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SM-560
WP-40
SERV+W&NUAL
WP40
CONTENTS
GROUP PAGE
FOREWORD ii
HOWTO USETHIS MANUAL iii
SAFETYSIGNSAND MESSAGES iV
USERSAFE MAINTENANCEPRACTICES V
GROUP PAGE
Planned MaintenanceProgram PM-1
Battery Removal,Cleaningand Charging 12-01
Direction/ AcceleratorControl 13-01
ElectricMotor Maintenance 16-01
PumpMotor 16-03
DriveMotor 16-04
Contactor Panel 19-01
DriveUnit 20-01
WheelsandTires 22-01
Brakes 23-01
Lift Mechanism 34-01
MachineJacking& Blocking 38-02
Truck Data,Specifications 40-01
Index- Provideshelpfor locatinginformationaboutvarioustopics.
SM560FWD i
FOREWORD
Clark EquipmentCompanywelcomesyou to the growinggroupof professional
peoplewho own,operateand maintainChtk lifttrucks. This manualwillfamiliarizeyou
with servicemaintenanceand overhaulinformationaboutyour newtruck. It has been
especiallypreparedto helpyou maintain your Clarklifttruck in an efficientand safe
operating condition.
Regular,correct maintenanceandcare of your lifttruckis not only importantfor full
and efficienttruck life;it is essentialfor your safety. A faulty lifttruck is a potential
source of dangerto the operator,and to other personnelworking near it. The
importanceof maintainingyour lifttruck in a safe operatingconditionby servicingit
regularlyand, when necessary,repairingit promptlycannot be emphasizedtoo
strongly.
To assistyou in keepingyour lifttruck in good operatingcondition,this manual
includes an outline of planned maintenance(PM)proceduresthat are considered
essentialto the life and safe performanceof your truck. Briefproceduresfor
inspections,operationalchecks, cleaning, lubrfcation,and adjustmentsare included
for your reference.
Clark recommendsthat a plannedmaintenanceand safetyInspectionprogram(PM)
be performedby a trainedand authorizedmechanicon a regularbasis. The PM
programprovidesthe opportunityto makethorough inspectionsand checks on the
safe condition of your truck. Necessaryadjustmentsand repairscan be done during
the PM,which will increasethe life of componentsand reduceunscheduled
downtime.The needfor majoradjustments,repairs,or replacementsis found and
correctionsmadeas required;not afterfailure has occurred.
SM56OPWDii
HOW TO USE THIS MANUAL
This manualis intendedto be used by personswho aretrained and authorizedto do
lifttruck maintenance. The recommendedproceduresfor routine servicingand
adjustmentsas well as for removalandoverhaulof majorcomponentsof the truck are
outlined. It is writtento show anddescribethe adjustment,removal,disassembly,
inspection,repair,and assemblystepsthat are normallyrequiredto servicethese
components.
The detailed proceduresare arrangedin sequenceby numberedGROUPand
Section. The GROUPnumbersare the sameas the componentgroup in the Master
PartsBook. EachGROUPhas its ownTableof Contents,so that you can find the
varioustopicswithin moreeasily. lf you cannotfind a topic in the Table of Contents,
check the Indexat the backof the manual.
Componentspecifications,informationnotes and safety messagesare included at
the proper step of each procedure. To be better preparedto do the necessary
servicework, pleasetake time to readthe entire procedure,includingany special
instructions, beforedoing any work.
Specificationsof selectedtruck componentsare included at the back of the manual
for easy reference.
Also referto the Operator’sManual,locatedon the truck, for additionalinformation
and instructionson the operationand maintenanceof your truck.
If you haveneedfor moreinformationon the care and repairof your truck, please
contact your authorizedClarkdealer.
NOTICE - The descriflions and specifications included in this manual were in effect at the time ofprinting. Clark
Equipment Company r8serves the rfght to make improvements and changes in specifications or de&n* without notice
and without incumhg ob&atEon.
or revisions.
Please check with your authorired CLARK d8af8r for information on possible updates
0 Clark EquipmentCompany 1989
SM58OPWDiii
SAFETY SIGNS AND SAFETY MESSAGES
improperor carelesstechniquescause accidents. Don’ttake chanceswith incorrector
damaged equipment. READ and UNDERSTAND the procedures for safe operation
and maintenanceoutlined in this manual.
STAY ALERT! Follow safety rules, regulationsand procedures. Accidents can be
avoided by recognizingdangerous proceduresor situations before they occur.
DRIVE AND WORK SAFELY and follow the safety signs and their messages
displayedon the truck and in this manual.
SAFETY SIGNS and MESSAGES are placed in this manual and also on the lift truck
to provideinstructionsand to identifyspecificareaswherepotentialhazardsexist and
special precautionsshould be taken. Be sure you know and understandthe meaning
of these instructions,signsand messages. Damageto the truck or death or serious
injury to you or other personsmay resultif these messagesare notfollowed.
NOTICE
This messageis usedwhen specialinformationis required to clarifyproceduresor
identify components pertainingto the truck.
IMPORTANT
This messageis used when additionalattentionis requiredfor properoperationor
maintenanceof the truck.
This messageis used as a reminderof safetypracticeswhichcan resultin personal
injury if properprecautionsare not taken.
(AWARNING: ]
This messageis usedwhen a hazardexistswhichcan resultin injuryor death, if proper
precautionsare not taken.
This messageis usedwhen an extremehazardexistswhichwill resultin deathor
serious injury if properprecautionsare not taken.
SM560 MID iv
The following instructions have been prepared
from current industry and governmentsafety
standardsapplicableto industrialtruck operations
and maintenance. These recommended
procedures specify conditions, methods, and
acceptedpracticesthat aid in the safe mainte-
nanceof industrtaltrucks. They are listedherefor
the referenceand safety of all workersduring
maintenanceoperations. Carefullyread and
understand these instructions and the specific
maintenance procedures before attemptingto do
any repairwork. Whenin doubtof any mainte-
nance procedure,please contact your local
CLARK dealer.
1. Poweredindustrial trucks can become
hazardousif maintenanceis neglected.
Therefore, suitable maintenancefacilities,trained
personnel, and procedures must be provided.
2. Maintenanceand inspectionof all powered
industrialtrucks shall be done In conformancewith
the manufacturer’srecommendations.
3. A scheduled planned maintenance,lubrication,
and inspectionprogramshall be followed.
4. Only trained and authorizedpersonnelshall be
permittedto maintain,repair,adjust,andinspect
industrialtrucks, and In accordancewiththe
manufacturer’sspecifications.
5. Properlyventilatework area, vent exhaust
fumes, and keep shop clean and floor dry.
6. Avoidfire hazards and havefire protection
equipmentpresent in the work area. Do not use
an openflameto check for level,or leakageof fuel,
electrolyte,or coolant. Do not use open pans of
fuel or flammablecleaningfluidsfor cleaningparts.
7. BeforeStartingWork On Truck:
a) Raisedrivewheelsoff of flooror disconnect
power source and use blocksor other positive
truck-positioning devices.
b) Put blocksunder the bad engagingmeans,
innermast( or chassisbeforeworking on them.
c) Disconnectbattery beforeworkingon the
electricalsystem.
8. Operationof the truckto check performance
must be conducted in an authorized,safe,clear
area.
USER SAFE MAINTENANCE PRACTICES
9. BeforeStartingTo DriveTruck:
a) Be in operatingposition.
b) Disengageclutch on manualtransmissions,or
applybrakeon truckswith powershifttransmission
and electrictrucks.
c) Putdirectionalcontrol in neutral.
d) Start engineor turn on power.
e) Checkfunctioningof lift and tilt systems,
directionaland speed controls, steering, brakes,
warningdevices,and any bad handling
attachments.
10. Before Leaving The Truck:
a) Stoptruck.
b) Put directionalcontrol in neutral.
c) Applythe parkingbrake.
d) Stopthe engineor turn off power.
e) Turn off the controlor ignitioncircuit.
9 Putblocksat the wheels,if truck is on an
incline.
11. Brakes, steering mechanisms,control
mechanisms,warningdevices,lights, guardsand
safety devices,andframe membersmustbe
carefullyand regularlyInspectedand maintainedin
a safeoperatingcondition.
12. Specialtrucks or devices designed and
approvedfor hazardousarea operationmust
receivespecialattentionto ensurethat main-
tenance preservesthe original, approvedsafe
operating features.
13. The truck manufacturer’scapacity, operation
and maintenanceinstructionplates,tags, or decals
must be maintainedin legiblecondition.
14. Batteries,motors, controllers, limit switches,
protectivedevices, electrical conductors and
connections must be inspected and maintained in
conformancewith good practice. Special attention
mustbe paid to the condition of electrical
insulation.
15. To avoid injury to personnelor damageto the
equipment,consult the manufacturer’s
proceduresin replacingcontacts on any battery
connection.
SM546 MD-v
USER SAFE MAINTENANCE PRACTICES
16. Industrialtrucks mustbe kept in a clean
conditionto minfmizefire hazardsand helpin the
detection of loose or defective parts.
17. Modificationsand additionsthat affect
capacityand safe truck operationmust not be
done without the manufacturer’spriorwritten
approval. Capacity,operation and maintenance
instructionplates,tags or decals mustbe changed
accordingly.
18. Care mustbe taken to assurethat all
replacementparts, includingtires, are
interchangeablewiththe originalparts and of a
qualityat least equalto that providedin the original
equipment. Parts, includingtires, are to be
installed per the manufacturer’sprocedures.
Alwaysuse genuine CLARKor CLARK-approved
parts.
19. When removingtires, follow industry safety
practices.
20. Use specialcare when removingheavy
componentsfrom the truck. Be sure that lifting
and handlingequipmentis of the correct capacity
and in good condition.
NOTICE-- You shouldalsobefamiliarwith
additionaloperatingand maintenancesafety
instructionscontained in the following
publications:
ANSWASME858.1 - 1983: Safety Standardfor
LowLiftand High LfftTrucks (SafetyCode For
PoweredIndustrialTrucks). Publishedby: Society
of Mechanical Engineers, United Engineering
Center,345 E. 47th Street, NewYork, N.Y.
10017.
NFPA505-1982: Fire Safety Standardfor
PoweredIndustrialTrucks: Type Designations,
Areas of Use, Maintenanceand Operation.
Availablefrom: NationalFire ProtectionAssoc.,
Inc.,BatterymarchPark,Quincy, MA 02269.
General IndustryStandards,OSHA 2206: OSHA
Safetyand HealthStandards(29 CFR 1910),
SubpartN-MaterialsHandlingand Storage,
Section 1910.178 PoweredIndustrialTrucks. For
sale by: Superintendentof Documents,U.S.
GovernmentPrintingCffice, Washington,DC
20402.
SM546FWD-vl
PM - PLANNED MAINTENANCE PROGRAM
A planned maintenance program of regular,
routine inspections and lubrication is
important for long life and trouble-free
operation of your lift truck. Make and keep
records of your inspections. Use these
records to help establish the correct PM
intervals for your application and to indicate
maintenance required to prevent major
problemsfrom occurringduring operation.
The periodic maintenance procedures
outlined in this manual are intended to be
used with the PM report form. They are
arranged in groupings of maintenance work
that are done in a logical and efficient
sequence.
A check mark or entry is made on the PM
Report Form when the PM is performed.
Please note the special coding system for
indicating the Importance of needed repairs
and/or adjustments.
When you have finished the PM inspections,
be sure to give a copy of the report to the
designated authority or the person
responsiblefor lifttruck maintenance.
Do not make repalrs or adjustments
unless authorized to do so.
For safety, It is good practice to:
Remove all jewelry (watch, rings, bracelets,
etc.) before workingon the truck.
Alwayswear safetyglasseswhen making
repairs.
Be sure to:
Makea recordof all maintenanceand
operating problemsyou find.
Writethe hour meter readingon the PM
reportform.
HOW TO PERFORM THE PM
PERIODIC INSPECTIONS AND
MAINTENANCE
Visual InspectIon
First, perform a visual inspection of the lift
truck and Its components. Walk around the
truck and take note of any obvious damage
and maintenanceproblems. Check for loose
fasteners and fittings.
NAMEPLATES AND DECALS
Check to be sure all capacity, safety, and
warning plates or decals are attached and
legible.
Do notoperateor albw a lifttnrdt with
damagedor missingdecals and nameplates
to be operated. They contain important
information. Replacethem immediately.
Be surethat safetydevicesare in place,
undamaged,and attached securely.
Wheels and Tires
Checkthe condition of the drive wheel and
tire andthe bad wheels. Removeobjectsthat
are embeddedin the tread. Inspectthe tires
for excessivewear and breaksor “chunking
out”, and bond failure betweenthe tire and
rim.
Check all wheelsfor propertightness. Adjust
if necessary.
SM560 PM- 1
PM - PLANNED MAINTENANCE PROGRAM
Functional Tests
Be sure that all controls and systems
are functioning correctly.
Test horn and all other safety equipmentand
accessories. Be sure they are properly
mounted and working correctly.
Press the horn button to check horn
function. If the horn or any other part does
not operate, report the failure and have it
repaired before the truck is put back into
operation.
Operatethe brakes,directionalcontrols, and
steeringsystem. Be sure all controlsoperate
freely and returnto neutral properly.
Test Drive The Truck
Check all around to be sure that your
intended path of travel is clear of obstructions
and pedestrians.
Test the tnrck for:
Generalcorrect operation
Drivetrain function
Steering performance
Brake performance
By driving the truck in both the foward and
reverse directions first in a straight line and
then, slowly, through a series of full right and
left turns.
Listen for any unusual drive train or other
running noises, such as wheel bearing noise,
vibration, etc. Note any lack of smoothness
in steering.
When you have completed the
operatlonal tests, park and leave
truck according to standard
shutdown procedures
Brakes
Checkthe brake system. The brakeshould
be appliedwhen the control handle is in the
fully raised positionor the fully lowered
position.
To check brake holdingcapabilityand
adjustment,drivethe truck on to a grade and
releasethe handle. The brake should hold
the truck on the gradethat the truck can climb
witha capacitybad or a 10% gradewhich
everis less.
, _ 4
vv CAUTION: 1 Do not oDerate a
truck If the brakes are not op’eratlng
properly.
Steerlng system
Checkthe steeringsystemfor abnormal
loosenessanddamage. Checkfor any
changesin steeringaction. Hard steeringor
looseness,unusual sounds when turning or
maneuveringindicates a need for inspection
and setvicing.
Never operate a truck which has a
steerlng system fault.
BATTERY
Inspectthe battery retainment.Replaceany
damagedor missingparts.
Inspectthe batteriesfor any damage,cracks
or leakingcondition. If your batterieshave
removablevent caps, check to be sure the
cellsare allfilled. Ifpossible,refillwith distilled
water to bottomof vent cap opening.
MECHANISMS
Finally,inspectall controls,handle, levers,
and linkagesfor wear and smoothness of
operation.
Air Cleaning
Always maintain a lift truck in a clean
condition. Do not allowdirt, dust, lint, or other
contaminants to accumulate on the truck.
Keep the truck free from leaking oil and
grease. Wipe up all oil spills. Keep the
handle and controls clean, dry, and safe. A
clean truck makes it easier to see leakage,
loose,missingor damagedparts, andwill help
preventfires. A clean truck will run cooler.
SM560 PM- 2
PM - PLANNED MAINTENANCE PROGRAM
The environmentin which a lift truck operates
will determine how often and to what extent
cleaning is necessary. For example, trucks
operating in manufacturingplantswhich have
a high level of dirt or lint (e.g., cotton fibers,
paper dust, etc.) in the air or on the floor, will
require more frequent cleaning.
LIFT TRUCKS SHOULD BE AIR CLEANED
AT EVERY PM INTERVAL, AND
OTHERWISE AS OFTEN AS REQUIRED.
Air cleaning should be done using an air hose
with special adapter or extension having a
control valve and nozzle to direct the air
properly. Use clean, dry, low-pressure
compressed air; restrict air pressure to (207
kPa]30 psi, maximum.
CAUTION- Wear suitable eye protection and
protective clothing.
Critical Fastener Torque
Checks
Checktorque of criticalitems, including:
Driveuti mounting
Drivewheelmounting
Components.
Replacemissingbolts and tightened loose
bolts to the correct torque before operating
the truck.
Fasteners in highly loaded (critical)
components can quickly fail if they become
loosened; also, loose fasteners can cause
damage or failure of the component. For
safety, it is important that the correct torque
be maintained on all critical fasteners of
components which directly support, handle
or control the load, and protect the operator.
SM560 PM- 3
PLANNED MAINTENANCE PROGRAM
SAFETY AND OPERATIONAL CHECKS
Notes:
*Replace As Required
PM Interval:
A = 8 - 10 hours, or daily
B = 50 - 250 hours, or every month
C = 450 - 500 hours, or every 3 months
D = 900 - 1000 hours, or every 6 months
E = 2000 hours, or every year
Nominal
Maintenance Interval
DAILY MAINTENANCE CHECKS
Check warning lights and hour meter.
Check horn operation and other warning devices.
Check steering operation.
Check brake operation.
Check directional and soeed controls ooeration.
SM 560 PM-4
PLANNED MAINTENANCE PROGRAM
RECCOMMENDED MAINTENANCE
AND LUBRICATION SCHEDULE
Notes:
PM Interval:
A=& 10 hours, ordaily
B = 50 - 250 hours, or every month
C = 450 - 500 hours, or every 3 months
*Replace As Required
#First PM only
D = 900 - 1000 hours, or every 6 months
E = 2000 hours, or every year
Nominal
Maintenance Interval
MAINTENANCE AND LUBRICATION A B C D E
. .
Check truck vlsumd msoect comDonents
Test drive truck -- Check functional Derformance
Air clean truck
SM 560 PM-5
PLANNED MAINTENANCE PROGRAM
WP40
LUBRICATION CHART
GREASE POINTS
1.
2.
3.
4.
5.
6.
LOAD WHEEL AXLE ( USE LUB GUN AND ADAPTOR FOR FLUSH TYPE FITTINGS )
PULL ROD - LOAD WHEEL END
LIFT CYLINDER MOUNTING PIN ( COLD STORAGE TRUCKS ONLY )
PULL ROD - LIFT LINK END
LIFT LINK ( COLD STORAGE TRUCKS ONLY )
DRIVE UNIT PIVOT BEARINGS ( COLD STORAGE TRUCKS ONLY )
SM 560 PM-6
01
PLANNED MAINTENANCE PROGRAM
WP40
LUBRICATION CHART
FILL POINTS
1. HYDRAULIC SYSTEM RESERVOIR
OIL CAPACITYIN RESERVOIR
FLUID TYPE
FLUID TYPE FOR COLD STORAGE
1 QUART
low-40 MOTOR OIL
DEXTRON II ATF
2. DRIVE UNIT FLUID
FLUID CAPACITY
FLUID TYPE
FLUID TYPE FOR COLD STORAGE
.85 QUARTS
80-9OW
DEXTRON II ATF
SM 560 PM-7
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your reading. Please Click
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GROUP G&EH&ION 01
CONTENT NO.
HANDLINGBATTERIES 12-01-01
BATTERY REMOVAL 12-01-02
CLEANINGPROCEDURES 12-01-03
CHARGINGPROCEDURE 12-01-04
l/p WARNING: 1
Battery Maintenance
BATTERY ACID; FUMESAND ELECTRICAL
POTENTIALCANCAUSEiNJURYOR DEATH.
READAND UNDERSTANDTHESE
PROCEDURESBEFOREWORKINGON
BATTERIES.
1. DO NOT SMOKEOR ALLOWOPEN
FLAMESOR SPARKSNEAR BATTERY
CHARGINGAREAS.
2. WEARPROTECTIVECLOTHING,GLOVES
ANDA FACESHIELDWHENWORKINGON
BATTERIES.
3. KEEP ALL METAL OBJECTSAWAY FROM
BATTERIES.
4. BATTERIESARE VERY HEAVY.HANDLE
THEMWlTHTHE CORRECTLlFTlNGDEVICES.
5. BATTERYCHARGINGAREASMUST
CONFORMTO FEDERALREGULATIONS.
6. DONOT PERFORM BATTERY SERVICE
UNLESS YOU ARE TRAINED AND QUALIFIED.
12*01-01 HANDLING BATTERIES
1. Changeor servicestoragebatteriesonly in a
batterysetice area.
2. Make surethis area hasthe equipment:
-to flushandneutralizeanyadd that may
spill.
- forventilationof fumes from batteries.
- for fire protection.
Before trying to remove, install, or charge a
storage battery, the truck must be in a battery
service area with the brake applied so that the
truck cannot move.
3. Make sure the area has material handling
equipment made for the purpose of removing
and installing batteries, such as an overhead
hoist. Make sure the overhead hoist has safety
hooks.
4. When a battery is to be removed, make sure
that the battery removalhook, Clark part number
1622063, is used.
5. Whena powerchain hoist is used, makesure
the hoist has a chain container to hold the
amountof chain used.
6. Whena hand hoist is used, a batterywithout a
cover must have a nonconductive material put
over it to preventthe chain from makingcontact
on the cell connectionsor terminals.
7. Keepall tools and other objects madeof metal
awayfromthe terminals.
8. Because of hydrogen gas from batteries that
are being charged, no smokingwill be permitted
in the battery area. Do not check electrolytelevel
with an open flame. No open flames, sparks, or
electric arcs will be permitted in the battery
chargingarea.
,9. When batteries are being charged, the vent
caps must be kept in position to prevent
electrolyte spray. The vent holes in the caps
must be open.
10. Electrical installations must follow the
National Electrical Code ( ANSI 856.2, 1974 ),
NFPA 50578, Part “C” and any local
ordinances.
SM 560 12-01-l
12-01-02 BATTERY REMOVAL
1A WARNING: 1
BEFORE YOU DO SERVICE WORK OR
REMOVEOR INSTALLA TRUCKBATTERYOR
BATTERY PAC, READ THE FOLLOWING
INSTRUCTIONS CAREFULLY. FAILURE TO
FOLLOW THESE INSTRUCTIONS CAN
RESULTINSERIOUSPERSONALINJURY.
1. Check the service and charging area for
proper fire protection. Make sure there are no
flames or heat in the area. Do not smoke. Make
sure all necessary equipment is in the area, in
good repair,and operatingcorrectly. If serviceis
to be done on the batteries, make sure there is
equipmentto flush and neutralize any acid that
may spill, ventilation to carry fumes from the
batteries, and equipmentto handle electrolyte.
2. Put the truck in the battery area, turn the key
switch to the “off” position, and disconnect the
battery receptacle.
3. Attach the battery pack removal hook, Clark
art number 1822063,to the battery pack.
4. Removethe battery pack fromthe truck.
12-01-03 BATTERY CLEANING
1. Cleanthe batteriesonly when they are
removedfrom the truck.
2. The vent caps must be in positiondurfng
cleaning.
3. Washthe batterieswith iowpressurecold
water.
The batteriescan also be washedwith a solution
of sodiumbicarbonate(put a box of sodium
bicarbonateIn a pailof coldwater and mix).Rinse
with cleancoldwater.
12-01-04 BATTERY CHARGING
PROCEDURE
b WARNING: 1
BATTERY CHARGING
TO AVOID PERSONALINJURYBATTERIES
MUSTBECHARGEDINAN APPROVED
CHARGINGAREAANDCHARGED
ACCORDINGTO APPROVEDPROCEDURES.
IMPORTANT
DONOTOPERATETHE CHARGERUNLESSIT
IS FIRSTCONNECTEDTOTHE BATTERIES.
1. Replaceany missingvent caps and tighten.
Check vent caps for proper operation ( the vent
hole is clean and open).
2. Open the battery charger cover. Disconnect
the battery pack from the truck receptacle and
turn the chargertimer to the “off position.
3. Connect the A.C. cord to a 115V. A.C. outlet
( or a 220V A.C. outlet, according to the type of
charger).
4. Connect the Battery receptacle to the
charger.
5. Turn the timer to the “on” position. The pilot
light and the ammeter show the charger is “on”
and charging.Whenthe charger is turned to the
“on” position, the charger will run for up to 12
hours maximum, or as set. See page 4 for
chargerates.
IMPORTANT- WEEKLY CHECK
AFTER CHARGING,CHECK THE HEIGHT OF
ELECTROLYTE IN EACH CELL. ADD
DISTILLED WATER IF NECESSARY. THEN,
AFTER BATTERIES HAVE BEEN CHARGED,
CONNECT THE BATTERIES TO THE
CHARGERAND SET THE TIMER TO 4 ON THE
DIAL. THIS ADDED CHARGING WILL
EQUALIZETHE CELLS AND HELP KEEP THE
BATTERIES IN GOOD CONDITION.WEEKLY
CHECKS ARE TO BE MADE ONLY BY
TRAINED AND AUTHORIZED BATTERY
MAINTENANCEPERSONNEL.
SM 560 12-01-2

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Clark wp 40 service repair manual

  • 2. SERV+W&NUAL WP40 CONTENTS GROUP PAGE FOREWORD ii HOWTO USETHIS MANUAL iii SAFETYSIGNSAND MESSAGES iV USERSAFE MAINTENANCEPRACTICES V GROUP PAGE Planned MaintenanceProgram PM-1 Battery Removal,Cleaningand Charging 12-01 Direction/ AcceleratorControl 13-01 ElectricMotor Maintenance 16-01 PumpMotor 16-03 DriveMotor 16-04 Contactor Panel 19-01 DriveUnit 20-01 WheelsandTires 22-01 Brakes 23-01 Lift Mechanism 34-01 MachineJacking& Blocking 38-02 Truck Data,Specifications 40-01 Index- Provideshelpfor locatinginformationaboutvarioustopics. SM560FWD i
  • 3. FOREWORD Clark EquipmentCompanywelcomesyou to the growinggroupof professional peoplewho own,operateand maintainChtk lifttrucks. This manualwillfamiliarizeyou with servicemaintenanceand overhaulinformationaboutyour newtruck. It has been especiallypreparedto helpyou maintain your Clarklifttruck in an efficientand safe operating condition. Regular,correct maintenanceandcare of your lifttruckis not only importantfor full and efficienttruck life;it is essentialfor your safety. A faulty lifttruck is a potential source of dangerto the operator,and to other personnelworking near it. The importanceof maintainingyour lifttruck in a safe operatingconditionby servicingit regularlyand, when necessary,repairingit promptlycannot be emphasizedtoo strongly. To assistyou in keepingyour lifttruck in good operatingcondition,this manual includes an outline of planned maintenance(PM)proceduresthat are considered essentialto the life and safe performanceof your truck. Briefproceduresfor inspections,operationalchecks, cleaning, lubrfcation,and adjustmentsare included for your reference. Clark recommendsthat a plannedmaintenanceand safetyInspectionprogram(PM) be performedby a trainedand authorizedmechanicon a regularbasis. The PM programprovidesthe opportunityto makethorough inspectionsand checks on the safe condition of your truck. Necessaryadjustmentsand repairscan be done during the PM,which will increasethe life of componentsand reduceunscheduled downtime.The needfor majoradjustments,repairs,or replacementsis found and correctionsmadeas required;not afterfailure has occurred. SM56OPWDii
  • 4. HOW TO USE THIS MANUAL This manualis intendedto be used by personswho aretrained and authorizedto do lifttruck maintenance. The recommendedproceduresfor routine servicingand adjustmentsas well as for removalandoverhaulof majorcomponentsof the truck are outlined. It is writtento show anddescribethe adjustment,removal,disassembly, inspection,repair,and assemblystepsthat are normallyrequiredto servicethese components. The detailed proceduresare arrangedin sequenceby numberedGROUPand Section. The GROUPnumbersare the sameas the componentgroup in the Master PartsBook. EachGROUPhas its ownTableof Contents,so that you can find the varioustopicswithin moreeasily. lf you cannotfind a topic in the Table of Contents, check the Indexat the backof the manual. Componentspecifications,informationnotes and safety messagesare included at the proper step of each procedure. To be better preparedto do the necessary servicework, pleasetake time to readthe entire procedure,includingany special instructions, beforedoing any work. Specificationsof selectedtruck componentsare included at the back of the manual for easy reference. Also referto the Operator’sManual,locatedon the truck, for additionalinformation and instructionson the operationand maintenanceof your truck. If you haveneedfor moreinformationon the care and repairof your truck, please contact your authorizedClarkdealer. NOTICE - The descriflions and specifications included in this manual were in effect at the time ofprinting. Clark Equipment Company r8serves the rfght to make improvements and changes in specifications or de&n* without notice and without incumhg ob&atEon. or revisions. Please check with your authorired CLARK d8af8r for information on possible updates 0 Clark EquipmentCompany 1989 SM58OPWDiii
  • 5. SAFETY SIGNS AND SAFETY MESSAGES improperor carelesstechniquescause accidents. Don’ttake chanceswith incorrector damaged equipment. READ and UNDERSTAND the procedures for safe operation and maintenanceoutlined in this manual. STAY ALERT! Follow safety rules, regulationsand procedures. Accidents can be avoided by recognizingdangerous proceduresor situations before they occur. DRIVE AND WORK SAFELY and follow the safety signs and their messages displayedon the truck and in this manual. SAFETY SIGNS and MESSAGES are placed in this manual and also on the lift truck to provideinstructionsand to identifyspecificareaswherepotentialhazardsexist and special precautionsshould be taken. Be sure you know and understandthe meaning of these instructions,signsand messages. Damageto the truck or death or serious injury to you or other personsmay resultif these messagesare notfollowed. NOTICE This messageis usedwhen specialinformationis required to clarifyproceduresor identify components pertainingto the truck. IMPORTANT This messageis used when additionalattentionis requiredfor properoperationor maintenanceof the truck. This messageis used as a reminderof safetypracticeswhichcan resultin personal injury if properprecautionsare not taken. (AWARNING: ] This messageis usedwhen a hazardexistswhichcan resultin injuryor death, if proper precautionsare not taken. This messageis usedwhen an extremehazardexistswhichwill resultin deathor serious injury if properprecautionsare not taken. SM560 MID iv
  • 6. The following instructions have been prepared from current industry and governmentsafety standardsapplicableto industrialtruck operations and maintenance. These recommended procedures specify conditions, methods, and acceptedpracticesthat aid in the safe mainte- nanceof industrtaltrucks. They are listedherefor the referenceand safety of all workersduring maintenanceoperations. Carefullyread and understand these instructions and the specific maintenance procedures before attemptingto do any repairwork. Whenin doubtof any mainte- nance procedure,please contact your local CLARK dealer. 1. Poweredindustrial trucks can become hazardousif maintenanceis neglected. Therefore, suitable maintenancefacilities,trained personnel, and procedures must be provided. 2. Maintenanceand inspectionof all powered industrialtrucks shall be done In conformancewith the manufacturer’srecommendations. 3. A scheduled planned maintenance,lubrication, and inspectionprogramshall be followed. 4. Only trained and authorizedpersonnelshall be permittedto maintain,repair,adjust,andinspect industrialtrucks, and In accordancewiththe manufacturer’sspecifications. 5. Properlyventilatework area, vent exhaust fumes, and keep shop clean and floor dry. 6. Avoidfire hazards and havefire protection equipmentpresent in the work area. Do not use an openflameto check for level,or leakageof fuel, electrolyte,or coolant. Do not use open pans of fuel or flammablecleaningfluidsfor cleaningparts. 7. BeforeStartingWork On Truck: a) Raisedrivewheelsoff of flooror disconnect power source and use blocksor other positive truck-positioning devices. b) Put blocksunder the bad engagingmeans, innermast( or chassisbeforeworking on them. c) Disconnectbattery beforeworkingon the electricalsystem. 8. Operationof the truckto check performance must be conducted in an authorized,safe,clear area. USER SAFE MAINTENANCE PRACTICES 9. BeforeStartingTo DriveTruck: a) Be in operatingposition. b) Disengageclutch on manualtransmissions,or applybrakeon truckswith powershifttransmission and electrictrucks. c) Putdirectionalcontrol in neutral. d) Start engineor turn on power. e) Checkfunctioningof lift and tilt systems, directionaland speed controls, steering, brakes, warningdevices,and any bad handling attachments. 10. Before Leaving The Truck: a) Stoptruck. b) Put directionalcontrol in neutral. c) Applythe parkingbrake. d) Stopthe engineor turn off power. e) Turn off the controlor ignitioncircuit. 9 Putblocksat the wheels,if truck is on an incline. 11. Brakes, steering mechanisms,control mechanisms,warningdevices,lights, guardsand safety devices,andframe membersmustbe carefullyand regularlyInspectedand maintainedin a safeoperatingcondition. 12. Specialtrucks or devices designed and approvedfor hazardousarea operationmust receivespecialattentionto ensurethat main- tenance preservesthe original, approvedsafe operating features. 13. The truck manufacturer’scapacity, operation and maintenanceinstructionplates,tags, or decals must be maintainedin legiblecondition. 14. Batteries,motors, controllers, limit switches, protectivedevices, electrical conductors and connections must be inspected and maintained in conformancewith good practice. Special attention mustbe paid to the condition of electrical insulation. 15. To avoid injury to personnelor damageto the equipment,consult the manufacturer’s proceduresin replacingcontacts on any battery connection. SM546 MD-v
  • 7. USER SAFE MAINTENANCE PRACTICES 16. Industrialtrucks mustbe kept in a clean conditionto minfmizefire hazardsand helpin the detection of loose or defective parts. 17. Modificationsand additionsthat affect capacityand safe truck operationmust not be done without the manufacturer’spriorwritten approval. Capacity,operation and maintenance instructionplates,tags or decals mustbe changed accordingly. 18. Care mustbe taken to assurethat all replacementparts, includingtires, are interchangeablewiththe originalparts and of a qualityat least equalto that providedin the original equipment. Parts, includingtires, are to be installed per the manufacturer’sprocedures. Alwaysuse genuine CLARKor CLARK-approved parts. 19. When removingtires, follow industry safety practices. 20. Use specialcare when removingheavy componentsfrom the truck. Be sure that lifting and handlingequipmentis of the correct capacity and in good condition. NOTICE-- You shouldalsobefamiliarwith additionaloperatingand maintenancesafety instructionscontained in the following publications: ANSWASME858.1 - 1983: Safety Standardfor LowLiftand High LfftTrucks (SafetyCode For PoweredIndustrialTrucks). Publishedby: Society of Mechanical Engineers, United Engineering Center,345 E. 47th Street, NewYork, N.Y. 10017. NFPA505-1982: Fire Safety Standardfor PoweredIndustrialTrucks: Type Designations, Areas of Use, Maintenanceand Operation. Availablefrom: NationalFire ProtectionAssoc., Inc.,BatterymarchPark,Quincy, MA 02269. General IndustryStandards,OSHA 2206: OSHA Safetyand HealthStandards(29 CFR 1910), SubpartN-MaterialsHandlingand Storage, Section 1910.178 PoweredIndustrialTrucks. For sale by: Superintendentof Documents,U.S. GovernmentPrintingCffice, Washington,DC 20402. SM546FWD-vl
  • 8. PM - PLANNED MAINTENANCE PROGRAM A planned maintenance program of regular, routine inspections and lubrication is important for long life and trouble-free operation of your lift truck. Make and keep records of your inspections. Use these records to help establish the correct PM intervals for your application and to indicate maintenance required to prevent major problemsfrom occurringduring operation. The periodic maintenance procedures outlined in this manual are intended to be used with the PM report form. They are arranged in groupings of maintenance work that are done in a logical and efficient sequence. A check mark or entry is made on the PM Report Form when the PM is performed. Please note the special coding system for indicating the Importance of needed repairs and/or adjustments. When you have finished the PM inspections, be sure to give a copy of the report to the designated authority or the person responsiblefor lifttruck maintenance. Do not make repalrs or adjustments unless authorized to do so. For safety, It is good practice to: Remove all jewelry (watch, rings, bracelets, etc.) before workingon the truck. Alwayswear safetyglasseswhen making repairs. Be sure to: Makea recordof all maintenanceand operating problemsyou find. Writethe hour meter readingon the PM reportform. HOW TO PERFORM THE PM PERIODIC INSPECTIONS AND MAINTENANCE Visual InspectIon First, perform a visual inspection of the lift truck and Its components. Walk around the truck and take note of any obvious damage and maintenanceproblems. Check for loose fasteners and fittings. NAMEPLATES AND DECALS Check to be sure all capacity, safety, and warning plates or decals are attached and legible. Do notoperateor albw a lifttnrdt with damagedor missingdecals and nameplates to be operated. They contain important information. Replacethem immediately. Be surethat safetydevicesare in place, undamaged,and attached securely. Wheels and Tires Checkthe condition of the drive wheel and tire andthe bad wheels. Removeobjectsthat are embeddedin the tread. Inspectthe tires for excessivewear and breaksor “chunking out”, and bond failure betweenthe tire and rim. Check all wheelsfor propertightness. Adjust if necessary. SM560 PM- 1
  • 9. PM - PLANNED MAINTENANCE PROGRAM Functional Tests Be sure that all controls and systems are functioning correctly. Test horn and all other safety equipmentand accessories. Be sure they are properly mounted and working correctly. Press the horn button to check horn function. If the horn or any other part does not operate, report the failure and have it repaired before the truck is put back into operation. Operatethe brakes,directionalcontrols, and steeringsystem. Be sure all controlsoperate freely and returnto neutral properly. Test Drive The Truck Check all around to be sure that your intended path of travel is clear of obstructions and pedestrians. Test the tnrck for: Generalcorrect operation Drivetrain function Steering performance Brake performance By driving the truck in both the foward and reverse directions first in a straight line and then, slowly, through a series of full right and left turns. Listen for any unusual drive train or other running noises, such as wheel bearing noise, vibration, etc. Note any lack of smoothness in steering. When you have completed the operatlonal tests, park and leave truck according to standard shutdown procedures Brakes Checkthe brake system. The brakeshould be appliedwhen the control handle is in the fully raised positionor the fully lowered position. To check brake holdingcapabilityand adjustment,drivethe truck on to a grade and releasethe handle. The brake should hold the truck on the gradethat the truck can climb witha capacitybad or a 10% gradewhich everis less. , _ 4 vv CAUTION: 1 Do not oDerate a truck If the brakes are not op’eratlng properly. Steerlng system Checkthe steeringsystemfor abnormal loosenessanddamage. Checkfor any changesin steeringaction. Hard steeringor looseness,unusual sounds when turning or maneuveringindicates a need for inspection and setvicing. Never operate a truck which has a steerlng system fault. BATTERY Inspectthe battery retainment.Replaceany damagedor missingparts. Inspectthe batteriesfor any damage,cracks or leakingcondition. If your batterieshave removablevent caps, check to be sure the cellsare allfilled. Ifpossible,refillwith distilled water to bottomof vent cap opening. MECHANISMS Finally,inspectall controls,handle, levers, and linkagesfor wear and smoothness of operation. Air Cleaning Always maintain a lift truck in a clean condition. Do not allowdirt, dust, lint, or other contaminants to accumulate on the truck. Keep the truck free from leaking oil and grease. Wipe up all oil spills. Keep the handle and controls clean, dry, and safe. A clean truck makes it easier to see leakage, loose,missingor damagedparts, andwill help preventfires. A clean truck will run cooler. SM560 PM- 2
  • 10. PM - PLANNED MAINTENANCE PROGRAM The environmentin which a lift truck operates will determine how often and to what extent cleaning is necessary. For example, trucks operating in manufacturingplantswhich have a high level of dirt or lint (e.g., cotton fibers, paper dust, etc.) in the air or on the floor, will require more frequent cleaning. LIFT TRUCKS SHOULD BE AIR CLEANED AT EVERY PM INTERVAL, AND OTHERWISE AS OFTEN AS REQUIRED. Air cleaning should be done using an air hose with special adapter or extension having a control valve and nozzle to direct the air properly. Use clean, dry, low-pressure compressed air; restrict air pressure to (207 kPa]30 psi, maximum. CAUTION- Wear suitable eye protection and protective clothing. Critical Fastener Torque Checks Checktorque of criticalitems, including: Driveuti mounting Drivewheelmounting Components. Replacemissingbolts and tightened loose bolts to the correct torque before operating the truck. Fasteners in highly loaded (critical) components can quickly fail if they become loosened; also, loose fasteners can cause damage or failure of the component. For safety, it is important that the correct torque be maintained on all critical fasteners of components which directly support, handle or control the load, and protect the operator. SM560 PM- 3
  • 11. PLANNED MAINTENANCE PROGRAM SAFETY AND OPERATIONAL CHECKS Notes: *Replace As Required PM Interval: A = 8 - 10 hours, or daily B = 50 - 250 hours, or every month C = 450 - 500 hours, or every 3 months D = 900 - 1000 hours, or every 6 months E = 2000 hours, or every year Nominal Maintenance Interval DAILY MAINTENANCE CHECKS Check warning lights and hour meter. Check horn operation and other warning devices. Check steering operation. Check brake operation. Check directional and soeed controls ooeration. SM 560 PM-4
  • 12. PLANNED MAINTENANCE PROGRAM RECCOMMENDED MAINTENANCE AND LUBRICATION SCHEDULE Notes: PM Interval: A=& 10 hours, ordaily B = 50 - 250 hours, or every month C = 450 - 500 hours, or every 3 months *Replace As Required #First PM only D = 900 - 1000 hours, or every 6 months E = 2000 hours, or every year Nominal Maintenance Interval MAINTENANCE AND LUBRICATION A B C D E . . Check truck vlsumd msoect comDonents Test drive truck -- Check functional Derformance Air clean truck SM 560 PM-5
  • 13. PLANNED MAINTENANCE PROGRAM WP40 LUBRICATION CHART GREASE POINTS 1. 2. 3. 4. 5. 6. LOAD WHEEL AXLE ( USE LUB GUN AND ADAPTOR FOR FLUSH TYPE FITTINGS ) PULL ROD - LOAD WHEEL END LIFT CYLINDER MOUNTING PIN ( COLD STORAGE TRUCKS ONLY ) PULL ROD - LIFT LINK END LIFT LINK ( COLD STORAGE TRUCKS ONLY ) DRIVE UNIT PIVOT BEARINGS ( COLD STORAGE TRUCKS ONLY ) SM 560 PM-6
  • 14. 01 PLANNED MAINTENANCE PROGRAM WP40 LUBRICATION CHART FILL POINTS 1. HYDRAULIC SYSTEM RESERVOIR OIL CAPACITYIN RESERVOIR FLUID TYPE FLUID TYPE FOR COLD STORAGE 1 QUART low-40 MOTOR OIL DEXTRON II ATF 2. DRIVE UNIT FLUID FLUID CAPACITY FLUID TYPE FLUID TYPE FOR COLD STORAGE .85 QUARTS 80-9OW DEXTRON II ATF SM 560 PM-7
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  • 16. GROUP G&EH&ION 01 CONTENT NO. HANDLINGBATTERIES 12-01-01 BATTERY REMOVAL 12-01-02 CLEANINGPROCEDURES 12-01-03 CHARGINGPROCEDURE 12-01-04 l/p WARNING: 1 Battery Maintenance BATTERY ACID; FUMESAND ELECTRICAL POTENTIALCANCAUSEiNJURYOR DEATH. READAND UNDERSTANDTHESE PROCEDURESBEFOREWORKINGON BATTERIES. 1. DO NOT SMOKEOR ALLOWOPEN FLAMESOR SPARKSNEAR BATTERY CHARGINGAREAS. 2. WEARPROTECTIVECLOTHING,GLOVES ANDA FACESHIELDWHENWORKINGON BATTERIES. 3. KEEP ALL METAL OBJECTSAWAY FROM BATTERIES. 4. BATTERIESARE VERY HEAVY.HANDLE THEMWlTHTHE CORRECTLlFTlNGDEVICES. 5. BATTERYCHARGINGAREASMUST CONFORMTO FEDERALREGULATIONS. 6. DONOT PERFORM BATTERY SERVICE UNLESS YOU ARE TRAINED AND QUALIFIED. 12*01-01 HANDLING BATTERIES 1. Changeor servicestoragebatteriesonly in a batterysetice area. 2. Make surethis area hasthe equipment: -to flushandneutralizeanyadd that may spill. - forventilationof fumes from batteries. - for fire protection. Before trying to remove, install, or charge a storage battery, the truck must be in a battery service area with the brake applied so that the truck cannot move. 3. Make sure the area has material handling equipment made for the purpose of removing and installing batteries, such as an overhead hoist. Make sure the overhead hoist has safety hooks. 4. When a battery is to be removed, make sure that the battery removalhook, Clark part number 1622063, is used. 5. Whena powerchain hoist is used, makesure the hoist has a chain container to hold the amountof chain used. 6. Whena hand hoist is used, a batterywithout a cover must have a nonconductive material put over it to preventthe chain from makingcontact on the cell connectionsor terminals. 7. Keepall tools and other objects madeof metal awayfromthe terminals. 8. Because of hydrogen gas from batteries that are being charged, no smokingwill be permitted in the battery area. Do not check electrolytelevel with an open flame. No open flames, sparks, or electric arcs will be permitted in the battery chargingarea. ,9. When batteries are being charged, the vent caps must be kept in position to prevent electrolyte spray. The vent holes in the caps must be open. 10. Electrical installations must follow the National Electrical Code ( ANSI 856.2, 1974 ), NFPA 50578, Part “C” and any local ordinances. SM 560 12-01-l
  • 17. 12-01-02 BATTERY REMOVAL 1A WARNING: 1 BEFORE YOU DO SERVICE WORK OR REMOVEOR INSTALLA TRUCKBATTERYOR BATTERY PAC, READ THE FOLLOWING INSTRUCTIONS CAREFULLY. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULTINSERIOUSPERSONALINJURY. 1. Check the service and charging area for proper fire protection. Make sure there are no flames or heat in the area. Do not smoke. Make sure all necessary equipment is in the area, in good repair,and operatingcorrectly. If serviceis to be done on the batteries, make sure there is equipmentto flush and neutralize any acid that may spill, ventilation to carry fumes from the batteries, and equipmentto handle electrolyte. 2. Put the truck in the battery area, turn the key switch to the “off” position, and disconnect the battery receptacle. 3. Attach the battery pack removal hook, Clark art number 1822063,to the battery pack. 4. Removethe battery pack fromthe truck. 12-01-03 BATTERY CLEANING 1. Cleanthe batteriesonly when they are removedfrom the truck. 2. The vent caps must be in positiondurfng cleaning. 3. Washthe batterieswith iowpressurecold water. The batteriescan also be washedwith a solution of sodiumbicarbonate(put a box of sodium bicarbonateIn a pailof coldwater and mix).Rinse with cleancoldwater. 12-01-04 BATTERY CHARGING PROCEDURE b WARNING: 1 BATTERY CHARGING TO AVOID PERSONALINJURYBATTERIES MUSTBECHARGEDINAN APPROVED CHARGINGAREAANDCHARGED ACCORDINGTO APPROVEDPROCEDURES. IMPORTANT DONOTOPERATETHE CHARGERUNLESSIT IS FIRSTCONNECTEDTOTHE BATTERIES. 1. Replaceany missingvent caps and tighten. Check vent caps for proper operation ( the vent hole is clean and open). 2. Open the battery charger cover. Disconnect the battery pack from the truck receptacle and turn the chargertimer to the “off position. 3. Connect the A.C. cord to a 115V. A.C. outlet ( or a 220V A.C. outlet, according to the type of charger). 4. Connect the Battery receptacle to the charger. 5. Turn the timer to the “on” position. The pilot light and the ammeter show the charger is “on” and charging.Whenthe charger is turned to the “on” position, the charger will run for up to 12 hours maximum, or as set. See page 4 for chargerates. IMPORTANT- WEEKLY CHECK AFTER CHARGING,CHECK THE HEIGHT OF ELECTROLYTE IN EACH CELL. ADD DISTILLED WATER IF NECESSARY. THEN, AFTER BATTERIES HAVE BEEN CHARGED, CONNECT THE BATTERIES TO THE CHARGERAND SET THE TIMER TO 4 ON THE DIAL. THIS ADDED CHARGING WILL EQUALIZETHE CELLS AND HELP KEEP THE BATTERIES IN GOOD CONDITION.WEEKLY CHECKS ARE TO BE MADE ONLY BY TRAINED AND AUTHORIZED BATTERY MAINTENANCEPERSONNEL. SM 560 12-01-2