Clark E357 Service and Adjustment Manual SM-548

Description

• Model List:
  • E357

• 1. SERVICE MANUAL SM548
• 2. CONTENTS
• 3. FOREWORD
• 4. HOW TO USE THIS MANUAL
• 5. PICTORIAL INDEX
• 6. SAFETY AND OPERATIONAL CHECKS
• 7. RECOMMENDED PLANNED MAINTENANCE AND LUBRICATION SCHEDULE
• 8. SAFETY SIGNS AND SAFETY MESSAGES
• 9. USER SAFE MAINTENANCE PRACTICES
• 10. PM PLANNED MAINTENANCE PROGRAM
• 10.1. Visual Inspection
• 10.2. Functional Tests
• 10.3. Test Drive The Truck
• 10.4. Air Cleaning
• 10.5. Critical Fastener Torque Checks
• 10.6. LUBRICATION, FLUIDS AND FILTERS
• 11. BATTERY REMOVAL MAINTENANCE
• 11.1. BATTERY REMOVAL AND HANDLING
• 11.2. BATTERY MAINTENANCE
• 12. ACCELERATOR CONTROL
• 12.1. ACCELERATOR CONTROL DESCRIPTION
• 12.2. ACCELERATOR MAINTENANCE
• 12.3. ACCELERATOR CONTROL REMOVAL
• 12.4. ACCELERATOR CONTROL INSTALLATION
• 13. ELECTRIC MOTOR GENERAL MAINTENANCE
• 13.1. ELECTRIC MOTOR MAINTENANCE GENERAL PROCEDURES
• 13.2. MOTOR CLEANLINESS
• 13.3. MOTOR INSULATION
• 13.4. TEST FOR MOTOR INSULATION
• 13.5. BRUSH AND COMMUTATOR INSPECTION
• 14. DRIVE MOTOR
• 14.1. MOTOR DESCRIPTION
• 14.2. DRIVE MOTOR MAINTENANCE
• 14.3. DRIVE MOTOR REMOVAL
• 14.4. DRIVE MOTOR DISASSEMBLY
• 14.5. DRIVE MOTOR COMPONENTS INSPECTION
• 14.6. DRIVE MOTOR ASSEMBLY
• 14.7. DRIVE MOTOR INSTALLATION
• 15. LIFT PUMP MOTOR
• 15.1. LIFT PUMP MOTOR DESCRIPTION
• 15.2. LIFT PUMP MOTOR MAINTENANCE
• 15.3. LIFT PUMP MOTOR REMOVAL
• 15.4. LIFT PUMP MOTOR DISSEMBLY
• 15.5. LIFT PUMP MOTOR INSPECTION
• 15.6. LIFT PUMP MOTOR ASSEMBLY
• 15.7. LIFT PUMP MOTOR INSTALLATION
• 16. STEER PUMP MOTOR
• 16.1. STEER PUMP MOTOR DESCRIPTION
• 16.2. STEER PUMP MOTOR MAINTENANCE
• 16.3. STEER PUMP MOTOR REMOVAL
• 16.4. STEER PUMP MOTOR DISASSEMBLY
• 16.5. STEER PUMP MOTOR INSPECTION
• 16.6. STEER PUMP MOTOR ASSEMBLY
• 16.7. STEER PUMP MOTOR INSTALLATION
• 17. EV100S SEQUENCE OF OPERATION AND TROUBLESHOOTING
• 17.1. OPERATION SEQUENCE 1
• 17.2. OPERATION SEQUENCE 2
• 17.3. OPERATION SEQUENCE 3
• 17.4. OPERATION SEQUENCE 4
• 17.5. OPERATION SEQUENCE 5
• 17.6. OPERATION SEQUENCE 6
• 17.7. OPERATION SEQUENCE 7
• 17.8. OPERATION SEQUENCE 8
• 17.9. OPERATING SEQUENCE 9
• 17.10. OPERATION SEQUENCE 10
• 17.11. OPERATION SEQUENCE 11
• 17.12. OPERATION SEQUENCE 12
• 17.13. OPERATING SEQUENCE 13
• 17.14. RECOMMENDED TESTS
• 17.15. TEST EQUIPMENT
• 17.16. TEST PROCEDURES
• 17.17. SYMPTOMS
• 18. CONTROL PANEL
• 18.1. CONTROL PANEL DESCRIPTION
• 18.2. CONTROL PANEL MAINTENANCE
• 18.3. CONTROL PANEL TROUBLESHOOTING
• 18.4. CONTROL PANEL REMOVAL
• 18.5. CONTROL PANEL DISASSEMBLY
• 18.6. CONTACTOR INSPECTION
• 18.7. CONTROL PANEL ASSEMBLY
• 18.8. CONTROL PANEL INSTALLATION
• 19. EV100F SEQUENCE OF OPERATION AND TROUBLESHOOTING
• 19.1. OPERATION SEQUENCE 1
• 19.2. OPERATION SEQUENCE 2
• 19.3. OPERATIONS SEQUENCE 3
• 19.4. OPERATION SEQUENCE 4
• 19.5. OPERATION SEQUENCE 5
• 19.6. OPERATION SEQUENCE 6
• 19.7. OPERATION SEQUENCE 7
• 19.8. OPERATION SEQUENCE 8
• 19.9. OPERATION SEQUENCE 9
• 19.10. OPERATION SEQUENCE 10
• 19.11. OPERATION SEQUENCE 11
• 19.12. OPERATION SEQUENCE 12
• 19.13. OPERATION SEQUENCE 13
• 19.14. OPERATION SEQUENCE 14
• 19.15. OPERATION SEQUENCE 15
• 19.16. CHECKING COMPONENTS
• 19.17. RECOMMENDED TESTS
• 19.18. TEST EQUIPMENT
• 19.19. TEST PROCEDURES
• 19.20. SYMPTOM CHART
• 20. HIGH PERFORMANCE CONTROL PANEL
• 20.1. CONTROL PANEL DESCRIPTION
• 20.2. CONTROL PANEL MAINTENANCE
• 20.3. CONTROL TROUBLESHOOTING
• 20.4. CONTROL PANEL REMOVAL
• 20.5. CONTROL PANEL DISASSEMBLY
• 20.6. CONTACTOR INSPECTION
• 20.7. CONTROL PANEL ASSEMBLY
• 20.8. CONTROL PANEL INSTALLATION
• 21. EV100P SEQUENCE OF OPERATION AND TROUBLESHOOTING
• 21.1. OPERATION SEQUENCE 1
• 21.2. OPERATION SEQUENCE 2
• 21.3. OPERATIONS SEQUENCE 3
• 21.4. OPERATION SEQUENCE 4
• 21.5. OPERATION SEQUENCE 5
• 21.6. OPERATION SEQUENCE 6
• 21.7. OPERATION SEQUENCE 7
• 21.8. OPERATION SEQUENCE 8
• 21.9. OPERATION SEQUENCE 9
• 21.10. OPERATION SEQUENCE 10
• 21.11. CARD ADJUSTMENTS
• 21.12. CARD VOLTAGE CHECKS
• 21.13. PUMP CONTROL ADJUSTMENT
• 21.14. SYMPTOM CHART
• 22. PUMP CONTROL PANEL
• 22.1. CONTROL PANEL DESCRIPTION
• 22.2. CONTROL PANEL MAINTENANCE
• 22.3. CONTROL TROUBLESHOOTING
• 22.4. CONTROL PANEL REMOVAL
• 22.5. CONTROL PANEL DISSASSEMBLY
• 22.6. CONTACTOR INSPECTION
• 22.7. CONTROL PANEL ASSEMBLY
• 22.8. CONTROL PANEL INSTALLATION
• 23. SUPPLEMENT
• 23.1. EV100 LXT CONTROL PANEL
• 23.2. FUNCTION SETUP PROCEDURES
• 23.3. EV100LXT CONTROL PANEL
• 23.4. CHECKING COMPONENTS
• 23.5. REPLACEMENT OF EV100 COMPONENTS
• 24. DRIVE AXLE
• 24.1. GENERAL DESCRIPTION
• 24.2. DRIVE AXLE MAINTENANCE
• 24.3. DRIVE AXLE REMOVAL
• 24.4. DRIVE AXLE OVERHAUL
• 24.5. AXLE INSTALLATION
• 24.6. SM581 SUPPLEMENT
• 25. WHEELS AND TIRES
• 25.1. DRIVE STEER TIRE SPECIFICATIONS
• 25.2. DRIVE TIRE REPLACEMENT
• 25.3. STEER TIRE REPLACEMENT
• 26. BRAKE BLEEDING PROCEDURE
• 27. STEERING GEAR
• 27.1. STEERING GEAR DESCRIPTION
• 27.2. STEERING SYSTEM RELIEF PRESSURE CHECK
• 27.3. GEAR TROUBLESHOOTING
• 27.4. STEERING GEAR REMOVAL
• 27.5. STEERING GEAR DISASSEMBLY
• 27.6. STEERING GEAR PARTS INSPECTION
• 27.7. STEERING GEAR REASSEMBLY
• 27.8. STEERING GEAR INSTALLATION
• 28. POWER STEERING SYSTEM, STEER AXLE
• 28.1. POWER STEERING SYSTEM
• 28.2. STEERING SYSTEM RELIEF PRESSURE CHECK
• 28.3. STEER AXLE DESCRIPTION
• 28.4. STEER AXLE REMOVAL
• 28.5. STEER AXLE OVERHAUL
• 28.6. STEER AXLE INSTALLATION
• 29. POWER STEERING PUMP
• 29.1. GENERAL DESCRIPTION
• 29.2. POWER STEERING PUMP RELIEF PRESSURE CHECK
• 29.3. PUMP TROUBLESHOOTING
• 29.4. PUMP REMOVAL
• 29.5. PUMP DISASSEMBLY
• 29.6. PUMP ASSEMBLY
• 29.7. PUMP INSTALLATION
• 30. MAIN HYDRAULIC SYSTEM, LIFT PUMP
• 30.1. GENERAL DESCRIPTION
• 30.2. HYDRAULIC FLUID AND FILTER CHANGE
• 30.3. MAIN HYDRAULIC PUMP
• 30.4. HYDRAULIC PUMP TROUBLESHOOTING
• 30.5. PUMP REMOVAL
• 30.6. PUMP DISASSEMBLY
• 30.7. PUMP ASSEMBLY
• 30.8. PUMP INSTALLATION
• 31. MAIN HYDRAULIC VALVE
• 31.1. GENERAL DESCRIPTION
• 31.2. MAIN VALVE RELIEF PRESSURE CHECK ADJUSTMENT
• 31.3. MAIN VALVE REMOVAL
• 31.4. VALVE DISASSEMBLY
• 31.5. MAIN VALVE INSPECTION
• 31.6. MAIN VALVE ASSEMBLY
• 31.7. MAIN VALVE INSTALLATION
• 32. TILT CYLINDER
• 32.1. TILT CYLINDER ADJUSTMENT
• 32.2. TILT CYLINDER REMOVAL
• 32.3. TILT CYLINDER DISASSEMBLY
• 32.4. TILT CYLINDER INSPECTION
• 32.5. TILT CYLINDER ASSEMBLY
• 32.6. TILT CYLINDER INSTALLATION
• 33. UPRIGHT
• 33.1. UPRIGHT MAINTENANCE
• 33.2. UPRIGHT SHIM INSPECTION, TRIPLE STAGE
• 33.3. CARRIAGE SHIM INSPECTION TRIPLE STAGE
• 33.4. CARRIAGE SHIM INSTALLATION TRIPLE STAGE
• 33.5. TRIPLE STAGE SHIM DISSEMBLY
• 33.6. TRIPLE STAGE SHIM DISASSEMBLY
• 33.7. UPRIGHT TRIPLE STAGE REASSEMBLY
• 33.8. TRIPLE STAGE CYLINDER TROUBLESHOOTING
• 33.9. HYDRAULIC CYLINDER REPAIR TRIPLE STAGE
• 33.10. UPRIGHT LIFT CHAIN MAINTENANCE
• 33.11. UPRIGHT SHIM INSPECTION STANDARD
• 33.12. CARRIAGE SHIM INSPECTION STANDARD
• 33.13. CARRIAGE SHIM INSTALLATION STANDARD
• 33.14. UPRIGHT STANDARD SHIM DISASSEMBLY
• 33.15. UPRIGHT STANDARD REASSEMBLY
• 33.16. STANDARD TYPE CYLINDER TROUBLESHOOTING
• 33.17. UPRIGHT CYLINDER REPAIR STANDARD
• 34. COUNTERWEIGHT
• 34.1. COUNTERWEIGHT MAINTENANCE
• 34.2. COUNTERWEIGHT REMOVAL
• 34.3. COUNTERWEIGHT INSTALLATION
• 35. MACHINE JACKING AND BLOCKING
• 35.1. RAISING DRIVE WHEELS
• 35.2. BLOCKING THE UPRIGHT IN RAISED POSITION
• 35.3. RAISING REAR OF TRUCK
• 35.4. RAISING ENTIRE TRUCK
• 35.5. RAISING TRUCK WITH A HOIST
• 36. TRUCK DATA PLATE AND DECALS
• 37. SPECIFICATIONS
• 37.1. LUBRICANT SPECIFICATIONS
• 37.2. CRITICAL FASTENER TORQUE SPECIFICATIONS
• 37.3. CONTROL CARD SPECIFICATIONS (IN BATTERY AMPS)
• 37.4. CURRENT DRAW
• 37.5. GROUND TEST
• 37.6. CONTACTORS