Clark EWP45 Service Manual SM-719

Description

• Model List:
  • EWP45

• 1. IMPORTANT SAFETY NOTICE
• 2. Arrangement and Use of this Manual
• 3. Contents by Section
• 4. Section Locations
• 5. INTRODUCTION
• 5.1. Truck Presentation.
• 5.2. Truck Side Views
• 5.3. Intended Truck Application
• 5.4. Prohibited Truck Application
• 5.5. Truck Data
• 5.6. Truck Dimensions
• 5.7. Data Plate
• 5.8. Reverser switch
• 5.9. Travel speed/direction selection
• 5.10. Horn switch
• 5.11. Fork raise switch
• 5.12. Fork lower switch
• 5.13. Battery
• 5.14. Load wheel
• 5.15. Drive unit with brake
• 5.16. Electric panel
• 5.17. Circuit breaker
• 5.18. Steering pivot point
• 5.19. Hydraulic unit
• 5.20. Hydraulic electric solenoid valve
• 5.21. Steering control handle
• 5.22. Key switch (toggle switch)
• 5.23. Emergency Disconnect Switch
• 5.24. Battery Receptacle
• 6. GROUP PS PERIODIC SERVICE
• 6.1. SECTION 1 Maintenance ScheduleE
• 6.1.1. Periodic Service and Planned Maintenance
• 6.1.2. Determining Maintenance Intervals
• 6.1.3. CHECK SHEET
• 6.1.4. Visual Inspection
• 6.1.5. Operational Tests
• 6.1.6. Lubrication Chart
• 6.1.7. Oil and Grease Specifi cations
• 6.1.8. Jacking Truck Off the Floor
• 6.2. SECTION 2 The PM Inspection Form
• 6.2.1. PM Report Form
• 7. GROUP 12 BATTERY
• 7.1. SECTION 1 Battery
• 7.1.1. Battery Handling
• 7.1.1.1. Keeping Battery Records
• 7.1.1.2. Install Battery
• 7.1.1.3. REPLACEMENT BATTERIES
• 7.1.1.4. Clean Battery Compartment
• 7.1.1.5. Battery Electrolyte
• 7.1.1.6. Battery Charging
• 7.1.1.7. Battery Maintenance
• 7.1.1.8. Battery Cleaning
• 7.1.1.9. Battery Vents
• 7.1.1.10. Battery Removal
• 7.1.2. Swing Out Battery Pack
• 7.1.3. Battery Cable Routing Diagram
• 7.1.4. Battery Connector
• 7.1.5. Battery Controller/Hourmeter
• 7.1.6. Battery Safety
• 7.1.7. Battery
• 7.1.8. Battery Maintenance
• 7.1.9. Storage
• 7.1.10. Charger Diagram
• 7.1.11. Troubleshooting
• 7.1.12. Electrical
• 7.1.13. Pilot Cell
• 8. GROUP 13 ELECTRICAL CONTROLS
• 8.1. SECTION 1 Electrical Controls
• 8.2. Directional Control Housing
• 8.3. Driver Protection (Reverser) Assembly
• 8.4. Direction Control Switches
• 8.5. Raise, Lower, and Horn Switches
• 8.6. Potentiometer
• 9. GROUP 14 ELECTRICAL
• 9.1. Electrical Functions
• 9.2. Electrical Panel Components
• 9.3. Wiring Schematic
• 9.4. Start / Stop Switches
• 10. GROUP 16 ELECTRIC MOTORS
• 10.1. General Information
• 10.2. Pump Motor
• 10.3. Inspection and Troubleshooting
• 10.4. Brush Inspection
• 10.5. Drive Motor Brush
• 10.6. Drive Motor Removal
• 10.7. Component Repair
• 10.8. Motor Disassembly
• 10.9. Motor Inspection
• 10.10. Assembly/Testing
• 11. GROUP 19 MOTOR CONTROLS
• 11.1. OVERVIEW
• 11.2. CONNECTIONS
• 11.3. PROGRAMMER MENUS
• 11.4. PROGRAM MENU
• 11.5. MONITOR MENU
• 11.6. SYSTEM FAULTS MENU
• 11.7. DIAGNOSTICS AND TROUBLESHOOTING
• 11.7.1. Troubleshooting Chart
• 11.8. STATUS LED DIAGNOSTICS
• 11.9. CONTROLLER MAINTENANCE
• 11.10. VEHICLE DESIGN CONSIDERATIONS
• 11.11. ELECTROSTATIC DISCHARGE (ESD)
• 11.12. HANDHELD PROGRAMMER
• 12. GROUP 20 DRIVE UNIT
• 12.1. System Description
• 12.2. Troubleshooting
• 12.3. Drive Unit Assembly Mounting
• 12.4. Drive Unit Repair
• 12.4.1. Disassembly
• 12.4.2. Reassembly
• 12.5. Axle Seal
• 13. GROUP 23 BRAKE SYSTEM
• 13.1. Brake Theory of Operation
• 13.2. Brake System
• 13.3. Brake Adjustment
• 13.4. Brake Shoe Removal / Installation
• 13.5. Brake Switch
• 13.6. Drive Wheel
• 14. GROUP 25 CASTER ASSEMBLY
• 15. GROUP 26 STEERING
• 15.1. Steering Stem
• 16. GROUP 30 HYDRAULICS
• 16.1. General
• 16.2. Adjustments
• 16.3. Installation
• 16.4. Assembly
• 16.5. Disassembly
• 16.6. Removal
• 16.7. Troubleshooting
• 17. GROUP 34 LIFT CYLINDER
• 17.1. Lift Cylinder Removal
• 17.2. Installation
• 18. GROUP 35 LIFT LINKAGE
• 18.1. Operational Check
• 18.2. Bearing Identifi cation
• 18.3. Lift Linkage Removal
• 18.3.1. Separate Lift Frame from Main Frame
• 18.3.2. Elevate and block truck as shown
• 18.3.3. Block Lift Frame and Main Frame
• 18.3.4. Remove Cylinder Pivot Shaft
• 18.3.5. Remove Upper Link Arms
• 18.3.6. Remove Left and Right Lower Link Arms
• 18.3.7. Disconnect Load Wheel Bracket
• 18.3.8. Bearing Removal
• 18.3.9. Cleaning and Inspections
• 18.3.10. Bearing Installation
• 18.4. Bearing Press Specifi cations
• 18.5. Lower Link Arms
• 18.6. Load Wheels
• 19. GROUP 39 SHEET METAL
• 20. GROUP 40 TRUCK SPECIFICATIONS