Clark WP45 Service Manual SM-698 - Image 2

Clark WP45 Service Manual SM-698 - Image 3

Clark WP45 Service Manual SM-698

$30.00

Type Of Manual: Service Manual
Manual ID: SM-698
Format: PDF
Size: 9.4MB
Number of Pages: 280

Category: Clark Service Manual PDF

Description
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Description

Model List:
- WP45

1. Standard Codes
2. Table of Contents
3. Warning Symbols
4. Prohibitory Symbols
5. Battery Safety
6. Static Safety
7. Welding Safety
8. Service Manual Introduction
9. Contents, Section M
9.1. Machine Information
9.1.1. General Product Information
9.1.1.1. Truck Presentation.
9.1.2. Main Components
9.1.3. Inch and Metric (SAE) Fasteners
9.1.3.1. Introduction
9.1.3.2. Nomenclature, Threads
9.1.3.3. Strength Identification
9.1.3.4. Conversion of English and Metric Units
9.1.4. Technical Service Data
9.1.5. Ordering Spare Parts
10. Contents, Section P
10.1. Planned Maintenance
10.1.1. Introduction, Maintenance
10.1.1.1. Jacking Truck Off The Floor
10.1.1.2. Lubricants
10.1.2. Service Schedule
10.1.2.1. Planned Maintenance Schedule
10.1.2.2. Planned Maintenance Procedures
10.1.2.3. Services Performed Every 480 or 960 Operating Hours
10.1.2.4. Services Performed Annually or Every 1440 Operating Hours
10.1.3. Lubrication Chart
10.1.4. Oil and Grease Specifications
10.1.4.1. Approved Oils and Grease
10.1.4.2. Grease Location Points
11. Contents, Section S
11.1. Service Instructions
11.2. Chassis/Lift Frame
11.2.1. Pull rod
11.2.1.1. Removal
11.2.1.2. Inspection
11.2.1.3. Installation
11.2.2. Carrier Frame Bushings
11.3. Inspection Covers
11.3.1. General Information
11.4. Driver Controls
11.4.1. Decal with Protective Sheet
11.4.2. Decal without Protective Sheet
11.5. Motor Maintenance Schedule/ Troubleshooting
11.5.1. General Information
11.5.2. Operating Conditions
11.5.3. Troubleshooting
11.6. Pump Motor
11.6.1. Mounting Points
11.6.1.1. Removal
11.6.1.2. Installation
11.6.2. Pump Motor Repair
11.6.2.1. Disassembly
11.6.3. Inspection and Troubleshooting
11.6.3.1. Drive End Head
11.6.3.2. Commutator End Head
11.6.3.3. Bearings
11.6.4. Brush Inspection
11.6.4.1. Brush Replacement Determination
11.6.4.2. Replacement Procedures
11.7. Drive Motor
11.7.1. Mounting Points
11.7.1.1. Drive Motor Brush
11.7.1.2. Drive Motor Removal
11.7.1.3. Drive Motor Installation
11.7.2. Component Repair
11.7.2.1. Motor Disassembly
11.7.3. Motor Inspection
11.7.3.1. External Motor
11.7.3.2. Brush and Commutator
11.7.3.3. Bearings
11.7.3.4. Armature Electrical Check
11.7.3.5. Frame and Field Service Recommendation
11.7.3.6. Assembly/Testing
11.8. Transmission
11.8.1. System Description
11.8.2. Troubleshooting
11.8.3. Transmission Mounting
11.8.3.1. Wrap Around Bumper
11.8.3.2. Removal
11.8.3.3. Installation
11.8.4. Transmission Repair
11.8.4.1. Disassembly
11.8.4.2. Reassembly
11.8.5. Axle Seal
11.8.5.1. Removal
11.8.5.2. Installation
11.9. Parking Brake System
11.9.1. Brake Theory of Operation
11.9.2. Brake Adjustment
11.9.3. Brake Shoe Removal / Installation
11.10. Drive Wheel
11.10.1. Removal
11.10.2. Installation
11.10.3. Tire Pressing Procedure
11.11. Support/Swivel Wheel (Optional)
11.11.1. Maintenance and Adjustments
11.11.1.1. Caster Adjustment
11.11.2. Troubleshooting
11.11.2.1. Stabilizing Caster
11.12. Fork Wheels
11.12.1. Removal/Installation
11.13. Steering
11.13.1. Control Handle Head
11.13.1.1. Removal
11.13.1.2. Installation
11.13.2. Driver Protection (Reverser) Assembly Replacement
11.13.3. Direction Control Switches
11.13.3.1. Removal
11.13.3.2. Installation
11.13.4. Raise, Lower, and Horn Switches
11.13.4.1. Removal
11.13.4.2. Installation
11.13.5. Potentiometer
11.13.5.1. Removal
11.13.5.2. Installation
11.13.6. Steering Stem
11.13.6.1. Removal
11.13.6.2. Installation
11.14. Electrical Functions
11.14.1. General
11.14.1.1. Adjustable Settings
11.14.1.2. References
11.14.1.3. Key Switch S17 in the ON Position
11.14.1.4. Operating Arm in Drive Position, S10, Brake Switch Closed
11.14.1.5. Travel Request, Fork First
11.14.1.6. Travel Request, Forks Trailing
11.14.1.7. Reversing/Motor Brake Forks First Direction to Forks Trailing Direction
11.14.1.8. Reversing/Motor Brake Forks Trailing Direction to Forks First Direction
11.14.1.9. Reverser switch
11.14.1.10. Lifting Forks
11.14.1.11. Lowering Forks
11.14.1.12. Lift Interrupt
11.15. Electrical Panel Components
11.16. Electrical Symbols
11.17. Electrical Schematics
11.18. Battery
11.18.1. Removal
11.18.2. Installation
11.18.3. Battery Maintenance
11.18.3.1. Battery Inspection and Care
11.18.3.2. Battery Exterior Cleaning
11.18.3.3. Charging
11.18.4. Storage
11.18.5. Battery History Record
11.19. Swing Out Battery Pack
11.19.1. Battery Cable Routing Diagram
11.19.2. Charger Diagram
11.19.3. Troubleshooting
11.19.3.1. Electrical Testing
11.19.3.2. Equipment required
11.19.3.3. Instructions
11.20. Battery Connector
11.20.1. Location
11.20.2. Inspection
11.20.3. Installation
11.21. Battery Controller/Hourmeter/ Lift Interrupt (Optional)
11.21.1. General Information
11.21.2. Electrical
11.21.2.1. Voltage
11.21.3. Battery Controller (BC)
11.21.3.1. General Information
11.21.3.2. Key Switch
11.21.3.3. Hourmeter
11.21.4. Troubleshooting
11.21.4.1. Battery Discharge Indicator (BDI)
11.21.4.2. Hourmeter
11.22. Battery Discharge Indicator / Hourmeter
11.22.1. General Information
11.22.2. Electrical
11.22.2.1. Voltage
11.22.3. Battery Discharge Indicator (BDI)
11.22.3.1. General Information
11.22.3.2. Key Switch
11.22.3.3. Hourmeter
11.22.4. Troubleshooting
11.22.4.1. Battery Discharge Indicator (BDI)
11.22.4.2. Hourmeter
11.23. Start/Stop Switches
11.23.1. General
11.23.1.1. Test/Inspection
11.23.2. Master Control On/Off Switch (S21)
11.23.2.1. Inspection
11.23.2.2. Removal
11.23.2.3. Installation
11.24. Transistor Controller
11.24.1. Basics Of Circuit Operation
11.24.1.1. Control Features
11.24.2. Maintenance
11.24.2.1. Cleaning
11.24.3. Motor Circuit
11.24.4. Control Circuit
11.24.5. Troubleshooting Guidelines
11.24.5.1. General
11.24.6. Shorts to Frame Test
11.24.7. Definitions
11.24.8. Diagnostics and Troubleshooting
11.24.8.1. Handset Diagnostics
11.24.8.2. Troubleshooting
11.24.8.3. Troubleshooting Chart
11.24.8.4. Technical Specification
11.24.8.5. Troubleshooting Chart Using Handset
11.25. Transistor Controller Troubleshooting
11.25.1. Troubleshooting Chart Index
11.25.2. Troubleshooting Charts
11.25.2.1. Special Instructions
11.26. Hydraulic System
11.26.1. General
11.26.2. Troubleshooting
11.26.3. Schematic
11.26.4. Description
11.26.4.1. Relief Pressure
11.26.5. Maintenance
11.26.6. Lift Limit Switch
11.27. Hydraulic Pump
11.27.1. Removal
11.27.2. Disassembly
11.27.3. Inspection
11.27.4. Reassembly
11.27.5. Installation
11.27.6. Adjustments
11.27.6.1. Relief valve
11.27.6.2. Solenoid Operated Valve
11.28. Lift Cylinder
11.28.1. Cylinder Repair
11.28.1.1. Removal
11.28.1.2. Disassembly
11.28.1.3. Inspection
11.28.1.4. Assembly
11.28.1.5. Installation
11.29. Battery Charger, Optima Pack
11.29.1. Battery Charger Wiring Diagram Optima Pack
11.30. Handset Operation
11.30.1. Operating Modes
11.30.2. Revert to Previous Settings
11.30.3. Handset Self Test