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Clark EWP45 Forklift Service Repair Manual

service repair manual

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Clark EWP45 Forklift Service Repair Manual

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  1. SM-719 EWP45 Service Manual Technical Publications Lexington, KY 40510 www.Clarkmhc.com

  2. Safety Notice IMPORTANT SAFETY NOTICE Read and understand all safety precautions and warnings before performing repairs on lift trucks. Appropriate service methods and proper repair procedures are essential to the safe, reliable operation of industrial trucks as well as the personal safety of the individual doing the work. This Service Manual provides general directions for accomplishing service and repair work with tested, effective techniques. Following them will help assure successful repair and reliable truck operation. There are numerous variations in procedures, techniques, tools, and parts for servicing industrial trucks, as well as in the skill of the individual doing the work. This manual cannot possibly anticipate all such variations and provide advice or precautions as to each. Accordingly, anyone departing from the instructions provided in this manual through procedures used or choice of tools, materials, and parts may jeopardize his or her personal safety and/or the safety of the vehicle user. Improper or careless techniques cause accidents. Don’t take chances with incorrect or damaged equipment. Read and understand the procedures for safe operation and maintenance outlined in this manual. STAY ALERT! Follow safety rules, regulations and procedures. Accidents can be avoided by recognizing dangerous procedures or situations before they occur. DRIVE AND WORK SAFELY and follow the safety signs and their messages displayed on the truck and in this manual. General Precautions The following list contains general precautions that should be followed when working on a lift truck: • Always wear safety glasses for eye protection. • Remove rings, watches, loose jewelry and open clothing before working on a vehicle, to avoid serious injury. • Do not smoke while working on a vehicle. • Put key switch in the OFF position, unless otherwise required by the procedure. • Set the parking brake. Place wheel chocks or wood blocks of 4" x 4" size or larger to the front and rear surfaces of the tires to provide further restraint from inadvertent vehicle movement. • Use safety stands or blocks whenever a procedure requires you to be under the vehicle. • Service Electric Truck Batteries in a well-ventilated area to avoid the danger of igniting explosive gases. • Follow the Safety Instructions outlined in GROUP 12 "Handling Storage Batteries". • Always Discharge the Capacitors prior to working on or around electrical components. Refer to the instructions outlined in GROUP 19 "Discharging Capacitors:. • Avoid contact with Battery Acid. The battery contains corrosive acid which can cause injury. Following the SM-719 iii June '07

  3. INTRODUCTION Arrangement and Use of this Manual Clark arranges parts and service procedures by standardized Groups. In this manual, Groups are similar to “chapters.” Groups are listed in the table of contents on the next page. You can quickly locate a specifi c point in the manual by using the headers and footers that appear on every Section page. The following illustration points out these areas. Each Group begins with a table of contents that shows the Sections contained within the Group. Lengthy Sections also begin with a table of contents showing the topics contained within the Section. Each Group and Section has an identifying name and num- ber, or “ID.” Each page also has a unique ID. The page ID consists of three numbers separated by hyphens. The three numbers represent the Group number, the Section number, and the Page number. For example, “00-1-2” on the lower corner of the page indicates Group 00, Section 1, Page 2. Figure Intro-1 This manual is intended for the use of trained service per- sonnel. © Copyright Clark Material Handling Company 1999 SM-719, June ‘07 Intro-1

  4. INTRODUCTION Contents by Group Contents are listed here by Group number. INTRO INTRODUCTION PS PERIODIC SERVICE 12 BATTERY 13 ELECTRIC CONTROLS 14 ELECTRICAL 16 ELECTRIC MOTORS 19 MOTOR CONTROL 20 DRIVE UNIT ASSEMBLY 23 BRAKE SYSTEM 25 CASTER ASSEMBLY 26 STEERING 30 HYDRAULIC SYSTEM 34 LIFT CYLINDER 35 LIFT LINKAGE AND LOAD WHEELS 39 SHEET METAL 40 SPECIFICATIONS Intro-2 SM-719, June ‘07

  5. INTRODUCTION Section Locations Figure Intro-2 SM-719, June ‘07 Intro-3

  6. INTRODUCTION Truck Presentation. Intended Truck Application The trucks are solely designed and manufactured to handle goods and should be fi tted with the ap- propriate accessories relevant to the application. The EWP45 is a battery powered walkie pallet truck intended solely to be operated handling pal- lets or similar load carriers indoors. The trucks are equipped with a steering arm with all the controls for operating within easy access. The trucks have maximum lifting capacities of up to 4500 pounds (2041 kg). Review data plate on the truck to note the maximum lifting capacity. Prohibited Truck Application The trucks are designed for handling goods indoors. The use of trucks for other purposes is not permitted. Do not use the truck for the following: The truck is equipped with a 24 volt electrical system. Truck speed is regulated by means of a transistor controller to provide infi nite control of acceleration and speed while driving. Chassis/lift frame is raised by means of a hydraulic unit. The control of the lift/lower is done electrically with the push button on the steering arm. The trucks can be fi tted with a battery pack. • As a towing tractor for trailers. • To tow other trucks. • To transport/lift passengers. • To drive on gravel or grass. Truck Data Truck Side Views The table below provides information regarding some technical data which is of value with daily use of the trucks. The terms right-hand and left-hand used indicate the right and left side of the truck as viewed from the operator’s line of sight for proper operation of truck. Use this view when ordering parts to assure proper selection of parts. Truck data Lifting capacity rated load, lb/kg Lift height, inches/mm Operating speed without load, mph/k 3.7/5.96 Operating speed with load, mph/k Service weight without battery, lb/kg Service weight including battery (minimum battery weight 150 lb (68 kg) maximum 330 lb (149.6 kg) 4500/2041 8.5/216 2.9/4.6 859/390 Above + battery weight The lifting capacity and weight of the truck can be found on the truck data plate. Figure Intro-3 Intro-4 SM-719, June ‘07

  7. INTRODUCTION Truck Dimensions The following diagram shows external dimensions for the EWP45 truck in its standard design. All dimensions shown for 48” (1219 mm) long pallet. Figure Intro-4 SM-719, June ‘07 Intro-5

  8. INTRODUCTION Data Plate Main Components The following diagram shows the data plate used on the truck. Figure Intro-5 Intro-6 SM-719, June ‘07

  9. INTRODUCTION 1. Reverser switch 10. Circuit breaker The end of the control handle is equipped with a red automatic reversing switch which causes the truck to travel in the rearward direction when activated. 15A, Control circuit breaker 80A, Power circuit breaker 11. Cover Removable to provide access for servicing. 2. Travel speed/direction selection 12. Steering pivot point Selects the direction truck moves. The further in that direction the faster the truck moves. Lubricate pivot point to prevent stiff steering. 3. Horn switch 13. Hydraulic unit Horn sounds to warn others of truck position. Pump motor, pump, electric valves and oil tank integrated in a compact unit. 4. Fork raise switch 14. Hydraulic electric solenoid valve Forks will raise when switch is pressed or until lift reaches upper limit switch. For controlling lifting and lowering functions with electric solenoid valve. 5. Fork lower switch 15. Steering control handle Forks will lower when switch is pressed or until lower stops are reached. Truck is controlled by the operator with 180 degree steering angle. The brake is applied in the upper and lower position of the steering control handle. 6. Battery 24 volt with different capacities and weights. 16. Key switch (toggle switch) 7. Load wheel Shuts off electrical power to control system. Lubricate load wheels to prevent wheels from locking up. 17. Gauge Combined hourmeter/battery indicator, hourme- ter/battery indicator with lift cutout or hourmeter only. 8. Drive unit with brake Fixed drive unit with a spring applied brake, drive motor, gear box, and drive wheel combined into a compact unit. The steering bearings are at the top of the drive unit. 18. Emergency Disconnect Switch Pushing in on this button disconnects the battery from all circuits on the truck shutting off all power to the truck. 9. Electric panel 24 volt electrical system. Truck speed is regulated by means of a transistor controller. 19. Battery Receptacle Pulling the battery connector shuts off all electrical power to truck. SM-719, June ‘07 Intro-7

  10. INTRODUCTION Figure Intro-6 Intro-8 SM-719, June ‘07

  11. PERIODIC SERVICE GROUP PS SECTION 1 Maintenance Schedule “Periodic Service” and “Planned Maintenance” .....................................PS-1-2 Determining Maintenance Intervals .........................................................PS-1-2 SM-719, June ‘07 Planned Maintenance • PS-1-1

  12. PERIODIC SERVICE Determining Maintenance Intervals “Periodic Service” and “Planned Maintenance” Time intervals on the charts and elsewhere in this manual relate to truck operating hours as recorded on the hourmeter, and are based on experience Clark has found to be convenient and suitable under normal operation. Standard operating condition classifi cations are: The term “periodic service” includes all mainte- nance tasks that should be performed on a regu- larly scheduled basis. The term “Planned Maintenance” indicates a for- malized program of basic inspections, adjustments, and lubrications that the Clark service organization provides customers at a prescribed interval, usually 50-250 hours. The recommended basic “Planned Maintenance” procedure is given in Section 2. Normal Operation: Eight-hour material handling, mostly in buildings or in clean, open air on clean, paved surfaces. Severe Operation: Prolonged operating hours or constant usage. The current Section,”Maintenance Schedules,” specifi es all maintenance tasks-including Planned Maintenance tasks-that should be performed pe- riodically, and suggests intervals at which they should be performed. Extreme Operation: • In sandy or dusty locations, such as cement plants, lumber mills, and coal dust or stone crushing sites. • High-temperature locations, such as steel mills and foundries. • Sudden temperature changes, such as constant trips from buildings into the open air, or in refrigeration plants. IMPORTANT MAINTENANCE INTERVALS. If the lift truck is used in severe or extreme operat ing conditions, the maintenance intervals should be shortened accord- ingly. Since the operating environments of lift trucks vary widely, the above descrip- tions are highly generalized and should be ap plied as actual conditions dictate. PS-1-2 • Planned Maintenance SM-719, June ‘07

  13. PERIODIC SERVICE P.M. CHECK SHEET Visual Inspection A. Oil leaks B. Switches C. Drive Tire D. Load Wheels E. Caster Wheels F. Control Linkage ✓ ✓ ✓ ✓ ✓ ✓ A special coding system on the P.M. Check Sheet allows truck condition to be reported with a mini- mum number of words. As the P.M. is performed, a check mark should be made in the appropriate box of the component being checked. Refer to Figure PS-1. Operational Tests A. Brakes B. Brake Switch C. Horn D. Steering E. Speed Control F. Lift and Lower Control s (✓) indicates the particular truck component or system has been checked and is O.K. r ✓ ✓ x ✓ (x) indicates the component or system is in need of a minor adjustment or service (not part of the normal P.M.) that should be taken care of in the near future. CODE = = = = ✓ X r s O.K. Adjust (Not P.M.) Repair or Replace Requires Shop Repair (r) indicates there is a potential problem that could result in damage to a component or system and requires attention. O.K. Potential Urgent Figure PS-1 (s) indicates the need for urgent repair or replace- ment of a component or system and the truck should be shut down as eminent damage or possible injury may result. The nature of problems found during a PM should be noted in the “comments” portion of the check sheet. Whenever a system or component is faulty or unsafe, it must be noted on the check sheet, and reported to the designated authority at the conclu- sion of the P.M. WARNING Remove all jewelry before examining electrical components. SM-719, June ‘07 Planned Maintenance • PS-1-3

  14. PERIODIC SERVICE Visual Inspection Inspect Battery Plug & Truck Receptacle • Disconnect battery from truck. Refer to Figure PS-2. • Inspect the spring loaded connectors in the truck battery receptacle and check the battery plug connectors. Severely burned connectors should be noted on the P.M. check sheet. Figure PS-2 Inspect Battery Cover for damage • Check cover for damage. Refer to Figure PS-3. • The cover should not be dented. A badly dented cover could short out across the battery cell connectors. • The cover should be free to swing open and closed without binding. Figure PS-3 Inspect Pallet Forks for obvious damage • Forks should not be bent or warped. If the forks are damaged, report condition to the designated authority. Refer to Figure PS-4. Figure PS-4 PS-1-4 • Planned Maintenance SM-719, June ‘07

  15. PERIODIC SERVICE Inspect Exterior • Inspect Frame Components • Check truck console, access covers and panels for damage. Refer to Figure PS-5. • Inspect nameplates and decals for damage and to be sure they are not missing. Figure PS-5 Check for obvious oil leaks • Make a quick overall inspection for leakage. If an oil leak appears to be major, note condition on the check sheet for immediate attention. Minor leaks should be repaired during the P.M. Refer to Figure PS-6. Figure PS-6 Inspect Tires & Wheels • Check for obvious damage to tires on the load, caster and drive wheels. Refer to Figure PS-7. • Look for excessive tire wear, cuts, breaks, chunking or bond failure between the tires and wheels. Note condition on the PM check sheet. • Remove embedded objects from the tires. • Be sure, wheel fasteners are secure and none are missing. • Make certain grease fi ttings are not damaged or missing. Figure PS-7 SM-719, June ‘07 Planned Maintenance • PS-1-5

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  17. PERIODIC SERVICE Expose Internal Components • Remove the covers exposing the drive unit, brake, lift cylinder, hydraulic unit and transis- tor control. Front panel and covers are held on with socket head screws. Refer to Figure PS-8. Figure PS-8 Connect Truck Battery • Connect truck battery and check truck opera- tion. Refer to Figure PS-9. Figure PS-9 PS-1-6 • Planned Maintenance SM-719, June ‘07

  18. PERIODIC SERVICE Operational Tests • Turn the key switch on. Refer to Figure PS- 10. • Pull the Emergency Disconnect Button out to connect the battery circuit. Figure PS-10 • Check the horn to be sure it operates. Refer to Figure PS-11. Figure PS-11 • Check the hour meter to be sure it operates. Refer to Figure PS-12. Figure PS-12 SM-719, June ‘07 Planned Maintenance • PS-1-7

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