Clark Forklift NPR 17/20/345 Workshop Repair Service Manual
Clark Forklift NPR 17/20/345 Workshop Repair Service Manual
- This Workshop Service Repair manual PDF download for the NPR 17 & NPR 20 Clark industrial lift trucks has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.
File Format : PDF Language : English Printable : Yes Searchable : Yes Bookmarked : Yes Total Pages : 492
This Service / Repair / Workshop Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!
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Index 1 of 2 Pictorial Index Pictorial Index #1 Pictorial Index #2 INDEX Cautions Foreword Planned Maintenance Procedures P.M. CHECK SHEET Visual Inspection Operational Tests CLEANING Adiusting for Lining Wear When to Replace Brake Linings Checks 81 Minor Adjustments Upright Lift Chains Chain Lubrication Lift Chain Adjustment Carriage Chains Carriage Stop - to - Upright Stop Adjusting For Brake Lining Wear Every 1,000 Operating Hours 01 - 1 Lubrication Chart & Illustrations Lubrication Chart Key Every P.M. (250 operating hours maximum) Corrosion Protection COLD STORAGE LUBRICATION 12 - 1 Battery WARNING BATTERY HANDLING Battery Removal Battery Vents Battery Cleaning Battery Charging Battery Electrolyte Clean Battery Compartment Install Battery KEEPING BATTERY RECORDS These records should contain: BATTERlES HOW TO GET MAXIMUM LIFE OUT OF YOUR BATTERY 13 - 1 Multi-Function Control Handle Switches REACH, TILT AND AUXILIARY UP (LIFT) AND DOWN (LOWER) TRANSDUCER, FORWARD AND SWITCHES 16 - 2 Electric Motors General WARNING Electric Motor Maintenance Inspection Procedures Motdr Cleanliness Motor Insulation TEST FOR MOTOR INSULATION "RESISTANCE TO GROUND" (Using a 500 Volt Megger) TEST FOR MOTOR INSULATION "RESISTANCE TO GROUND" (Using a Simpson Volt-Ohmeter) BRUSH AND COMMUTATOR INSPECTION BRUSH AND COMMUTATOR INSPECTION Operating Conditions General Brush & Commutator Inspection Brush Inspection Chart 16 - 3 Traction Motors 24 & 36 Volt GENERAL Disassembly Component Inspection & Trouble Shooting TESTING When changing brushes 24-Volt Motor Specifications 36-Volt Motor Specifications Brush Inspection Chart 16 - 5 Pump Motors 24 & 36 Volt GENERAL Disassembly Component Inspection & Trouble Shooting TESTING When changing brushes 24-Volt Pump Motor Specifications 36-Volt Pump Motor Specifications Brush Inspection Chart 16 - 7 Auxiliary/Steer Pump Motors 24 & 36 Volt WARNING GENERAL TROUBLE SHOOTING PRIOR TO DISASSEMBLY MOTOR DISASSEMBLY Component Inspection & Trouble Shooting WHEN CHANGING BRUSHES 24-Volt Auxiliary/Steer Pump Motor Specifications 36-Volt Auxiliary/Steer Pump Motor Specifications Brush Inspection Chart 17 - 17 Contactors Forward I Reverse Contactors Disassemble the contactors. Forward / Reverse Contactors Parts Inspection Forward I Reverse Contactors Reassembly I-A, Line & Pump Contactors Disassembly Parts Inspection Reassembly 19 - 2 Electrical Sequence of Operation OPERATIONAL SEQUENCE #l Connect the Battery Close the Key Switch Steering Function Brake Switch & Static Return to Off (SRO) Checks Energizing the Directional Contactors Turning ON the Transistors Turning ‘OFF’ the Transistors, Capacitor Charging and Flyback Accelerator, Thermal Protector and Pulse Monitor Trip (PMT) IA Contactor Operation Plugging Plugging (continued) Plugging (continued) Travel Speed Limit Solenoid Functions Lift Lower Reach / Retract Reach / Retract (Continued) Tilt Tilt (Continued) Side Shift (Optional) Side Shift (continued) 19 Status Codes -01 -02 -03 -06 -07 -08 -09 -15 -16 -17 -23 -24 -26 -27 -41 -42 -43 -44 -45 -46 -48 -50 -51 -53 -54 -57 -99 19 - 4 Oscillator Card Settings WARNING NPR (24 Volt Truck) EV-T15 Card Factory Settings NPR (36 Volt Truck) EV-TIS Card Factory Settings 19 - 5 Steering Control Adjustments EV-T5PS WARNING Steer Control Adjustments Steps 1-3 Steer Control Adjustments Steps 4-5 Steer Control Adjustments Steps 6-7 Steer Control Adjustments Step 8-9 19 - 6 Wiring Diagrams NPR-345 19 - 7 Forward & Reverse Switches, Up (Lift) & Down (Lower) Switches and Transducer Adjustments WARNING Forward, Reverse, Up (Lift) & Down (Lower) Switch Adjustment TRANSDUCER ADJUSTMENT FORWARD AND REVERSE SWITCH ADJUSTMENT 19 - 8 Periodic Electrical Checks Periodic Electrical Inspection Electrical Inspections Power Cables Cables & Wiring Solenoid Control Card Multi-Function Control Handle Cables must be routed as shown Install truck battery 19 - 10 Oscillator Card Remove & Replace Truck Preparation Oscillator Card Removal Installation 19 - 16 Solenoid Control Card Trouble Shooting Voltage Data Sheet RH5 Voltage Checks RH5 Voltage Checks Lift Function ONLY Disabled NEW SOLENOID CONTROL CARD INSTALLATION 20 - 20 Axle, Articulation Adjustment Illustration Truck Preparation Check Adjustment of Axle Stop Bolts 20 - 2 Drive Unit WARNING LUBRICATION Removing the top of the gear unit (300) from the basic gear unit (100). Dismantling the housing lid Dismantling the crown gear (104) and wheel shaft (119) Dismounting the outer race Dismantling the inner race Dismounting the helical spur gear (201) and the conical pinion shaft (104) Mounting the gear unit Measuring the assembly dimension of the conical pinion shaft (104) Pre-assembly of the wheel shaff Pre-assembly of wheel shaft bearing in the housing Checking the tooth pattern Setting the conical pinion shaft (KM), helical gear (201) and setting the bearing clearance Adjustment of bearing clearance. Checking the bearing clearance of the pinion shaft Mounting the wheel shaft (119), crown gear (104), and setting the bearing clearance. Mounting the housing lid (134) Mounting the top of the gear unit (300) Special Tools 22 - 22 Traction Wheel & Tire Illustration, exploded view Truck Preparation Replacing Traction Wheel Tire 22 - 2 Caster Wheel & Tire Illustration, exploded view Truck Preparation Replacing Caster Wheel Tire Check Caster Wheel Bearings Adjustment 23 - 1 Brake, Motor Motor Brake Service Brake Adjustment Final Adjustment Specification 23 - 2 Caster Brake Truck Preparation Caster Brake Service SLAVE CYLINDER BRAKE BACKING PLATE 23 - 3 Brake Bleeding Procedure Bleeding Brake System 23 - 4 Brake Pedal Adjustment Pedal Up-Height Adjustment 26 - 1 Hydraulic Pressure Checks NPR-345 HYDRAULIC PRESSURE CHECKS Relief Valve Adjustment Check Lift Control Circuit Relief Valve Setting Relief Valve Adjustment 29 - 1 Hydraulic Sump Tank Filter and Strainer WARNING Drain Hydraulic Sump Tank Check Sump Tank Fluid Level 29 - 2 Hydraulic Schematic NPR-345 29 - 4 Hydraulic Pump Overhaul Pump Disassembly Parts Inspection Pump Reassembly 30 - 1 Hydraulic Control Valves and Solenoid Control Valves Truck Preparation Control Linkage Removal of Hydraulic Lines Lift, Auxiliary, Reach & Tilt Control Valves Flow Regulator Auxiliary and Lowering Solenoid Valves REASSEMBLY SUGGESTIONS Mounting the Lift and Tilt Control Valve Assemblies Hydraulic Tube Installation 30 - 2 Auxiliary, Reach & Tilt Control Valve Valve Cut-A-Way with Specifications Disassembly Cleaning and Inspection Valve Reassembly Port Plug Valve Spool Spool Spring Assembly Check Sump Tank Level 30 - 3 Lift Control Valve WARNING Specifications Pilot Operated Relief Valve Assembly with Schematic Cut-A-Way View of Valve LIFT CONTROL VALVE Valve Disassembly Valve Reassembly 30 - 4 Lowering Solenoid Valve Specifications, Warnings and Caution Hydraulic Schematic DISASSEMBLY REASSEMBLY INSTALLATION 30 - 5 Auxiliary Solenoid Valve (Reach and Tilt Control) Specifications, Warnings and Caution Hydraulic Schematic Disassembly REASSEMBLY INSTALLATION Check Sump Tank Level 30 - 6 Reach & Tilt Selector Valve Truck Preparation Discharge Capacitors Hydraulic Plumbing Diagram Specifications and Hydraulic Schematic REACH 81 TILT SELECTOR VALVE REMOVAL DISASSEMBLY Location and Mouting Illustration Removal, Disassembly & Reassembly INSTALLATION Mounting Selector Valve Installing clamps, connect wire plugs, tighten nuts and bolts 30 - 7 Side Shifter Solenoid Control Valve (Optional Equipement) Truck Make Ready Removal Specifications and Hydraulic Schematic Disassembly Reassembly Installation Route Hosing As Shown 32 - 2 Tilt Cylinder Overhaul Safety Preparation Cleaning & Inspection Suggestions Disassembly Cleaning & Inspection Reassembly Check Sump Tank Level 32 - 3 Reach Cylinder Overhaul Safety Preparation Cleaning & Inspection Suggestions Disassembly Cleaning & Inspection Reassembly Check Sump Tank Level 34 - 1 Upright & Pantograph Remove & Replace Roller Shim Adjustments PANTOGRAPH UPRIGHT REMOVAL Cable, Hose & Chain Sheaves Free Lift Cylinder Cylinder Cable and Chain Sheaves Pantograph Assembly PANTOGRAPH CARRIAGE ROLLERS Upright Rollers Upright Rails to Rollers Triple Stage Upright Roller Clearance Inspection Checking Lower Rollers Checking Upper Rollers Determine Number of Shims needed to make roller adjustments Shim Adjustment 34 - 2 Pantograph & Fork Carriage Assembly Safety Preparation Fork Removal Servicing Fork Carriage Fork Carriage Removal SERVICING PANTOGRAPH ARM ROLLERS 34 - 3 Rail Lift Cylinder Overhaul WARNING Disassembly Cleaning & Inspection Reassembly 34 - 4 Free Lift Cylinder Overhaul WARNING Disassembly Reassembly 34 - 5 Lift Fork Inspection Inspection Procedure Fork Wear Calipers Fork Inspection Illustrations 34 - 6 Upright Chain Inspection, Adjustment & Replacement Periodic Inspections Elongation Edge Wear Turning or Protruding Pins Cracked Plates Chain Length Adjustments Triple-Stage Upright (TSU) Chain Length Adjustments Chain Lubrication Chain Removal and Replacement General Guidelines Lift Chains (Standard and TSUs) Primary Cylinder/Carriage Chains(TSUs) Other Chain Service Notes 35 - 1 Load Wheels Remove & Replace Inspection Installation & Lubrication 40 Specifications NPR-345 Wiring Color Code Ikavel Speeds with Capacity Load Lift Speeds Wheels & Tires (Type & Size) Fork Spread Overall Dimensions Lift Cylinder Downdrift Test Tilt Cylinder Drift Test Service/Parking Brake(s) Caster Brake ELECTRICAL SYSTEM SPECIFICATIONS Hydraulic System Specifications Critical Fastener Torque Specifications 40 - 2 Service Weights SERVICE WEIGHTS IN POUNDS 40 - 3 Lubricants and Shop Supplies Easy Reference Listing ADHESIVE PRODUCTS CLEANERING PRODUCTS LUBRICANTS THREADLOCKER PRODUCTS Detailed Product Descriptions Lubricants Sealants Gasket Materials Threadlocks and Threadsealers Adhesives Cleaners Miscellaneous Shop Supplies