Clark NS, NP 246 Service and Adjustment Manual SM-538

Description

• Model List:
  • NS 246
  • NP 246

• 1. SERVICE MANUAL SM538
• 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. GENERAL
• 10.2. VISUAL INSPECTION
• 10.3. FUNCTIONAL TESTS
• 10.4. TEST DRIVE THE TRUCK
• 10.5. AIR CLEANING
• 10.6. CRITICAL FASTENER TORQUE CHECK
• 10.7. LUBRICATION, FLUIDS AND FILTERS
• 11. BATTERY HANDLING AND CARE
• 11.1. BATTERY HANDLING
• 11.2. BATTERY REMOVAL PROCEDURE
• 11.3. BATTERY MAINTENANCE
• 11.4. BATTERY RECORDS
• 11.5. FOR MAXIMUM BATTERY LIFE
• 11.6. BATTERY INSTALLATION
• 12. ACCELERATOR CONTROL SYSTEM
• 12.1. ACCELERATOR DESCRIPTION
• 12.2. ACCELERATOR TROUBLESHOOTING
• 12.3. CONTROL REMOVAL
• 12.4. HAND MASTER SWITCH (HMS) DISASSEMBLY.
• 12.5. MASTER SWITCH ASSEMBLY
• 12.6. CONTROL INSTALLATION
• 13. ELECTRIC MOTOR GENERAL MAINTENANCE
• 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 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 DISASSEMBLY
• 15.5. LIFT PUMP MOTOR INSPECTION
• 15.6. MOTOR ASSEMBLY
• 15.7. 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. SCR CONTROL, RECOMMENDED TEST, TEST EQUIPMENT AND PROCEDURES
• 18. SCR, SYMPTOM CHARTS
• 19. CONTROL PANEL
• 19.1. CONTROL PANEL DESCRIPTION
• 19.2. CONTROL PANEL MAINTENANCE
• 19.3. CONTROL TROUBLESHOOTING
• 19.4. SCR CONTACTOR PANEL AND RELAY PANEL REMOVAL
• 19.5. CONTROL PANEL DISASSEMBLY
• 19.6. CONTACTOR INSPECTION
• 19.7. CONTROL PANEL ASSEMBLY
• 19.8. CONTROL PANEL INSTALLATION
• 20. DRIVE UNIT
• 20.1. GENERAL DESCRIPTION
• 20.2. DRIVE UNIT MAINTENANCE
• 20.3. DRIVE UNIT REMOVAL
• 20.4. DRIVE UNIT DISASSEMBLY
• 20.5. DRIVE UNIT INSPECTION
• 20.6. DRIVE UNIT ASSEMBLY
• 20.7. DRIVE UNIT INSTALLATION
• 21. WHEELS AND TIRES
• 21.1. DRIVE TIRE SPECIFICATIONS
• 21.2. DRIVE TIRE REPLACEMENT
• 22. BRAKE
• 22.1. BRAKE DESCRIPTION
• 22.2. BRAKE ADJUSTING PROCEDURE
• 22.3. BRAKE REMOVAL
• 22.4. BRAKE DISASSEMBLY
• 22.5. BRAKE ASSEMBLY
• 22.6. BRAKE INSTALLATION
• 23. CASTER ADJUSTMENT PROCEDURE
• 23.1. CASTER DESCRIPTION
• 23.2. CASTER REMOVAL
• 23.3. CASTER SERVICE/ ADJUSTMENT
• 24. STEERING SYSTEM
• 24.1. POWER STEERING SYSTEM
• 24.2. TORQUE GENERATOR REMOVAL.
• 24.3. SHAFT/GEAR REMOVAL
• 24.4. TORQUE GENERATOR DISASSEMBLY
• 24.5. TORQUE GENERATOR INSPECTION
• 24.6. TORQUE GENERATOR ASSEMBLY
• 24.7. SHAFT/GEAR INSTALLATION
• 24.8. TORQUE GENERATOR INSTALLATION
• 25. POWER STEERING PUMP
• 25.1. GENERAL DESCRIPTION
• 25.2. RELIEF PRESSURE CHECK
• 25.3. PUMP TROUBLESHOOTING
• 25.4. PUMP REMOVAL
• 25.5. PUMP DISASSEMBLY
• 25.6. PUMP INSPECTION
• 25.7. PUMP ASSEMBLY
• 25.8. PUMP INSTALLATION
• 26. HYDRAULIC LIFT PUMP
• 26.1. PUMP OVERVIEW
• 26.2. PUMP MAINTENANCE
• 26.3. LIFT PUMP REMOVAL
• 26.4. PUMP DISASSEMBLY
• 26.5. PUMP PARTS INSPECTION
• 26.6. PUMP ASSEMBLY
• 26.7. PUMP INSTALLATION
• 27. MAIN HYDRAULIC VALVE
• 27.1. GENERAL DESCRIPTION
• 27.2. MAIN VALVE RELIEF PRESSURE CHECK ADJUSTMENT
• 27.3. MAIN VALVE TESTING
• 27.4. MAIN VALVE TROUBLESHOOTING
• 27.5. MAIN VALVE REMOVAL
• 27.6. VALVE DISASSEMBLY
• 27.7. MAIN VALVE INSPECTION
• 27.8. MAIN VALVE ASSEMBLY
• 27.9. MAIN VALVE INSTALLATION
• 28. TILT CYLINDER MODEL C
• 28.1. TILT CYLINDER ADJUSTMENT
• 28.2. TILT CYLINDER REMOVAL
• 28.3. TILT CYLINDER DISASSEMBLY
• 28.4. CYLINDER ASSEMBLY
• 28.5. TILT CYLINDER INSTALLATION
• 29. REACH CYLINDER MODEL C
• 29.1. REACH CYLINDER ADJUSTMENT
• 29.2. REACH CYLINDER REMOVAL
• 29.3. REACH CYLINDER DISASSEMBLY.
• 29.4. REACH CYLINDER ASSEMBLY
• 29.5. REACH CYLINDER INSTALLATION
• 30. LIFT CYLINDER MODEL D
• 30.1. LIFT CYLINDER REMOVAL (STANDARD UPRIGHT)
• 30.2. LIFT CYLINDER DISASSEMBLY (STANDARD UPRIGHT)
• 30.3. LIFT CYLINDER ASSEMBLY (STANDARD UPRIGHT)
• 30.4. LIFT CYLINDER INSTALLATION (STANDARD UPRIGHT)
• 30.5. LIFT CYLINDER REMOVAL (THREE STAGE UPRIGHT)
• 30.6. LIFT CYLINDER DISASSEMBLY (THREE STAGE UPRIGHT)
• 30.7. LIFT CYLINDER ASSEMBLY (THREE STAGE UPRIGHT)
• 30.8. LIFT CYLINDER INSTALLATION (THREE STAGE UPRIGHT)
• 31. TILT CYLINDER NP300D
• 31.1. TILT CYLINDER ADJUSTMENT
• 31.2. TILT CYLINDER REMOVAL
• 31.3. TILT CYLINDER DISASSEMBLY.
• 31.4. CYLINDER ASSEMBLY
• 31.5. TILT CYLINDER INSTALLATION
• 32. TILT CYLINDER NS300D
• 32.1. TILT CYLINDER ADJUSTMENT
• 32.2. TILT CYLINDER REMOVAL
• 32.3. TILT CYLINDER DISASSEMBLY.
• 32.4. CYLINDER ASSEMBLY
• 32.5. TILT CYLINDER INSTALLATION
• 33. REACH CYLINDER NP300D
• 33.1. REACH CYLINDER ADJUSTMENT
• 33.2. REACH CYLINDER REMOVAL
• 33.3. REACH CYLINDER DISASSEMBLY.
• 33.4. REACH CYLINDER ASSEMBLY
• 33.5. REACH CYLINDER INSTALLATION
• 34. UPRIGHT REMOVAL MODEL C
• 34.1. UPRIGHT REMOVAL
• 34.2. UPRIGHT INSTALLATION
• 35. UPRIGHT MAINTENANCE MODEL C
• 35.1. UPRIGHT MAINTENANCE
• 35.2. UPRIGHT ROLLER CHECK AND ADJUSTMENT PROCEDURES
• 35.3. UPRIGHT LIFT CHAIN CHECK AND ADJUSTMENT PROCEDURE
• 35.4. BLEEDING COMPOUND LIFT CYLINDERS
• 35.5. UPRIGHT DOWNDRIFT TEST
• 35.6. UPRIGHT DESCRIPTION (TSU)
• 35.7. OPERATIONAL CHECKS AND ADJUSTMENTS (TSU)
• 35.8. LATCH OPERATION (TSU)
• 35.9. INTERMEDIATE RAILS (TSU)
• 35.10. CARRIAGE CHAIN ADJUSTMENT (TSU)
• 35.11. CHECKING ROLL PATTERN
• 35.12. CHECKING CYLINDER AND SEALS
• 35.13. LOAD TESTING
• 35.14. LIFT CYLINDER DRIFT TEST
• 35.15. TILT CYLINDER DRIFT TEST
• 35.16. CARRIAGE REMOVAL
• 35.17. ADJUSTING CARRIAGE ROLLERS
• 35.18. CARRIAGE INSTALLATION
• 35.19. UPRIGHT CLEARANCE (TSU)
• 35.20. ROLLER SHIM INSTALLATION (TSU)
• 36. UPRIGHT LIFT CYLINDER MODEL C
• 36.1. UPRIGHT CYLINDER DESCRIPTION
• 36.2. UPRIGHT MAINTENANCE TROUBLE SHOOTING
• 36.3. STANDARD CYLINDER DISASSEMBLY
• 36.4. STANDARD LIFT CYLINDER ASSEMBLY
• 36.5. COMPOUND CYLINDER DISASSEMBLY
• 36.6. CYLINDER PARTS INSPECTION
• 36.7. COMPOUND CYLINDER ASSEMBLY
• 37. PANTOGRAPH MODEL C
• 37.1. PANTOGRAPH REMOVAL (WITH TILT)
• 37.2. PANTOGRAPH INSTALLATION (WITH TILT)
• 38. UPRIGHT REMOVAL MODEL D
• 38.1. UPRIGHT REMOVAL
• 38.2. UPRIGHT INSTALLATION
• 39. UPRIGHT MAINTENANCE MODEL D
• 39.1. UPRIGHT MAINTENANCE
• 39.2. UPRIGHT ROLLER CHECK AND ADJUSTMENT PROCEDURES
• 39.3. UPRIGHT LIFT CHAIN CHECK AND ADJUSTMENT PROCEDURE
• 39.4. BLEEDING LIFT CYLINDERS
• 39.5. UPRIGHT DOWNDRIFT TEST
• 39.6. CHECKING ROLL PATTERN
• 39.7. CHECKING CYLINDER AND SEALS
• 39.8. LOAD TESTING
• 39.9. LIFT CYLINDER DRIFT TEST
• 39.10. TILT CYLINDER DRIFT TEST
• 39.11. CARRIAGE REMOVAL
• 39.12. ADJUSTING CARRIAGE ROLLERS
• 39.13. CARRIAGE INSTALLATION
• 40. PANTOGRAPH NP300D
• 40.1. PANTOGRAPH REMOVAL
• 40.2. PANTOGRAPH DISASSEMBLY
• 40.3. PANTOGRAPH INSTALLATION
• 41. MACHINE JACKING AND BLOCKING
• 41.1. RAISING DRIVE WHEEL
• 41.2. LOAD WHEEL ACCESS BLOCKING
• 41.3. RAISING REAR OF TRUCK
• 41.4. RAISING ENTIRE TRUCK
• 41.5. RAISING TRUCK WITH A HOIST
• 42. TRUCK DATA, SPECIFICATIONS