Clark Forklift NPR 17/20/345 Workshop Repair Service Manual

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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.


APPLICABLE MODELS :

Clark NPR-345
Clark NPR-17
Clark NPR-20


TABLE OF CONTENTS :

01 - 1 Lubrication Chart & Illustrations
12 - 1 Battery
13 - 1 Multi-Function Control Handle Switches
16 - 2 Electric Motors General
16 - 3 Traction Motors 24 & 36 Volt
16 - 5 Pump Motors 24 & 36 Volt
16 - 7 Auxiliary/Steer Pump Motors 24 & 36 Volt
17 - 17 Contactors
19 - 2 Electrical Sequence of Operation
19 - Status Codes
19 - 4 Oscillator Card Settings
19 - 5 Steering Control Adjustments EV-T5PS
19 - 6 Wiring Diagrams NPR-345
19 - 7 Forward & Reverse Switches, Up (Lift) & Down (Lower) Switches and Transducer Adjustments
19 - 8 Periodic Electrical Checks
19 - 10 Oscillator Card Remove & Replace
19 - 16 Solenoid Control Card Trouble Shooting
20 - 20 Axle, Articulation Adjustment
20 - 2 Drive Unit
22 - 22 Traction Wheel & Tire
22 - 2 Caster Wheel & Tire
23 - 1 Brake, Motor
23 - 2 Caster Brake
23 - 3 Brake Bleeding Procedure
23 - 4 Brake Pedal Adjustment
26 - 1 Hydraulic Pressure Checks NPR-345
29 - 1 Hydraulic Sump Tank Filter and Strainer
29 - 2 Hydraulic Schematic NPR-345
29 - 4 Hydraulic Pump Overhaul
30 - 1 Hydraulic Control Valves and Solenoid Control Valves
30 - 2 Auxiliary, Reach & Tilt Control Valve
30 - 3 Lift Control Valve
30 - 4 Lowering Solenoid Valve
30 - 5 Auxiliary Solenoid Valve (Reach and Tilt Control)
30 - 6 Reach & Tilt Selector Valve
30 - 7 Side Shifter Solenoid Control Valve (Optional Equipement)
32 - 2 Tilt Cylinder Overhaul
32 - 3 Reach Cylinder Overhaul
34 - 1 Upright & Pantograph Remove & Replace Roller Shim Adjustments
34 - 2 Pantograph & Fork Carriage Assembly
34 - 3 Rail Lift Cylinder Overhaul
34 - 4 Free Lift Cylinder Overhaul
34 - 5 Lift Fork Inspection
34 - 6 Upright Chain Inspection, Adjustment & Replacement
35 - 1 Load Wheels
40 - Specifications NPR-345
40 - 2 Service Weights
40 - 3 Lubricants and Shop Supplies Easy Reference Listing


MANUAL SPECIFICATION :

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

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