Clark Sm 614 Service Manual

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SM-614
PWC 30, PWT 7
Service Manual

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 TABLE OF CONTENTS

GENERAL INFORMATION (GI)

Section 1 Pages l-3 Introduction & Specifications
Section 2 Page 1 Serial Number Location
Section 3 Pages l-2 Record Keeping
Section 4 Pages 1-16 Tools Required, Torque Chart, Conversion Factors, Standard
Speed & SCR Potentiometer Adjustments, General Service Guide,
Maintenance Schedule and Lubrication Chart
Section 5 Pages l-9 Battery Care and Service
Section 6 Pages l-9 Battery Controller
Section 7 Pages l-6 Paint & Decal

ELECTRIC CONTROL (EC)

Section 1 Pages l-5 Basic Electrical Theory
Section 2 Pages l-30 Troubleshooting, DC Measurement, Measuring Resistance &
Meters, Troubleshooting Do’s & Dont’s
Section 3 Pages l-10 Basic Operation & Troubleshooting for PWT with Resistor Control
Section 4 Pages 1-19 Service Guide for Curtis PMC Control
Section 5 Pages l-8 Basic Operation & Troubleshooting for PWT with Curtis PMC
\
Control
Section 6 Pages l-8 Basic Operation & Troubleshooting for PWC with Curtis PMC
.
Control
Section 7 Pages 1-9 Standard Speed Potentiometer Adjustments for Curtis PMC and
EV- 100 Contactor & Maintenang

HYDRAULIC SYSTEM (IID)

Section 1 Pages l-8 Basics of Hydraulics
Section 2 Pages 1-8 Basic Hydraulic Operation, Hyd. Pump Operation, Diagnosis and
Maintenance

DRIVE ASSEMBLY (DA)

Section 1 Pages l-4 Transmission Drive Assembly (General Information)
Section 2 Pages l-5 Transmission Drive Assembly (Repair and Service & Installation)
Section 3 Pages l-3 Transmission Drive Assembly (Dismantling Lower Section)
Section 4 Pages l-6 Transmission Drive Assembly (Assembling Lower Section)
Section 5 Pages 1-21 G.E. DC Drive Motors
Section 6 Pages l-2 Drive Tire

BRAKE SYSTEM (BR)

Section 1 Pages l-2 Operation & Service Procedure
Section 2 Pages l-3 Tilt Steerhead Brake Adjustment
Section 3 Pages l-5 Fixed Steerhead Brake Adjustment

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STEERING SYSTEM (ST)

Section 1 Pages l-3 Operation and Planned Maintenance & Service

LOAD CARRIER (LC)

Section 1 Pages l-4 General Introduction
Section 2 Pages l-2 Planned Maintenance
Section 3 Pages l-5 Load Wheels and Load Wheel Replacement
Section 4 Pages l-3 Fork Height Setting

BODY AND FRAME (BF)

OPTIONAL EQUIPMENT (OE)

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NOTICE
“CLARK Trucks meet all applicable requirements of ASME B56.1 or ASMB B56.9 at time of manu-
facture. .

CLARK will not assume any liability for injuries or damages arising from or caused by the removal,
disconnection or disengagement of any part from any of its trucks.

CLARK recommends all replacement parts are of OEM (Original Equipment Manufacturer) origin.

Any modifications and/or additions which affect capacity or safe operation of CLARK trucks shall not
be performed without CLARK’s prior written approval.

A user should consult the Local Authorized Dealer if the user’s intended application is outside the
designated performance characteristics of the truck.

Dimensions and performance specifications shown may vary due to manufacturing tolerances. Per-
formance is based on an average size truck and is affected by weight, condition of the trucks, battery,
optional equipment and operation area.

CLARK products and specifications are subject to change without prior notification.”

:P

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Main Table of Contents

GENERAL INFORMATION
(GI)

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 GENERAL INFOIMiATION
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PWT & PWC
INTRODUCTION

This manual has been assembled to assist in the training of a service technician to service, maintain
and repair if required the units covered.

This manual covers the PWT tow tractor and the PWC center controlled pallet truck manufactured
after 1989. Even though these units serve different applications, the power section or tractor section
of these units are the same.

We have made every effort to disguise between the models so the authorized technician will be
working with the correct service specifications.

You will find that the PWT tractor can have either resistor or PMC for drive motor control, and the
PWC is standard with PMC drive motor control.

Also the reverse function is different for these units which will be covered under Basic Electrical
Operation (EC Section).

All schematics and part numbers included in this manual are for standard units. These are
subject to change please reference the units specific parts manual for correct information.

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SPECIFICATIONS FOR
PWT

Electrical System 24V Standard

PMC Controller (Standard) Mosfet Transistor
Resistor (Contactor - Optional) 3 Speed (Electric Timer)

Model Standard Standard Hi-Speed Hi-Speed Hi-Torque Hi-Torque

Motor 39100-009 39100-009 39100-010 39100-010 39100-011 39100-011
HP/Amp 1.0/91 2.51120
Gear Ratio 181 12:l 21:l 12:l 18:l 15:l
Approx. Speed Empty 6.3 Empty 7.5 Empty 6.3 Empty 8.5 Empty 6.3 Empty 7.0
Loaded 3.3 Loaded 5.0 Loaded 3.8 Loaded 6.5 Loaded 3.5 Loaded 4.8
Towing Capacity 10,000 7.000 12,000 6,000 15,000 15.000

Tires A. Drive Tire Standard Option # 1 Option #2

10x4 Rubber Non-Marking 83 duro Poly
Part Number 11905-021 18849-004 13076-030
B. Rear Wheel Rubber
7x4 28000042-000

Dimensions
A. Overall Length without Coupler (Hitch) 45.88”
B. Wide 32.75”
C. Weight without Battery PWT 950#
PWT Hi-Torque 1300#
D. Battery Sizes 30.69” x 12.81” x 23.25” AMP. HR. 450 960#
30.69” x 12.81” x 23.25” AMP. HR. 510 1OOO#
30.69” x 12.94” x 3 1.OO”AMP. HR. 625 1180#
30.69” x 12.94” x 3 1.OO”AMP. HR. 750 1500#

E. Steering 180” Total (90° to Left or Right)

Note: All specifications subject to change without prior notification.

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 GENERAL INFORMATION
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SPECIFICATIONS FOR
PWC

Electrical System 24V Standard

PMC Controller Mosfet High Speed Truck

Capacity Standard 6000# Option 8000#

Motor 39100-010 39100-010
HP/Amp 2.51113 2.5/l 13
Gear Ratio 18:l 18:l
Approx. Speed Empty 6.2 Empty 6.2
Loaded 4.4 Loaded 4.0
Walking 3.5 Walking 3 5

Hyd. Capacity Pints

Hyd. Pump Type Barnes
Hyd. Relief psi Approx.* @6000# = 185Opsi
@SOOO#= 2 1OOpsi
Hyd. Oil Valvoline F32U

*Note: Units are tested to lift its r&d load in 4.0 to 4.5 sec. relief valve is adjusted to meet this
standard.

Tires A. Drive Tire Standard Option #l Option #2

10x4 Rubber Non-Marking 83 duro Poly
Part Number 11905-021 18849-004 13076-030
B. Cater Wheel Poly
3.25 x 6 27462-008
C. Load Wheel Poly Poly 8000# Only
3.25 x 6 9988-048 9988-048V

Dimensions with 96” Forks

A. Overall Length 151.34”
B. Overall Width 34.90”
C. Weight without Battery 1910#
D. Battery Sizes 30.69” x 12.81” x 23.25” AMP. HR. 450 960#
30.69” x 12.81” x 23.25” AME’.HR. 510 lOOO#
30.69” x 12.94” x 3 1.00” AME? HR. 625 1180#
30.69” x 12.94” x 31.00” AMP. HR. 750 1500#
E. LiR Height to top of Forks 9.25”

E. Steering 180” Total (90’ to Left or Right)

Note: All specifications subject to change without prior notification.

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SERIAL NUMBER LOCATION
CURRENT MODELS

PWT & PWC

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RECORD KEEPING

Webster defines maintenance as the art of maintaining, or the upkeep of property or equipment.

There is a constant search for a maintenance program that encompasses all requirements with mini-
mum effort and maximum results.

All maintenance systems have four basic requirements:

1. Capable trained personnel to perhorm the required maintenance.

2. Delegate adequate authority to the service personnel so that the needed service can and is
being done.
3. Keep simple records in order to evaluate the operation of the vehicle and to be certain that
the scheduled services are performed.
4. Follow the manufacture’s basic maintenance recommendations.

To implement proper product maintenance, we suggest following our basic truck and tractor mainte-
nance schedule in this section.

In order to provide a quick visual check on the daily status of the units requiring maintenance, we
have prepared a sample maintenance record board on the next page. The size of this board will be
determined by the number of units to be serviced. Sample covers a six month period - actual should
cover a twelve month period.

With newer computer based maintenance programs it is much easier to keep track of units perfor-
mance and cost.

:f No maintenance schedule can cover all possible types of operations and conditions. Service records
will enable you to obtain the highest product efficiency through planned maintenance.

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 GENERAL INFORMATION
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RECORD KEEPING

Model & Serial No. Stock No.

Date Placed in Service

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TOOLS REQUIRED TO SERVICE
THESE PRODUCTS

Mechanical, electrical, hydraulic, and maintenance service on these products can be performed with
standard hand tools.

Various size roll pins are used throughout all our products. The removal and installation can be made
by the use of hardened steel punches of various diameters and length.

In some cases, the replacement of hydraulic cylinder packing requires the use of the packing installer
tool or guide to ease installation of the packing. Tools can be provided for such use; however, due to
the various sizes and continual changes, a standard engine piston ring compressor can be used effec-
tively for this service. All basic electrical services can be performed with standard hand tools, a good
VOM (Volt Ohm Meter) and AMP Meter. We have added tool requirements in some of the servicing
sections. These tools may include impact tools, lifting straps, hoist, torque wrench and jacks which
are readily available locally.

Always use good quality tools to ensure your safety and the safety of others.

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 GENERAL INFORMATION
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TORQUE CHART

Feeler Gauges, Micrometers, Calipers Wrenches

z?.m inches mm inches inches m inches

0.01 0.0004 0.46 0.0181 0.91 0.0358 6 15164

0.02 0.0008 0.47 0.0185 0.92 0.0362 7 9132
0.03 0.0012 0.48 0.0189 0.93 0.0366 8 5116
0.04 0.0016 0.49 0.0193 0.94 0.0370 9* 11/32
0.05 0.0020 0.50 0.0197 0.95 0.0374 10** 13132
0.06 0.0024 0.51 0.0201 0.96 0.0378 11 7/16
0.07 0.0028 0.52 0.0205 0.97 0.0382 12* 15132
0.08 0.0031 0.53 0.0209 0.98 0.0386 13 l/2
0.09 0.0035 0.54 0.0213 0.99 0.0390 14 9116
0.10 0.0039 0.55 0.0216 I,00 0.0394 15* 19132
0.11 0.0043 0.56 0.0220 16 518
0.12 0.0047 0.57 0.0224 17 11/16
0.13 0.0051 0.58 0.0228 19 314
0.14 0.0055 0.59 0.0232 21 12/16
0.15 0.0059 0.60 0.0236 22 718
0.16 0.0063 0.61 0.0240 24 15116
0.17 0.0067 0.62 0.0244 26 1II
0.18 0.0071 0.63 0.0248 27 l-1/16
0.19 0.0075 0.64 0.0252 30 l-306
0.20 0.0079 0.65 0.0256 32 l-1/4
0.21 0.0083 0.66 0.0260 36 l-7/16
0.22 0.0087 0.67 0.0264 41 l-518
0.23 0.0091 0.68 0.0268 46 l-13/16
0.24 0.0094 0.69 0.0272 50 2"
0.25 0.0098 0.70 0.0276 55 2-l/8
0.26 0.0102 0.71 0.0279 60 2-318
0.27 0.0106 0.72 0.0283
0.28 0.0110 0.73 0.0287
0.29 0.0114 0.74 0.0291
0.30 0.0118 0.75 0.0295
0.31 0.0122 0.76 0.0299
0.32 0.0126 0.77 0.0303
0.33 0.0130 0.78 0.0307
0.34 0.0134 0.79 0.0311
0.35 0.0138 0.80 0.0315
0.36 0.0142 0.81 0.0319
0.37 0.0146 0.82 0.0323
0.38 0.0150 0.83 0.0327
0.39 0.0154 0.84 0.0331
0.40 0.0157 0.85 0.0335
0.41 0.0161 0.86 0.0339
0.42 0.0165 0.87 0.0342
0.43 0.0169 0.88 0.0346
0.44 0.0173 0.89 0.0350
0.45 0.0177 0.90 0.0354

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 GENERAL INFOR2MATION
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TORQUE CHART

TORQUE WRENCHES
Newton Meters

-lb in N.m. -lb fi N.m

10 1.13 10 13.56
20 2.26 20 27.12
30 3.39 30 40.68
40 4.52 40 54.24
50 5.65 50 67.80
100 11.30 60 81.36
150 16.95 70 94.92
200 22.60 80 108.48
250 28.25 90 122.04
300 33.90 100 135.60
350 39.55 110 149.16
400 45.20 120 162.72
450 50.85 130 176.18
500 56.50 140 189.84
550 62.15 150 203.40
600 67.80 160 216.96
650 73.45 170 230.52
700 79.10 180 244.08
750 84.75 190 257.64
800 90.40 200 271.20
850 96.05 210 284.76
900 101.70 220 298.32
950 107.32 230 311.88
1000 113.00 240 325.44

1 lb. in.=O.l1298 N.m 1 lb. ft.=1.3558 N.m

Recommended Tightening Torques for Bolt and Screw Joints

114 6 0.5 4
5116 8 1.5 11
318 10 2.0 15
l/2 12 5.0 36
518 16 10.0 72
314 20 15.0 110
1II 24 35.0 250
l-1/4 30 60.0 430

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CONVERSION FACTORS

To Convert From To Multiply By

bar Psig 14.5

C” F” (Co x 1.8) - 32

gam OZ/h 128

s/h 0Zl-h .03527

gfltWh oz/BHPh .0263

.!dm U.S. gal4000 cu. ft. .0091

J/l BHP/lOO cfm .0683

kg lb. 2.205

km lb/e 23.730

kg/h U.S. gal/h .32

kW BhP 1.341

1 gal (U.S.) .2642

l/s CftTl 2.119

l/s U.S. gal/min 15.85

m ft/ 3.281

m K/w btu/hiF”lft 5.678

m ft 35.3 15

mg/m odcu. ft. 1 x 10

mm. in. .0394

Nm lb. ft. .738

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STANDARD SPEED AND
SCR POTENTIOMETER ADJUSTMENTS

Speed Test Track

60 divided by Time - mph

Example:

60 divided by 10 seconds = 6 mph

60 divided by 18 seconds - 3.3 mph

Lift Speed Test

Mast Height Cinches) = Distance

12

Lift SDeed Time (seconds) = Time

60

D = Feet/min.
T

Example:

12 divided by 270 = .04

60 divided by 14 sec. = 4.2
4.2 divided by .04 = 105 ft./min.

A WARNING: All tests should be carried out in a safe area away from normal
operational traffic. Follow all plant safety regulations when performing
tests.

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GENERAL
SERVICE GUIDE

Symptom Possible Cause Remarks

Sluggish performance, erratic Battery discharged or defective Charge and inspect battery
switching, slow lift Loose connection (power Tighten connections
wiring) Replace the brushes
Motor brushes are worn See brake adjustments in
Brake is dragging Maintenance Section

Load Wheels are binding Check for clearance

Defective SCR control Refer to SCR manual and
Improper creep speed - SCR System is misadjusted schematic
improper acceleration in SCR See SCR manual and schematic
range
improper time delay on SCR
bypass or inadequate power

Fuses open Short circuit Inspect circuits

Overload Study duty cycle, reduce load
Defective fuse Replace fuse

No lit? (motor runs) Excessive load Check the load

Direction control O.K. Air lock Bleed the hydraulic cylinder
Check oil pressure - repair or
replace if necessary
Low oil supply Add oil
Plugged suction screen Clean screen, flush and refill the
reservoir
Valve is not operating Check the valve

No lift (motor does not run) Control wiring is open (pump Refer to SCR manual and
contactor does not energize) schematic
Power wiring is open (pump Refer to SCR manual and
contactor does energize) schematic

Slow lift Battery is discharged Charge the battery

Excess Load Check the load
Leaks in lift cylinder Tighten or replace cylinder
packing

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GENERAL
SERVICE GUIDE

Symptom Possible Cause Remarks

No lower Suction screen plugged Clean the screen, flush and refill
the reservoir
Worn pump/motor unit(s) Check oil pressure (rebuild or
replace)
One pump/motor unit inopera- Inspect and/or repair
Lowers excessively slow tive (only dual systems)

Control valve sticking Inspect and repair

Hydraulic systems leaks oil Mechanical binding Inspect Mast
Flow valve is defective Replace
Electric circuit See Schematic
Reservoir overflows
Flow valve is defective Clean or replace valve
Fast speed circuit defective Check switches, valves, etc.

Defective hose Replace the hose

Lit3 cylinder leaking Loose fittings Tighten

Overfilled Drain proper oil level

Insufficient lift
Air entering system Return tube in reservoir defec-
tive - Inspect and replace
Inner column sticks
Seals or *damaged Replace
Rod is&&aged Inspect and replace

Forks will not drop to lowered Low oil supply Check oil level - fill to proper
height level

No operation Binding in column Clean bearing surfaces on

rollers and columns
Defective roller(s) Replace roller(s)

Mechanical Binding Check for sprung frame

Check for bending or corrosion

Battery disconnected or dis- Connect and/or charge battery

charged
Control fuses blown Replace fuses
Power fuse blown Refer to SCR manual and
Open circuit or PMT trips schematic

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PWT MAINTENANCE SCHEDULE

Period Time Function

Daily
Check water level in battery.

Check oil level transmission.

Check all wheels and tires. Remove any and all tape,
plastic and material.

Check operation of truck steering and speed change

including all warning and safety devices (if equipped),
horn, speed limit switches and lights.

Check brake operation and stopping distance (approx.

twice the length of the truck, unloaded).

Weekly 100 Hours

Check speed of truck and plugging distance (PMCBCR
only).
* * Check brake linkage, adjust as necessary. Lubricate pivot
points, see lubrication chart (located in Service
Information Section).

Check entire truck for loose items, power and control

wiring, linkage, nuts and bolts.

Clean battery terminals of corrosion. Check electrolyte

level. Inspect plug and battery cables.

Clean and inspect motor brushes. Use only low pressure

air or vacuum.

Inspect contact tips.

Clean any and all dirt or corrosion from terminal area of

PMC Controller units.

30 Days 200 Hours

Check steerhead bearing for wear.

* Lubricate entire truck see lubrication chart (located in

Service Information Section, for type and points).

Check safety devices, horn, alarms (if equipped) and

slow speed adjustment. Repair or adjust before truck goes
back into operation.

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GENERAL INFORRXATION
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PWT MAINTENANCE SCHEDULE

Period Time Function

60 Days 300 Hours

NOTE NOTE Check current limit on only EV-1 and EV-100 SCR
trucks, adjust as needed.

Check entire truck frame and pivoting points for cracks

or worn bearings, repair or replace as needed.

Inspect brake drum and shoe lining and brake drum.

Check drive tire and torque bolts to 200 ft. lbs.

Clean drive motor and inspect commutator. Use only low

pressure air or vacuum.

Yearly 1000 Hours

Change transmission fluid (requires 3-314 pints refill).

Check amp draw readings of drive motors.

Repair or replace as necessary when inspection finds this part worn or damaged:

1. Drive motor brushes.

Springs should be replaced along with brushes.

2. Brake shoe lining.

Replace as an assembly.

3. Contact tips.

4. Load wheel.

- Always repack bearing whenever a wheel is changed. Remember the largest cause of load wheel
failure is material getting caught in wheel.

NOTE: Current limit should be checked whenever 200 amp fuse has failed, any EV-1 and
EV- 100 SCR panel part has been replaced or drive motor has been repaired or replaced.

* Trucks operating in freezer, wet or brine conditions must be serviced twice in the standard
maintenance period and special types of lubricants should be used.

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