug) and SO (Socket/Receptacle) number for easy identification. ZS CAUTION If disconnected, match plug number with appropriate receptacle number before making a connection. if not, electrical shorts and possible damage to equipment ‘may result. Le., Plug #PL-6 plugs into pin socket #50-6, etc. mat Clamps, Cable Guides and Marking Tapes: IMPORTANT Cables must be positioned so all tape markers are aligned with or hidden under clamps or guides. Dec os 184-2 ‘SM-587Switches GROUP 13 UP (LIFT) AND DOWN (LOWER) SWITCHES Switch Remove & Replace ‘These adjustable switches control lift and ower func- tions of theuprightand are mountedtoabracketon the left side of the handle bracket. See opposite illustra- tion, ‘Switch Removal 1, Remove cam fastener, washer and cam. See illustration below. 2. Disconnect switch (to be removed) from the wire hamess, 3. Remove fasteners securing switch and switch adjustor to bracket. 4, Remove switchadjustor bolt, bothlock washers, spring, and switch adjustor. Remove switch. Adjustor Bolt Lower Switch Washer: Oo _ eo ener a ‘Spring )) Fastener(s) > +t} Handle Bracket Cam Washer Lift Switch 1, Install new switch assembly and route wires as illustrated below and on Page 4. 2. Connect switch hamess assembly Socket SO-7 to main wire hamess Plug PL-7. See Page 1. 3. RefertoGROUP19, Section7 forswitchadjust- ment procedures. SM-587 134-3 Dec 94GROUP 13 Switches Terminals to be 90" to switch body. Wirg#12B ~~ Horn ‘Switch wives Terminals to be Horn Switch ‘Assemble horn “switch” with terminals positioned as. shown to provide clearance for the reach, ‘it & aux. switch holder. [=] Wire #458 Tilt Switeh Harness(s) be pesi- tloned with all markers 131-4 ‘SM-587Transducer, F & R Switches GROUP 13 TRANSDUCER, FORWARD AND ‘Transducer Installation SWITCHES + Install new transducer to the transducer plate. Forward and Reverse Switch ges wansdiboetand ened Daten) to bracket Remove & Replace Two adjustable switches mounted to 2 bracket at the rear of the multi-function control pro- vide forward and reverse direction of travel. A trans- + Route the transducer's wire assembly through the clamp and securely fasten the socket clamp as shown in illustration on page 1. ducer and adjustor plate are attached toa mounting * Connecttransducerhamess SocketSO-10tothe plate attherearof the control. The transducer provides ‘main wire harness Plug PL-10. ‘variable speed control. Refer to GROUP 19, Section 7 for switch and Switch Removal transducer adjustment procedures. + Disconnect switch harness assembly Plug PL-8 (to be removed) from the main wire hamess Socket SO-8. Refer to illustration on page 1. + Remove clamp screw and remove the trans- ducer clamp assembly hamess from the clamp. ‘+ Remove adjustor screw and lock washer secur- ing the switches, switch adjustors, lock washers and springs to the switch bracket. Switch Installation | + Install new switch, switch adjustors, lock wash- crs and springs in the reverser order of removal. Secure the sub-assembly with adjustor serew(s) Control Handle Mounting Bracket Reverse Switch Adjustor T Screw and lock washer(s). Lock Washer + Route switch wires as shown in illustrations on ef Page 1 and Page 4. | 7 Adjustor + Connect switch hamess assembly Plug PL-8 to ¢ \ Switch Guide ‘main wire hamess Socket SO-8. el \ \ I fa beck Washer] Transducer Remove & Replace \ VS Bracket ‘Transducer Removal _ + Disconnect transducer hamess Socket $O-10 from the main wire hamess Plug PL-10. + Remove clamp screw and remove transducer clamp assembly hamess from the clamp. + Remove fastener switch securing the transducer and transducer plate to the bracket. + Remove mut and washer securing transducer to transducer plate. ‘SM-587 134-5 Dec 94CLARK titra -_ GROUP 16 Section 2 Electric Motors General Contents Safety... Motor Inspection, Cleaning and Insulation Testing Procedures Brush and Commutator Inspectio: Brush Inspection Chart Cable and Clamp Inspection CLEANING, INSPECTION & TESTING PROCEDURES Torque Cable Fasteners to: Refer to: Group 16, Section 7 So) Torque Cable Fasteners C3 Steer \ 75 b.in, (8.5 Nem) \ ee) \ ‘Torque Cable Fasteners \ w: V4 150 Ib.in. (16.9 Nem) (Traction ) Motor r Dec94 18241 ‘SM587GROUP 16 Motors A WARNING Wear eye protection and protective clothing when cleaning or drying with air pressure. Reduce air pressure to 30 PSI (207 kPa). Debris removed with alr pressure can cause injury. Remove all Jewelry before working on truck. Always wear Safety Glasses Dischargethe Capacitors before workingontruck + Be sure the battery is unplugged. + Discharge capacitors using a 100 ohm, 10 watt resistor connected between the Positive and ‘Negative power terminals on the SCR control. Hold the resistor in place for 2 seconds before removing. QS CAUTION Using ashorting device without a "resistor load" could cause damage to the control. A WARNING Discharging the capacitors without using specifiedresistor could cause serious injury to yourself and bystanders. ‘SM-587 162-2 Decs4Motors GROUP 16 Electric Motor Maintenance A planned maintenance program of regular, routine inspections is important for long life and trouble- ‘free operation of electric motors. Make and keep records of your inspections. Use these records to help establish correct P.M. intervals and to indicate maintenance required to prevent major problems from occurring during operation. Inspection Procedures To perform these service procedures, it is recom- mended that you first: + Park ruck safely. + Fully lower upright. + Apply parking brake. + Tum key switch OFF. + Disconnect battery from truck recepatacle. + Discharge capacitors, see page 2. Motor Cleanliness Electric motors should be kept clean at all times to prevent shorting, minimize wear, and for bestcool- ing. + Wipe off all dust, dirt, oil, water, etc., from outer surface of motor. + Remove any debris from cooling air ventsand around motor frame to prevent overheating. + Airclean (blow out) open motors using clean, dry (moisture-free) compressed air at [207 KPa) 30 psi. maximum air pressure. Airclean allinnerareasaroundcommutatorandbrushes, including cooling air vents and fan. Wear safety glasses. ‘The presence of any oilon ornear motor could indicate either bad bearings or leaking hydraulic system. Determine cause and repair problem before extensive motor damage occurs. Motor Insulation Ifa reduction in motor performance has been noted, it may be due to breakdown in motor insu- lation causing internal grounding or a short circuit. Fail fm + (1) contamination + (2) mechanical factors + @high temperatures Contamination includes dirt, moisture, oily va- ors, metal chips, carbon dust from brushes, etc. Mechanical factors include shock, vibration, over speed, etc, Operation at prolonged or excessively high tem- perature will cause insulation tobecome brittle and crack leading to premature failure. The insulation condition can be judged both visually and by test measurement. Regular, periodic measurements of insulation resistance can givea useful indicationof the rate of insulation deterioration, A sudden drop or consistent trend toward low values of insulation resistance give evidence that insulation is deteriorating and that failure may be imminent. ‘SM-587 Dec 94GROUP 16 ‘TEST FOR MOTOR INSULATION “RESISTANCE TO GROUND" (Using a 500 Volt Megger) (Test must be made with motor out of truck). 1. Disconnect battery from truck receptacle, 2, Discharge the capacitors. Refer to Group 19, 3, Disconnect power cables from all motor termi- nals. 4, Connect one lead of a 500-volt megger to any motor terminal. NOTE: Test ALL temminals individually or by interconnecting with jumper wires, Connectotherleadtomotor frame. Apply voltage. 5, Resistance should be measureat least 1,000,000 ohms (1 megohm). If less than this, motor should be air-cleaned or dried to attempt to increase insulation resistance, Motors TEST FOR MOTOR INSULATION “RESISTANCE TO GROUND" (Using a Simpson 260-6p Volt-Ohmmeter or equivalent calibrated on the Rx10,000Scale). This test may be made with motor in the truck. 1. Disconnect battery from truck receptacle. Discharge the capacitors. Refer to Group 19. Disconnect power cables frommotor terminals. Connect the positive lead of the VOM to all terminal studs of estmotor. Use jumper wiresto connect betweenmotorterminals. Connect VOM. negative lead to motor frame. NOTE Test all terminals individually, or joined together, as noted. APN 5, VOM must show 1,000,000 ohms (1 megohm) resistance or higher fora good motor insulation. 6. Ifless than 1 megohm is measured, air clean motor and repeat test. If cleaning does not make an improvement, the motor will have to be removed from the truck and disassembled for a closer inspection. Disconnect Truck Battery, Discharge the Capacitors - Refer to Group 19 s0Pig . boon > Motor ) "Out of Truck"! Test :S Volt Ohm [000 oh iia Truck Test 16-24 Dec a4Motors GROUP 16 BRUSH AND COMMUTATOR INSPECTION ‘The key to planned maintenance of the brush and commutator is recognizing the undesirable brush and commutator conditions. If this is done, corrective action can be taken before a major component is damaged beyond serviceability. The brushes and commutator should be inspected for even wear and good commutation. Good Commutation: A dark uniform coloring pattem at the brush wearing surface. Poor Commutation: ‘The surface of the commutatorappearing rough, pitted, scored or signs of burning or heavy arcing between bars. The coloring pattern will be: . Streaky film with commutator wear. + Baredge burning. + Uneven film. + Carbon dust bridging between bars Different Grade Brushes: When the brushes being fitted are of a different grade from those previously used, then itis advisable to remove the film left by the previous grade brushes. This film removal should be done by scouring with a strip of abrasive cloth (donot use emery cloth) while the armature is rotating. Do not finish with a lapped, highly polished surface. A moderately abraded commutator surface will help the new brushes to run in and the commutator will acquire more readily the film appropriate to the new brush grade. Operating Conditions Operating environment of lift truck motors varies widely: The following recommen- dations should be applied as actual conditions dictate. Normal Service: Basically an eight- Severe Service: Extended operating hour day of indoor hours, or constantus- material handling. age. Extreme Service: Dusty or Sandy Locations Flour Mills Cement Plants Coal Dust Areas Lumber Mills Stone-Crushing Areas ‘SM-587 16-25 Dec 94GROUP 16 Motors Eee Se General Brush & Commutator Inspection 1, Remove brush cover(s) and remove brushes from brush holders. Clean brushes and hold- ers. 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, 3. Clean commutator surface. Wipe commuta- tor with a dry, lint-free cloth. DO NOT USE LUBRICANT OR SOLVENT ON COMMUTATOR. 4, Check appearance of commutator surface where brushes ride Inspect commutator bars for bumed, damaged orraised areas. The best signs of good commutation area dark brown highly-polished commutator and uniform glossy brush-wearing surfaces. 5. Measure and make a record of brush length at eachinspection. Therecord wil verify amount of brush wear and indicate if there is enough brush length remaining until next scheduled inspection. 6 In general brushes must be replaced when ‘worn to approximately half of original length. IMPORTANT NEWBRUSHES MUST BE OF SAME SIZE AND GRADE (MATERIAL SPECIFICATION) AS REPLACED BRUSHES. AWAYS REPLACE BOTH BRUSHES AND SPRINGS.DO NOT REUSE OLD SPRINGS. Observe how brushes are assembled in brush hold- ers, and position of brush lead (pigtail). New brushes must be installed in same manner. 7. Check brush shunt for good contact with brush holder. Be sure shuntisnot damaged or bumed since this may cause brush spring to cary current and lose tension. 8. Clean and check brush box and.connector screws. Tighten if loose. Be sure brush box shunt connection is tight. 9. If brushes do not need to be replaced, and commutator is in good condition, install brushes and brush springs into brush holders. Be sure brush spring is correctly placed on brush holder and that brush is free to slide in brush box. 10, Install brush cover on motor case. 11, Check and tighten all motor bolts. Check Jower nut on each terminal post. It should be installed finger-tight, then tightened another 1/4.tum with a wrench. ‘Typical ilustaton Dec.94 16-26 ‘SM-587Motors GROUP 16 Brush Inspection Chart BRUSHES WORN REPLACE BRUSH UNEVEN iF oe x<— ee Y CHIPPED y CHECK TENSION cy <4 BROKEN eee OF EACH SPRING 8 Y y IF SPRING TENSION IS NOT THE SAME FOR EACH BRUSH, REPLACE SPRINGS. REPLACE BRUSH IF OIL SOAKED REPLACE BRUSH IF IF BRUSH PIGTAIL PIGTAIL IS LOOSE IS LOOSE AT THE IN THE BRUSH. BRUSH HOLDER — TIGHTEN SCREW. REPLACE BRUSHES WHEN WORN TO |< HERE. <—__________ NEW BRUSHES ‘Typical ttustraton Decs4 1627 ‘SMES?GROUP 16 Motors Typical Inch Pound ; Torque Wrench Seal Pivted Force or Pull Pointer Typkal Foot Pound Pivoted Torque Wrench Scale Handle cet Force or Pull Pointer IMPORTANT Improperly Torqued Fasteners Can Cause Damage. + Use an appropriate torque wrench and tighten all fasteners to the torques specified in the illustation on the following page. Dec 94 16-28 ‘SM-587Motors GROUP 16 Mar Te92 IMPORTANT Torque Cable Guide Nut to 100 Ib.in. (11.3 Nem) Dec 94 16-2-9 ‘M587CLARK tinea" GROUP 16 Section 3 Traction Motors 24 & 36 VOLT Contents ‘Motor Reassembly Specifications . Inspection Charts 24 & 36 Volt Ventilated and Enclosed Motors Note: Open Motor has no band. 2 “Lee uncza tema] Deco4 14 ‘SM587GROUP 16 Motors Pd A EEE & WARNING Wear eye protection and protective clothing when drying with air pressure. Reduce alr pressure to 30 PSI (207 kPa). Debris remoyed with air pressure can cause injury. Remove all-Jewelry before working on truck. Use a Torque Wrench to tighten Terminal Connections. Typical Inch Pound Proved Torque Wrench vot - Sele Handle — Force or Pull Pointer SM-587 16-32 DecoMotors -_ GROUP 16 GENERAL Routine Maintenance Schedule with Recorded Findings the best way toreduce costly shut-downs and repair of equipment during operating hours ‘The goal of any maintenance program, long-life and trouble-free operations, is related to the time spent making inspections and correcting minor problems as they occur. Thekey toplanned maintenance ofthe brush and commutatorisrecognizingundesirablebrush and commutator conditions. If this is done, corrective action can be taken before a major component is damaged beyond serviceability. The brushes and commutator should be inspected for even wear and good commutation. Commutation: A dark uniform coloring pattem at the brush wearing surface. Poor Commutation: The surface of the commutator appearing rough, pitted, scored or signs of buming or heavy arcing between bars. The coloring pattem will be: + Streaky film with commutator wear. + Baredge buming. + Uneven film. + Carbon dust bridging benween bars. Operating Conditions Operating environment of lift truck motors varies widely: The service frequency shall depend upon the severity of operating conditions. Normal Service: Basically an eight- Severe Service: Extended operating hour day of indoor ‘hours, or constant us- material handling. age. Extreme Service: Dusty or Sandy Location Flour Mills Cement Plants Coal Dust Areas Lumber Mills Stone-Crushing Areas Decs4 163-3 ‘SM-587GROUP 16 Motors 22) 2 <<} 3. Remove four screws 1. Remove brushes. == from drive end head. 2. Remove two screws from commutator 2c go end head. 42 82 >>> 4, Remove bearing cap (if so equipped) from com- 5. Remove drive end ‘mutator. ‘=| << head with bearing. >» 223 2 6. Install jaw pullers. as shown,pusharmatureout jf Jew of bearing and commuta; =; SS tor end head ‘Screw Aci ge cal Jaw 22, 2 = pull armature 7. Remove commutator i E si a end head and... => i i outofhousing. >» os c Aemanre al Housing Fistd Cols & Pole Shoes ‘Armature Assembly Dive End Head ‘SM-587 16-34 Decs4