Clark TM 12-25 36 Volt Service Manual SM-555

Description

• Model List:
  • TM 12-25 36 Volt

• 1. CONTENTS
• 2. INTRODUCTION
• 3. HOW TO USE THIS MANUAL
• 4. SUBJECT/PICTORIAL INDEX
• 5. SAFETY INFORMATION
• 6. DRIVERS DAILY CHECKLIST
• 7. PM REPORT FORM
• 8. PM PLANNED MAINTENANCE PROGRAM
• 8.1. VISUAL INSPECTION
• 8.2. OPERATIONAL CHECKS / TEST DRIVE
• 8.3. AIR CLEANING
• 8.4. CRITICAL FASTENER TORQUE CHECKS
• 8.5. CHASSIS COMPONENTS MAINTENANCE / INSPECTION
• 8.6. LUBRICATION, FILTERS FLUID LEVEL CHECKS
• 8.7. ELECTRICAL TESTS
• 9. PLANNED MAINTENANCE SCHEDULE
• 10. PLANNED MAINTENANCE AND LUBRICATION CHARTS
• 11. BATTERY REMOVAL
• 12. BATTERY MAINTENANCE
• 13. LIFT PUMP MOTOR MICROSWITCH ADJUSTMENT
• 14. SERVICE BRAKE MICROSWITCH ADJUSTMENT
• 15. PARKING BRAKE MICROSWITCH ADJUSTMENT
• 16. ACCELERATOR CONTROL
• 17. ELECTRICAL SYSTEM
• 18. ELECTRICAL MOTOR MAINTENANCE
• 19. DRIVE MOTOR BRUSH REPLACEMENT
• 20. STEER MOTOR BRUSH REPLACEMENT
• 21. STEER PUMP AND MOTOR ASSEMBLY REMOVAL
• 22. STEER PUMP MOTOR OVERHAUL
• 23. DRIVE MOTOR REMOVAL
• 24. DRIVE MOTOR OVERHAUL
• 25. LIFT PUMP AND MOTOR ASSEMBLY REMOVAL
• 26. LIFT PUMP MOTOR OVERHAUL
• 27. STEER AXLE TRUNNION MICROSWITCH ADJUSTMENT
• 28. CONTROL PANEL
• 28.1. CONTROL PANEL DESCRIPTION
• 28.2. CONTROL PANEL MAINTENANCE
• 28.3. CONTROL PANEL TROUBLESHOOTING
• 28.4. CONTROL PANEL REMOVAL
• 28.5. CONTACTOR INSPECTION
• 28.6. CONTROL PANEL INSTALLATION
• 29. EV100M SEQUENCE OF OPERATION AND TROUBLESHOOTING
• 29.1. OPERATION SEQUENCE DRIVE CONTROL
• 29.1.1. DRIVE CONTROL
• 29.1.2. BATTERY
• 29.1.3. BATTERY INDICATOR AND PUMP MOTOR
• 29.1.4. HOUR METER, STEERING SRO
• 29.1.5. FWD/REV CONTACTORS
• 29.1.6. CONTACTOR OPERATION CAPACITOR PRECHARGE
• 29.1.7. 1 REC ON, 5 REC ON
• 29.1.8. CAPACITOR CHARGING REACTOR OPERATION
• 29.1.9. 2 REC ON, 1 REC OFF
• 29.1.10. FLYBACK
• 29.1.11. ACCELERATOR MODULE, THERMAL PROTECTOR PMT
• 29.1.12. CONTACTOR OPERATION
• 29.1.13. PLUGGING
• 29.2. CHECKING COMPONENTS
• 29.2.1. SPECIFIC GRAVITY TEST
• 29.2.2. CHECK l, 2, 5 RECS
• 29.2.3. CHECK CAPACITOR (1C)
• 29.2.4. CHECK 22, 23, 24, 25 FILTER BLOCKS
• 29.2.5. CHECK 3, 4 RECS
• 29.2.6. CHECK FILTER MOUNTING BLOCK
• 29.2.7. CHECK SENSOR
• 29.2.8. CHECK THERMAL PROTECTOR
• 29.2.9. CHECK REACTOR/CHOKE MODULE
• 29.2.10. CARD ADJUSTMENTS
• 29.2.11. CARD VOLTAGE CHECKS
• 29.2.12. CONNECTOR PLUG A, B, Z
• 29.3. RECOMMENDED TEST, TEST EQUIPMENT AND PROCEDURES
• 29.3.1. GROUND FAULT CONDITION
• 29.3.2. POWER STEER IDLE CURRENT
• 29.3.3. SCR CURRENT LIMIT
• 29.3.4. FREE WHEELING CURRENT
• 29.3.5. TIME DELAY
• 29.3.6. CREEP SPEED MOTOR VOLTS
• 29.3.7. PLUGGING FUNCTION
• 29.4. SYMPTOM CHARTS
• 29.4.1. CONTACTORS WILL NOT CLOSE
• 29.4.2. CONTACTORS CLOSE, NO POWER, NO HUM, TRUCK INOPERATIVE IN SCR RANGE
• 29.4.3. CONTACTORS CLOSE, NO POWER, SCR HUM, TRUCK INOPERATIVE IN SCR RANGE
• 29.4.4. CONTACTORS CLOSE BUT POP OPEN, PMT TRIPS
• 29.4.5. ONE CONTACTOR CLOSES, OTHER WILL NOT
• 29.4.6. STIFF PLUG AND/OR PLUGGING DISTANCE NOT ADJUSTABLE
• 29.4.7. CONTACTOR WILL NOT CLOSE
• 29.4.8. PMT TRIPS WHEN HYDRAULIC SWITCHES ARE ACTIVATED
• 29.4.9. POWER STEER MOTOR DOES NOT OPERATE
• 29.4.10. LIFT/TILT/ATTACHMENTS DO NOT OPERATE
• 30. SUPPLEMENT
• 30.1. EV100 LXT CONTROL PANEL
• 30.2. EV100 LXT CONTROL PANEL STATUS CODES
• 30.3. CHECKING COMPONENTS
• 30.4. REPLACEMENT OF EV100 COMPONENTS
• 30.5. EV100LXT CARD FUNCTION SETUP
• 31. DRIVE AXLE MAINTENANCE
• 32. DRIVE AXLE REMOVAL
• 33. DRIVE UNIT OVERHAUL
• 34. PNEUMATIC TIRE AND WHEEL MAINTENANCE
• 35. BRAKE SYSTEM (CARLISLE BRAKE)
• 35.1. BRAKE SPECIFICATIONS
• 35.2. BRAKE SYSTEM BLEEDING
• 35.3. BRAKE PEDAL REMOVAL, REPLACEMENT, AND ADJUSTMENT
• 35.3.1. INTRODUCTION
• 35.3.2. PEDAL REMOVAL
• 35.3.3. PEDAL REPLACEMENT
• 35.3.4. PEDAL ADJUSTMENT
• 35.4. BRAKE REMOVAL AND REPLACEMENT
• 35.5. PARKING BRAKE REMOVAL, REPLACEMENT, AND ADJUSTMENT
• 35.6. BRAKE OVERHAUL
• 36. BRAKE BLEEDING PROCEDURE
• 37. PARKING BRAKE ADJUSTMENT
• 38. SERVICE BRAKE CALIPER ASSEMBLY REMOVAL
• 39. SERVICE AND PARKING BRAKE, BRAKE CALIPER ASSEMBLY OVERHAUL
• 40. BRAKE MASTER CYLINDER REMOVAL
• 41. MASTER CYLINDER OVERHAUL
• 42. PYLON RELEASE LEVER ADJUSTMENT
• 43. POWER STEERING CONTROL UNIT REMOVAL
• 44. STEERING GEAR
• 45. STEER AXLE TRUNNION BEARINGS CHECK AND ADJUSTMENT
• 46. STEER WHEEL BEARING MAINTENANCE
• 47. POWER STEERING SYSTEM RELIEF PRESSURE CHECK
• 48. STEER CYLINDER LINKAGE CHECK AND ADJUSTMENT
• 49. STEER AXLE, STEERING LINKAGE, AND STEER AXLE TRUNNION OVERHAUL
• 50. STEERING CYLINDER REMOVAL
• 51. POWER STEERING CYLINDER OVERHAUL
• 52. POWER STEERING PUMP REMOVAL
• 53. POWER STEERING PUMP OVERHAUL
• 54. HYDRAULIC SYSTEM FLUID AND FILTER CHANGE
• 55. LIFT PUMP REMOVAL
• 56. LIFT PUMP OVERHAUL
• 57. HYDRAULIC SYSTEM RELIEF PRESSURE CHECK AND ADJUSTMENT
• 58. MAIN HYDRAULIC VALVE REMOVAL
• 59. MAIN HYDRAULIC VALVE OVERHAUL
• 60. HYDRAULIC SYSTEM SCHEMATIC DIAGRAM
• 61. TILT CYLINDER ADJUSTMENT
• 62. TILT CYLINDER DRIFT TEST
• 63. TILT CYLINDER REMOVAL
• 64. TILT CYLINDER OVERHAUL
• 65. UPRIGHT LIFT CHAIN CHECK AND ADJUSTMENT PROCEDURE
• 66. UPRIGHT DOWNDRIFT TEST
• 67. FORK MAINTENANCE
• 68. LIFT CHAIN MAINTENANCE
• 69. UPRIGHT REMOVAL
• 70. COUNTERWEIGHT REMOVAL
• 71. FRONT BATTERY PLATE ADJUSTMENT
• 72. MACHINE JACKING AND BLOCKING
• 73. OVERHEAD GUARD REMOVAL
• 74. HOOD REMOVAL
• 75. TRUCK DATA PLATES AND DECALS
• 76. SUGGESTED EQUIPMENT FOR ELECTRIC TRUCK PM
• 77. FIRE EXTINGUISHER RECOMMENDATIONS
• 78. LUBRICANT SPECIFICATIONS AND RECOMMENDATIONS
• 79. TRUCK DATA AND SPECIFICATIONS
• 80. MEASURING VOLTAGES WITH THE VOLTOHM METER ( VOM )
• 81. MEASURING RESISTANCE WITH THE VOLTOHM METER ( VOM )