Clark Sm 576 Service Manual

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Main Index

Service
Manual

SM576
OPI 5B

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 Main Index

SERVICE MANUAL INDEX

SPECIFICATIONS
ELECTRICAL
SPEEDS
HYDRAULICS
TIRES AND WHEELS
FLUIDS
SCR TRIMPOTS
TORQUE

PLANNED MAINTENANCE 4

ADJUSTMENTS 6

LOAD WHEEL 9

DRIVE TIRE IO

ELECTRIC MOTOR REPAIR 11

MOTOR SPECIFICATIONS 21

EVl OOLX SCR 22

SCHEMATIC 33
TROUBLESHOOTING 34
HANDSET INTRUCTIONS 41
STATUS CODES 46

HYDRAULIC 73
HYDRAULIC TROUBLESHOOTING 82

MAST 88

JACKING AND HOISTING 102

TRANSMISSION 103

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 Main Index

SPECIFICATIONS

1.0 Electrical, Amp Draws

1.1 Travel, unloaded, 1A speed

Drive motor amps 85 A

1.2 Travel, loaded w/3000 lbs., 1A speed

Drive motor amps 95 A

1.3 Lifting, unloaded, pump motor amps

2 stage mast 3 stage mast

1.3.1 slow speed, freelift __ 150 A

1.3.2 high speed, freelift __ 230 A
1.3.3 slow speed, staging 165 A 190 A
1.3.4 high speed, staging 245 A 295 A

1.4 Lifting, loaded w/3000 lbs., pump motor amps

2 stage mast 3 stage mast

1.4.1 slow speed, freelift __ 26O.A

1.4.2 high speed, freelift __ 430 A
1.4.3 slow speed, staging 280 A 300 A
1.4.4 high speed, staging 465 A 505 A

1.5 Steering, Motor Amps

1.5.7 Parked, not steering 20 A

1.5.2 Steering pump at relief 40 A

2.0 Speeds

2.1 Travel, unloaded, 1A speed 5.1 mph

2.2 Travel, loaded w/3000 lbs., 1A speed 4.6 mph

2.3 Lifting, unloaded

2 stage mast 3 stage mast

2.3.1 slow speed, freelift __ 49 fpm

2.3.2 high speed, freelift __ 68 fpm
2.3.3 slow speed, staging 44 fpm 38 fpm
2.3.4 high speed, staging 67 fpm 59 fpm

2.4 Lifting, loaded w/3000 lbs.

2 stage mast 3 stage mast

2.4.1 slow speed, freelift __ 33 fpm

2.4.2 high speed, freelift _- 46 fpm
2.4.3 slow speed, staging 31 fpm 28 fpm
2.4.4 high speed, staging 41 fpm 36 fpm

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 Main Index

2.7 Lowering, unloaded, overall

2.7.1 slow speed 30 fw

2.7.2 high speed 60 fpm

2.8 Lowering, loaded w/3000 lbs., overall

2.8.1 slow speed 30 fw

2.8.2. high speed 60 fpm

3.0 Hydraulics

3.1 Capacity of hydraulic reservoir 7.0 gal.

3.2 Type of fluid Hydo 32

(Sun Vis 832)

3.3 Lifting relief valve setting 2500 psi

+ 100-O psi

3.4 Steering relief valve setting 850 psi

r_ 5 psi

3.5 Brake relief valve setting 180 psi -.

+5psi

4.0 Tires and Wheels

4.1 Drive tire

size 6ilw x 5” x lot"

4.2 Drive tire compound polyurethane

Shore HAN, 88-92 durometer

4.3 Load wheels

size 4” x 6”

4.4 Load wheel compound polyurethane

Dylon nBrc
Shore "An 83 durometer

5.0 Fluids and Lubricants

5.7 Transmission

5.1.1 Type of lubricant ATF Dexron II

5.1.2 Capacity .8 quart

5.2 Hydraulics

5.2.1 Type of fluid HYDO 32

(SunVis 832)

5.2.2 Capacity 7.c gal.

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 Main Index

6.0 SCR Card Trimpots

6.1 The trimpots on this card cannot be quick turned. They must be
set by using the EV-100 LX Handset. See electrical section 7.4
of this manual.

Speed Limit

SLl 2.5 mph

sL2 1.0 mph
a3 0 mph

7.0 Torque

7.2 Drive wheel lug bolts 125 ft./lbs.

7.3 Drive axle hub nut 250 ft./lbs.
7.5 General

.'7.51 Roller ring bolts 50 ft./lbs.

7.52 Chain anchor jam nuts 200 ft./lbs.
7.53 Hydraulic cylinder rod nut 30 ft./lbs.
7.54 SAE specs

Lrrlr DF Lub.

t/440 8.00 6.25 S-50 4.17

t/ea to.00 7.16 6-33 4.66
S/16-18 17.00 t3*ao 11.00 8.00
9 16-S 19.00 14.00 12.00 9.00
y8-16 30.00 23.00 8.00 tr.00 -
38-24 35.00 5.00 23.00 17.00
7/16-14 fo.00 35.00 32.00 24.00
7/t6-r0 5.00 4G.ao 36.00 2'7.00
l/2-13 15.00 5.00 50.00 3s.00
t/2-20 go.00 65.00 55.00 90.00
98-11 tfo.00 tto.00 100.00' 75.00
5/a-ta 180.00 tja.oo 110.60 85.00 L

l UUply by (0.1383)far metic &io

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1.0 LUBRICATION CHART

Description Work Directions Materials

1 Load Wheel Axle Use Lubi Gun & Adapter for
flush type fittings Tex. Ref. C & C #880
2 Sheave Pin Use Lub. Gun Tex. Ref. C & C #880
3 Battery Roller Bearings
(optional) Remove, Clean and Repack Tex. Ref. C & C #880
4 Lift Chain Check for Rusting, and Clean SAE 40 Motor Oil
5 Hydraulic Oil Filter Change Oil Filter Filter Element
6 Gear Case -
Transmission I
‘Drain, Flush and Refill * I ATF Dexron II

7 Hydraulic Reservoir Drain, Fjush and Refill SAE lo-30W Oil

8 Hydraulic Reservoir
Outlet Screens Clean in solvent Solven’t
9 Side Guide Rollers Use Lub Gun & Adapter for
(optional) flush tyde fittings Tex. Ref. C & C #880
10 Sheave Pin on Free
Lift Cylinder - Three
Stage Mast. Only Use Lub. Gun Tex. Ref. C & C #880

After any major disassembly and/or repair the following lubricant should be performed.
Transmission Pivot Brg. Repack Bearing Tex. Ref. c & C #880
Transmission Roller Brg’s. Repack Bearings Tex. Ref. C & C #880
Steering Wheel Shaft Reoil Light Weight Oil
Steering Chain Clean and Reoil / Heavy Weight Oil
Lift Chain Clean and Reoil SAE 40 grade Motor oil
 DATE

PLANNEDMAINTENANCE
SCilEDiLE

l&w Serial No.

Ja Fe Ma
2.0
I., Cheok machine
24
operation;
Clean with OOUIpre888d air
Cheok level of hydraulio
100 Hour or Monthly

all

oil
funotiona and
PM
safety 8WitOhe8 l-l- I I
;: Servioe all urease fittings, inoluding side auide rollers
Check transmission lubrioant fluid level
i: Inspeot all tires and wheels
76 Clean and lubrioate lift Ohain8 _
84 Cheok lift ohain adjustment
-9, Inepeot and adjust steering oontrol oable
1Ob Cheok brake adjustment and stopping diatanoe
rl. Inapeot fitting8 and valves for leaks
12. Inspeot for loose & missing part8 I I
13. Inspeot wiring
i4, Inapeot oontaotor tips for pitting
15* Lubrioate door hinges

3.0 500 Hour or Semi-Annual PM

.I, Change hydraulio oil filter

21 Clean and lubrioate battery rollers
34 Clean battery and maohine

4.0 1000 Hour or Annual PM

!I Steamolean maohine
24 Drain, flush, and refill gear ease
34 Drain, flush, and refill hydraulio reservoir
ilb Clean hydraulio reservoir outlet so&ens
5* Check hydraulio pressure relief settings
61 lnspeot oondition of lift ohains
7e Inepeot motors; brushes (length) b oommutator
8, Cheek mast and carriage .: lube, adjust, and shim as needed

Lubrioation Speoifioation
Orease, lube points and battery pivot point8 and lift ohaina - Transmission - ATF Dexron II
roller8 i Texas IW. C&C#OS0 heavy weight oil Hydraulio reservoir - SAE 1OW(IS0 32)
 Main Index
Adjustments

1.0 Brake

. The brake release cylinder should have 318" to 112" of travel. The
cylinder travel itself is non-adjustable and the only brake adjust-
ment is the agressiveness adjusting'screwson the side cover of the
transmission case. Three allen head screws at the top of the
transmission side cover adjust braking agressiveness.

Loosen the locknuts and turn all three screws out of the transmission
case until no force is felt pushing against any screw. Turn the screws
back into the transmission case just until spring resistance is felt.
Now turn each screw an additional tw turn and tighten lock nut.

Test braking action.

3.0 Brake Interlock Switch

Make any required brake adjustment prior to this adjustment.

Leave the brake pedal up.

Loosen the switch on the bracket and slide the switch towards
the cam arm until it clicks and then slide approximately l/32"
further.

Tighten the switch.

Test the switch by stepping on the brake pedal. The switch

should activate with approximately l/32" movement of the brake
rod.

5.0 Steering

steering is cable and chain operated and power assisted

through the use of a hydraulic torque generator. Because of the
complexity of the steering linkage, if any adjustments are required,
the entire adjusting procedure must be followed.

5.1 Adjust transmission steering ring guide rollers snug, but not
tight, against the guide ring.

Guide rollers are mounted on eccentric pins. Loosen bolts and

turn cam on eccentric. Be sure to tighten nuts or bolts.

5.2 Adjust steering chain around transmission and bottom sprocket of

torque generator.

Loosen two 3/8" NC bolts that lock chain ends to transmission

case. Turn adjusting turn buckle to tighten chain so that it
has l/8" to l/4" of slack. Tighten locking bolts.

5.3 Adjust upper chain around torque generator and jackshaft.

Jackshaft mounting bracket is on a pivot. Loosen locknuts on

stud and pivot mounting bracket to adjust chain for l/8" to l/4"
of slack. Tighten lock nuts.
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 Main Index

5.4 Adjust steering cable in mast.

Raise carriage so that cable tensioner springs and turn buckles

are visible. Roth turn buckles must be adjusted an equal amount
so that the steering remains centered.

Adjust turn buckles so that tensioner springs are collapsed all

but one full coil.

6.0 Lift Chains

6.1 Three Stage

6.11 Stage cylinder chains

The chains should be adjusted until the tops of the mast
channels are flush within 318”. The chains should be equal
tension.

6.12 Free lift chains.

The chains should be adjusted until the platform is 1"
from the straddle arms.

6.2 Two Stage LFL

The chains should be adjusted until the platfhrm is 1" from the
straddle arms.

6.3 Two Stage FFL

The chains should be adjusted until the platform is 1" from the
straddle arms.

11.0 Speed limiting switch

Loosen switch on the bracket and slide switch toward lug on inner
channel until it clicks, then slide approximately l/32" further.

12.0 SCR Card Trimpots

See Electrical Section 7.4 of this manual. Handset must be used.

18.0 Gate switch

18.1 Remove panel from rear of operator platform.

18.2 Place gate in lower position.

18.3 Loosen switch on the bracket and slide toward the cam until it
clicks, then slide approximately l/32" further.

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Clark Sm 576 Service Manual
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Main Index

5.4 Adjust steering cable in mast.

Raise carriage so that cable tensioner springs and turn buckles

are visible. Roth turn buckles must be adjusted an equal amount
so that the steering remains centered.

Adjust turn buckles so that tensioner springs are collapsed all

but one full coil.

6.0 Lift Chains

6.1 Three Stage

6.11 Stage cylinder chains

The chains should be adjusted until the tops of the mast
channels are flush within 318”. The chains should be equal
tension.

6.12 Free lift chains.

The chains should be adjusted until the platform is 1"
from the straddle arms.

i-.
_
6.2 Two Stage LFL
The chains should be adjusted until the platform is 1" from the
straddle arms.

6.3 Two Stage FFL

The chains should be adjusted until the platform is 1" from the
straddle arms.

11.0 Speed limiting switch

Loosen switch on the bracket and slide switch toward lug on inner
channel until it clicks, then slide approximately l/32" further.

12.0 SCR Card Trimpots

See Electrical Section 7.4 of this manual. Handset must be used.

18.0 Gate switch

18.1 Remove panel from rear of operator platform.

18.2 Place gate in lower position.

18.3 Loosen switch on the bracket and slide toward the cam until it
clicks, then slide approximately l/32" further.

19.0 Potentiometer

19.1 Connect VOM to wire #29 and wire P13 of the potentiometer.

19.2 Loosen mounting screws rotation to the highest reading on the

VOM.

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