Clark P-25, HWP-25, PWD-25, HWD-25, P-30, HWP-30, PWP-30, HWD-30, HWD-36, PWD-36 Service Manual SM-568

Description

• Model List:
  • P-25
  • HWP-25
  • PWD-25
  • HWD-25
  • P-30
  • HWP-30
  • PWP-30
  • HWD-30
  • HWD-36
  • PWD-36

• 1. SERVICE MANUAL SM568
• 2. FOREWORD
• 3. About This Manual
• 4. IMPORTANT SAFETY NOTICE
• 5. PICTORIAL INDEX
• 6. Planned Maintenance Procedures
• 6.1. CHECK SHEET
• 6.2. Visual Inspection
• 6.3. Operational Tests
• 7. LUBRICATION PLANNED MAINTENANCE
• 7.1. LUBRICATION SPECIFICATIONS
• 7.2. HYDRAULIC SYSTEM
• 7.3. LUBRICATION CHART RIDER MODELS
• 7.4. LUBRICATION CHART WALKIES MODELS
• 7.5. Optional Equipment
• 7.6. Miscellaneous Linkage
• 8. BATTERY
• 8.1. BATTERYHANDLING
• 8.2. Battery Removal
• 8.3. Battery Vents
• 8.4. Battery Cleaning
• 8.5. Battery Maintenance
• 8.6. Battery Charging
• 8.7. Battery Electrolyte
• 8.8. Clean Battery Compartment
• 8.9. Install Battery
• 8.10. KEEPING BATTERY RECORDS
• 9. ELECTRIC MOTORS
• 9.1. Electric Motor Maintenance
• 9.1.1. Inspection Procedures
• 9.1.2. Motor Cleanliness
• 9.1.3. Motor Insulation
• 9.2. TEST FOR MOTOR INSULATION RESISTANCE TO GROUND
• 9.3. BRUSH AND COMMUTATOR INSPECTION
• 9.4. Operating Conditions
• 10. ELECTRIC MOTORS
• 10.1. Drive (Traction)
• 10.2. Pump Motor
• 10.3. Disassembly
• 10.4. CLEANING INSPECTION
• 10.5. Visual Insoection
• 10.6. Bearings
• 10.7. Frame and Field Assembly
• 10.8. Armature
• 10.9. Commutator Undercutting
• 10.10. TESTING
• 10.10.1. Frame and Field Assembly
• 10.10.2. Grounded Circuit
• 10.10.3. Open Circuit
• 10.10.4. Ifthearmaturehasbeenturnedand
• 10.10.5. Armature
• 10.10.6. Equalizer Winding Connections
• 10.10.7. Standard Winding Connections
• 10.11. FRAME AND FIELD SERVICE NOTES
• 10.12. FIELD COIL INSTALLATION
• 10.13. ASSEMBLY AND TESTING
• 10.14. Bearing Installation
• 10.15. Brush Inspection Chart
• 10.16. Operating Conditions
• 11. CONTACTORS
• 11.1. Replacement of Contact Tips
• 11.2. Install New Tips
• 11.3. Check Operation
• 11.4. FORWARD REVERSE CONTACTOR ASSEMBLIES
• 11.4.1. Replacement of Contact Tips
• 11.4.2. Install New Tips
• 11.4.3. Check Operation
• 12. CONTACTOR AND EVT5 CONTROL PANELS
• 12.1. CONTROL PANEL REMOVAL
• 12.2. DIsconnect Panels
• 12.3. Control Card Removal Installation
• 12.4. Replacement Control Card Data
• 12.5. Capacitors
• 12.6. CONTROL BOX INTERNAL WIRING
• 13. EVT5 CONTROL
• 13.1. Description
• 13.2. Control Features
• 13.3. Maintenance
• 13.4. TROUBLESHOOTING
• 13.5. Trouble Shooting Notes
• 14. CHECKING COMPONENTS AND CONTROL CARD ADJUSTMENTS
• 14.1. EVT5 CARD ADJUSTMENTS AND INPUT/OUTPUT CONNECTIONS
• 14.2. EVT5 COMPONENT IDENTIFICATION
• 14.3. EVT5 INTERNAL WIRING
• 14.4. CHECKING COMPONENTS
• 14.4.1. Specific Gravity Test
• 14.4.2. Battery Tests
• 14.4.3. 3 and I4 REC Module
• 14.4.4. C Capacitors
• 14.4.5. Thermal Protector
• 14.4.6. Current Sensor Shunt
• 14.4.7. Snubber (1 FIL)
• 15. SEQUENCE OF OPERATION
• 15.1. OPERATIONAL SEQUENCE I
• 15.2. OPERATIONAL SEQUENCE 2
• 15.3. OPERATIONAL SEQUENCE 3
• 15.4. OPERATIONAL SEQUENCE 4
• 15.5. OPERATIONAL SEQUENCE 5
• 15.6. OPERATIONAL SEQUENCE 6
• 15.7. OPERATIONAL SEQUENCE 7
• 15.8. OPERATIONAL SEQUENCE 8
• 15.9. OPERATIONAL SEQUENCE 9
• 15.10. OPERATIONAL SEQUENCE 10
• 15.11. OPERATIONAL SEQUENCE 11
• 16. EVT5 FLOW CHART TROUBLE SHOOTING PROCEDURES
• 16.1. SYMPTOM I
• 16.2. SYMPTOM 2
• 16.3. SYMPTOM 3
• 16.4. SYMPTOM 4
• 16.5. SYMPTOM 5
• 16.6. SYMPTOM 6
• 16.7. SYMPTOM 7
• 16.8. SYMPTOM 8
• 16.9. SYMPTOM 9
• 17. DRIVE UNIT ASSEMBLY
• 17.1. DESCRIPTION
• 17.2. REMOVAL
• 17.3. DISASSEMBLY
• 17.4. Cleaning Inspection
• 17.5. REASSEMBLY
• 17.6. ADJUSTMENT SPECIFICATIONS
• 17.7. BACKLASH
• 17.8. Installation
• 18. DRIVE MOTOR BRAKES
• 18.1. MOTOR BRAKE ASSEMBLY
• 18.2. MOTOR BRAKE INSPECTION
• 18.3. BRAKE INSTALLATION
• 18.4. Brake Linkage Installation
• 18.5. BRAKE SWITCH
• 18.6. BRAKE SWITCH ADJUSTMENT
• 19. COAST CONTROL
• 19.1. COAST CONTROL DESCRIPTION
• 19.2. Coast Control Preparation
• 19.3. Coast Control Operational Check
• 19.4. Coast Control Operational Adjustment
• 20. CASTER ASSEMBLY
• 20.1. TORQUE SPECIFICATION
• 20.2. Caster Adjustment
• 21. HYDRAULIC SYSTEM
• 21.1. REMOVAL
• 21.2. Installation
• 21.3. Torque Specifications
• 22. HYDRAULIC UNIT
• 22.1. ASSEMBLY OF HYDRAULIC UNIT
• 22.2. SPECIFICATIONS
• 23. LIFT CYLINDER
• 23.1. LIFT CYLINDER REMOVAL
• 23.2. Block Lift Frame
• 23.3. Disconnect Hoses
• 23.4. Disconnect Lift Cylinder
• 23.5. Disassembly
• 23.6. Inspection
• 23.7. Reassembly
• 23.8. INSTALLATION SPECIFICATIONS
• 24. LIFT LINKAGE LOAD WHEELS
• 24.1. OPERATIONAL CHECK
• 24.2. Pull Rod Adjustment Check
• 24.3. BUSHING IDENTIFICATION
• 24.4. LIFT LINKAGE REMOVAL
• 24.5. Bushing Removal
• 24.6. Bushing Installation
• 24.7. DUAL LOAD WHEELS
• 24.7.1. Inspection
• 24.7.2. Assembly
• 24.8. SINGLE LOAD WHEELS
• 24.8.1. Inspection
• 24.8.2. Assembly
• 24.9. LIFT LINKAGE INSTALLATION
• 24.10. Pallet Entry Skids
• 25. BODY PARTS
• 25.1. Walkie Model Trucks
• 25.2. Rider Model Trucks
• 26. TRUCK SPECIFICATIONS
• 26.1. BATTERY
• 26.2. BRAKE, MOTOR
• 26.3. CONTROL (EVTS SOLID STATE CONTROL
• 26.4. ELECTRICAL
• 26.5. HYDRAULIC SYSTEM
• 26.6. TRUCK SERVICE WEIGHTS
• 26.7. Torque Specifications
• 27. WIRING SCHEMATICS
• 27.1. IN2222 (Early Model Trucks) Schematic
• 27.2. (Early Model Trucks) Diagram
• 27.3. IN24029 (Late Model Trucks) Schematic
• 27.4. (Late Model Trucks) Diagram