Clark OP 7 Service and Adjustment Manual SM-549

Description

• Model List:
  • OP 7

• 1. SERVICE MANUAL SM549
• 2. CONTENTS
• 3. FOREWORD
• 4. HOW TO USE THIS MANUAL
• 5. SAFETY SIGNS AND SAFETY MESSAGES
• 6. USER SAFE MAINTENANCE PRACTICES
• 7. PM PLANNED MAINTENANCE PROGRAM
• 7.1. Visual Inspection
• 7.2. Functional Tests
• 7.3. Test Drive The Truck
• 7.4. Air Cleaning
• 7.5. Critical Fastener Torque Checks
• 7.6. LUBRICATION. FLUIDS AND FILTERS
• 8. BATTERY
• 8.1. REMOVAL AND HANDLING
• 8.2. CLEANING PROCEDURES
• 9. DIRECTIONAL CONTROL
• 9.1. DIRECTIONAL CONTROL DESCRIPTION
• 9.2. DIRECTIONAL CONTROL MAINTENANCE
• 9.3. DIRECTIONAL CONTROL SWITCH REMOVAL
• 9.4. MASTER SWITCH REMOVAL
• 10. ELECTRIC MOTOR GENERAL MAINTENANCE
• 10.1. GENERAL PROCEDURES
• 10.2. INSPECTION PROCEDURES
• 10.3. MOTOR CLEANLINESS
• 10.4. MOTOR INSULATION
• 10.5. TEST FOR MOTOR INSULATION RESISTANCE TO GROUND
• 10.6. BRUSH AND COMMUTATOR INSPECTION
• 11. DRIVE MOTOR
• 11.1. DRIVE MOTOR DESCRIPTION
• 11.2. DRIVE MOTOR MAINTENANCE
• 11.3. DRIVE MOTOR REMOVAL
• 11.4. DRIVE MOTOR DISASSEMBLY
• 11.5. DRIVE MOTOR INSPECTION
• 11.6. DRIVE MOTOR ASSEMBLY
• 11.7. DRIVE MOTOR INSTALLATION
• 12. PUMP MOTOR
• 12.1. PUMP MOTOR DESCRIPTION
• 12.2. PUMP MOTOR MAINTENANCE
• 12.3. PUMP MOTOR REMOVAL
• 12.4. PUMP MOTOR DISASSEMBLY
• 12.5. PUMP MOTOR INSPECTION
• 12.6. PUMP MOTOR ASSEMBLY
• 12.7. PUMP MOTOR INSTALLATION
• 13. CONTACTOR PANEL
• 13.1. CONTACTOR PANEL DESCRIPTION
• 13.2. AMPERE CONTACTORS SINGLEPOLE, DOUBLETHROW TYPE (ONE NORMALLY OPEN CONTACT)
• 13.3. AMPERE CONTACTORS SINGLEPOLE, DOUBLETHROW TYPE (ONE NORMALLY OPEN AND ONE NORMALLY CLOSED CONTACT)
• 13.4. CONTACTOR ASSEMBLY (Cableform) A27185 CONTACTORS
• 14. DRIVE UNIT (221 RATIO)
• 14.1. DRIVE UNIT DESCRIPTION
• 14.2. DRIVE UNIT REMOVAL
• 14.3. DRIVE UNIT DISASSEMBLY
• 14.4. DRIVE UNIT INSPECTION
• 14.5. DRIVE UNIT BRAKE ASSEMBLY
• 14.6. DRIVE ASSEMBLY
• 14.7. DRIVE UNIT GEAR BACKLASH ADJUSTMENT
• 15. WHEELS AND TIRE
• 15.1. DRIVE TIRE REMOVAL
• 15.2. DRIVE TIRE INSPECTION
• 15.3. DRIVE TIRE REMOVAL AND REPLACEMENT
• 15.4. DRIVE WHEEL TIRE ASSEMBLY INSTALLATION
• 15.5. LOAD WHEEL INSPECTION
• 15.6. LOAD WHEEL REMOVAL AND REPLACEMENT
• 16. BRAKE
• 16.1. BRAKE DESCRIPTION
• 16.2. BRAKE ADJUSTING PROCEDURE
• 16.3. BRAKE PEDAL AND CONTROL REMOVAL
• 16.4. BRAKE PEDAL AND CONTROL INSTALLATION
• 17. STEERING SYSTEM
• 17.1. STEERING DESCRIPTION
• 17.2. STEERING CABLE MAINTENANCE
• 17.3. STEERING CABLE INSTALLATION
• 17.4. ROLLER MAINTENANCE
• 17.5. ROLLER REPAIR
• 18. HYDRAULIC SYSTEM
• 18.1. GENERAL DESCRIPTION
• 18.2. HYDRAULIC FLUID AND FILTER CHANGE
• 18.3. HYDRAULIC PUMP
• 18.4. PUMP TROUBLE SHOOTING
• 18.5. PUMP REMOVAL
• 18.6. PUMP REPLACEMENT
• 19. UPRIGHT REMOVAL AND INSTALLATION
• 19.1. Upright Inner Rail Removal
• 19.2. Upright Inner Rail Installation
• 20. UPRIGHT
• 20.1. UPRIGHT MAINTENANCE
• 20.2. UPRIGHT ROLLER CHECK AND ADJUSTMENT
• 20.3. LIFT CHAIN CHECK
• 20.4. LIFT CYLINDER REPAIR
• 21. MACHINE JACKING AND BLOCKING
• 21.1. BLOCKING THE OPERATORS COMPARTMENT IN RAISED POSITION
• 21.2. RAISING THE FRONT OF THE TRUCK
• 21.3. RAISING ENTIRE TRUCK
• 21.4. RAISING TRUCK WITH A HOIST
• 22. TRUCK DATA AND SPECIFICATIONS
• 22.1. BASIC DIMENSIONS
• 22.2. PERFORMANCE
• 22.3. WEIGHTS
• 22.4. CHASSIS
• 22.5. DRIVE LINE
• 22.6. TORQUE TABLE