PDF Planned Maintenance Manual Clark PMA 540 Forklift - 3 MB
This Planned Maintenance and Adjustment Manual is specifically for the Clark PMA 540 Forklift series, starting with serial number 540 5001.
It outlines the crucial steps for preventative care and precise adjustments to maintain optimal safety and efficiency.
Using this guide will help you schedule and perform regular checks, preventing costly breakdowns.
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--- Page 1 ---
PMA 540
Parts
Book db
RUBBER TIRED LOADER
SERIAL NUMBERS 540 -5001 a”dw
ik DRESSER@
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
--- Page 3 ---
Cl!‘!‘RK GROUP
14
GROUP
14
SECTION
1
ELECTRICAL SYSTEM
WIRING DIAGRAMS
Code: PMA-540, NOV 85 Copyrighted Material GROUP 14, Section 1, Page 1
Intended for CLARK dealers only
Do not sell or distribute
--- Page 4 ---
CLSRK GROUP
16
Brush and Comutator Inspection
Remove brush cover(s) and remove the 7 Check the tension on the brush
brushes from the brush holders. Clean springs. Spring pressure (load) on
the brushes and holders. Check the all brushes must be equal. Refer to
brush holders for damage. brush spring tension check below.
Inspect the condition of the brushes. 8 Check brush shunt for good contact
Remove each brush from the brush holder with brush holder. Be sure shunt is
and inspect the brushes and commutator not damaged or burned, since this may
for worn condition and uneven wear, cause brush spring to carry current
burning, electrical arcing, etc. The and lose tension.
brushes should be worn evenly. Refer
to brush inspection chart, page 6. 9 If brushes do not need to be
replaced, and commutator is in good
Clean the commutator surface. condition, install the brushes and
Wipe the commutator with a dry, lint- brush springs into brush holders. Be
free cloth. DO NOT USE LUBRICANT sure brush spring is correctly in
OR SOLVENT ON THE COMMUTATOR. place on the brush and that brush
slides freely in brush box.
Check appearance of commutator surface
where the brushes ride. Inspect the 10 Clean and check brush box and
commutator bars for burned, damaged, connector screws, as applicable.
or raised areas. The best signs of Tighten if loose. Be sure the
good commutation are a dark brown- brush shunt connection is tight.
colored, highly-polished commutator and Install brush cover on motor case.
uniform glossy brush-wearing surfaces.
11 Check and tighten all motor bolts.
Refer to the COMMUTATOR CHECK CHART at
Check the lower nut on each terminal
the end of this section.
post. It should be installed finger-
tight, then tighten another l/4-turn
Measure and make a record of brush
with a wrench.
length at each inspection. The record
will verify the amount of brush wear
Measuring Brush Spring Tension
and indicate if there is enough brush
length remaining until the next Put a piece of paper between the
scheduled inspection. brush and commutator.
Use a spring scale with its hook or
Brushes must be replaced when worn to
an adapter fitted around the spring
approximately half their original
between the brush and spring, at the
length.
point where the spring presses on
BRUSHES MUST BE REPLACED WHEN WORN TO the brush.
DIMENSION NOTED IN TRUCK SPECIFICA-
Pull the scale to lift the brush
TION. REFER TO GROUP 40, SECTION 5.
spring until the paper under the
brush can be moved freely in the
IMPORTANT
direction of rotation of the
NEW BRUSHES MUST BE THE SAME SIZE motor. Measure the tension.
AND GRADE (MATERIAL SPECIFICATION)
Replace the spring if the tension
AS THE OLD BRUSHES.
is too weak (does not meet the
Observe how brushes are assembled in spring tension specification).
the brush holders, and position of Refer to GROUP 40, Section 5.
brush lead (brush shunt). New brushes
must be installed in same manner.
Code: PMA-540, NOV 85 Copyrighted Material GROUP 16, Section 1, Page 5
Intended for CLARK dealers only
Do not sell or distribute
--- Page 5 ---
CLARK GROUP
16
STEER PUMP AND MOTOR REMOVAL FROM TRUCK
NOTICE - Inspection of the steer pump motor
requires removal of the sump filter mounting
bracket, disconnection of the hydraulic lines
from pump, and removal of the motor from its
mounting on the front battery plate.
1 Adjust front battery plate for maintenance
access. (Refer to GROUP 38, Section 2.)
85M861
2 Loosen and remove the nuts from the mounting
bolts, then remove hydraulic oil filter
mounting bracket from the battery plate.
85M707
3 Put the bracket, with hydraulic lines and
filter attached, aside out of the way.
85M682
4 Loosen the clamp and remove intake hose
from pump.
85M695
Code: PMA-540, NOV 85
Copyrighted Material GROUP 16, Section 4, Page 3
Intended for CLARK dealers only
Do not sell or distribute
--- Page 6 ---
GROUP
17
Steer Axle Trunnion Switch Adjustment
Step 1: Open the battery compartment cover.
NOTICE - Access to the switches will
be made much easier when the battery is
removed from truck.
85M616
Step 2: Turn the steer axle wheel to the
straight-ahead pos ition.
(Shown in partia lly-turned position.)
Refer to illustrations, Pages 2 and 4.
85M774
Step 3: For centering of the SW itches over
the cam plate on axle, loosen the mounting
screws and 1) adjust the L-shaped bar (13.489)
at its attachment to the contactor panel,
and/or 2) the switch bracket (65.476) at its
attachment to the L-bar. Tighten mounting
screws.
26534
Step 4: For correct height of switch
rollers to contact cam plate, loosen mounting
screws and adjust the hinged switch bracket
assembly (13.684 and 13.192) vertically at
its attachment to mounting bracket (65;476)
on L-bar.
26535
Code: PMA-540, NOV 85 Copyrighted Material GROUP 17, Section 4, Page 5
Intended for CLARK dealers only
Do not sell or distribute
--- Page 7 ---
CLARK GROUP
a9
ASSEMBLY COMPLETE
(Continued)
go.471
91.096
-17.341
17.538-i &,7.362
17.036 1
-m 17.015
--J&
*w
-i -2
7l
0
NOTE:
NON SERVICEABLE
ITEMS MARKED-N”
1N
I DA&ICI
,“I_ rMlYLL
19-583
7.000 PANEL ASSEMBLY, ELECTRIC TRUCK CONTROL (CONT'D) 65.304 CONTACTOR ASSEMBLY, FORWARD & REVERSE LH
4.294 FUSE, POWER STEERING CIRCUIT 90.059 LOCKWASHER, POWER FUSE FASTENER
7.015 CONTACTOR ASSEMBLY, FORWARD 6 REVERSE RH 90.076 LOCKWASHER, RJD 6 REV CONTACTOR FASTENER
7.029 CONDUCTOR, CONTROL PANEL FWD 6 REV CONTACTOR 90.193 LOCKWASHER, FWD 6 REV CONTACTOR DIODE FASTENER
7.032 CAPSCREW, CONTACTOR PANEL POWER FUSE MOUNTING 90.194 WASHER, RJD 6 REV CONTACTOR DIODE FASTENER
7.033 CONTACTOR ASSEMBLY. POWER STEERING PUMP 90.471 LOCKWASHER, POWER FUSE FASTENER
7.035 FASTENER, CONTACTOR PANEL PWR STRG PUMP CONTACTOR 91.096 WASHER, MAIN FUSE MOUNTING FASTENER
7.036 CONDUCTOR, CONTACTOR PANEL PWR STRG PUMP CONTACTOR 91.483 NUT, CONTACTOR.PANEL POWER FUSE MOUNTING FAST
7.041 FUSE, POWER 91.852 LOCKWASHER, CONTACTOR PANEL POWER FUSE MTG BLOCK
7.269 DIODE, FORWARD 6 REVERSE CONTACTOR 91.862 LOCKWASHER. POWER STRG PUMP CONTACTOR MTG FAST
r.362 BLOCK, MAIN FUSE MOUNTING 91.992 WASHER, CONTACTOR PANEL POWER FUSE MOUNTING FAST
7.411 STUD, CONTACTOR PANEL POWER FUSE MOUNTING BLCCK 92.532 CAPSCREW, CONTACTOR PANEL PWR STRG CIRCUIT FUSE
7.530 FASTENER, FORWARD & REVERSE CONTACTOR DIODE 92.533 WASHER,CONTACTOR PANEL PWR STRG CIRCUIT FUSE FAS
3.215 WIRING HARNESS, CONTACTOR PANEL 93.093 FASTENER, FORWARD & REVERSE CONTACTOR BASE
3.449 CAPSCREW, FORWARD 6 REVERSE CONTACTOR ASSEMBLY 93.094 LOCKWASHER, FWD 6 REV CONTACTOR BASE FASTENER
3.496 BASE, FORWARD 6 REVERSE CONTACTOR 93.334 FASTENER, POWER STEERING CONTACTOR
i.082 LOCKWASHER, PWR STRG CIRCUIT FUSE CONN COND FAST 93.335 LOCKWASHER, POWER STEERING CONTACTOR BRKT FAST
5.373 BRACKET, POWER STEERING CONTACTOR MOUNTING 1N BASE, CONTACTOR PANEL
Code: PMA-540, NOV 85 Copyrighted Material GROUP 19, Section 1, Page 9
Intended for CLARK dealers only
Do not sell or distribute
--- Page 8 ---
Cl!!RK GROUP
19
m
800%
AVEIIAGE
be reversed (short OFF time, long ON
time}. This variation of ON and OFF
- - - CUnnL*l
time of the oscillator produces the
c
t 50%
optimum frequencies through the SCR
E range. The frequency curve of the
z oscillator is shown in Figure 25469.
ON OFT ON oft ON OFF
25468
The time for the next ON and OFF
cycle to start is determined by the time
that the control card takes to oscil-
late. This frequency of oscillation is
controlled by the counter circuit in the
accelerator and automatic circuitry in
the card. Slow speed is obtained by
having maximum volts in the accelera-
tor. As the voltage in the accelerator
decreases, the speed of the motor 25469
increases. The SCR circuit is capable
of delivering approximately 95% speed. The rate at which the oscillator may
For full speed operation, the 1A con- increase its % ON time is limited by
tactor is closed to apply full battery "Controlled Acceleration". The minimum
voltage across the motor. time required to go from creep speed to
80-85% ON time point may be varied by
Control Features trimpot (C/A) on the card, adjustable
from approximately 0.5 seconds to
l Oscillator - the oscillator section 3.5-4.5 seconds.
of the card has two adjustable features
and one fixed feature. With the accel- l Current Limit - This circuit
erator counter circuit at maximum volts, monitors motor current by utilizing a
the creep speed can be adjusted by the sensor in series with the armature. The
"creep" trimpot on the card. Top speed information detected across the sensor
is fixed by card design, and is obtained is fed back to the card so current ma.y
with the accelerator counter circuit at be limited to preset value. If heavy-
minimum volts. The XON time has a range load currents are de t ected, this circuit
of approximately 5 to 95 percent. The overrides oscillator and limits the
center operating condition of the os- average current to a value set by the
cillator is at 50 percent ON time with a C/L adjustment pot. The C/L setting is
nominal 1.8 milliseconds ON time and 1.8 based on the maximum thermal rating of
milliseconds OFF time. This corresponds 1REC and the peak vo tage on the
to a maximum operating frequency of capacitor. Because of the flyback
about 300 hertz. At creep, the ON time current through 3REC, the motor current
will decrease to approximately 0.8 usually runs 2 to 3 times battery
milliseconds while OFF time will become current. The current limit is set with
in the order of 20 milliseconds. At the "C/L" trimpot on the card.
full SCR operation, this condition will
Copyrighted Material
Code: PMA-540, NOV 85 Intended for CLARK dealers only GROUP 19, Section 4, Page 3
Do not sell or distribute
--- Page 9 ---
GROUP CMRU
19
CONTROL (OSCILLATOR) CARD REMOVAL
Screw Terminals
Plugs z Plug
1 thru 6
/
Mounting'
Screw Mounting
Screw
SCR PANEL
IMPORTANT
TO PREVENT DAMAGE TO PLUG AND LOCKING'TABS,
ALWAYS REMOVE A, B AND Z PLUGS BY PRESSING
DOWN ON CENTER TAB OF PLUG WITH A WIDE-BLADE
SCREWDRIVER, THEN ROTATE SCREWDRIVER 90°
(WHILE PRESSING DOWN) TO PRY (JACK) THE PLUG
OUT OF ITS SOCKET. WHEN INSTALLING PLUGS,
BE SURE PLUGS ARE PRESSED COMPLETELY INTO
SOCKET AND LOCKING TAB POSIT VELY ENGAGED.
I
J I
26533
GROUP 19, Section 7, Page 2 Copyrighted Material
Code: PMA-540, NOV 85
Intended for CLARK dealers only
Do not sell or distribute
--- Page 10 ---
GROUP Cl!!RK
19
EV-100 SCR CONTROL
LIFT PUMP AND 1A CONTACTORS
(Refer to GROUP 19, Section 1, for additional information.)
17.222 -8
PUMP @2
CONTROL PAN EL 19-582
Copyrighted Material
GROUP 19, Section 8, Page 2 Intended for CLARK dealers only Code: PMA-540, NOV 85
Do not sell or distribute
--- Page 11 ---
GROUP
19
.581
17.033 CONTACTOR ASSEMBLY. POWER STEERING
go.080
17.230 COIL, POWER STEERING CONTACTOR --
17.240 CONTACT SET, POWER STEERING CONTACTOR
17.243 SEAT, POWER STEERING MOVABLE CONTACT SPRING
17.244 SPRING, POWER STEERING CONTACTOR MOVABLE CONT
19.899 ARMATURE, POWER STEERING CONTACTOR
65.052 INSULATOR, P/S CONTACTOR STAT CONTACT SUPPORT
90.080 LOCKWASHER, POWER STEERING CONTACTOR FASTENER
91.539 LOCKWASHER, PWR STRG CONTACTOR CONDUCTOR FAST
17.2’10
91.581 SCREW, POWER STRG STAT CONTACT SUPP INSULATOR
93.145 NUT, POWER STEERING CONTACTOR CONDUCTOR
93.146 NUT, POWER STEERING PUMP CONTACTOR
- lg.899
POWER STEERING PUMP CONTACTOR
19-168
17.230
CONTACT SET
POWER STEERINQ
CONTACTOR
Copyrighted Material
Code: PMA-540, NOV 85 Intended for CLARK dealers only GROUP 19, Section 9, Page 5
Do not sell or distribute
--- Page 12 ---
GROUP
20
DRIVE AXLE FLUID CHANGE
NOTICE
It is recommended to:
Frequent changes of lubricant is
l Drain and replace the drive axle an inexpensive way to protect and
fluid every 1000 operating hours. prolong the safe operating life of
an essential and relatively costly
major component such as the drive
axle.
Extending the recommended intervals
at which drive axle fluid is change
should be considered only after
careful evaluation of your oper-
ating conditions and/or analysis
To change oil in the drive axle: of the condition of the oil.
l The oil should be drained when it
is warmed to operating temperature.
l Put the truck in a level position.
l Apply the parking brake and block
the wheels to prevent the truck
from moving.
l Turn key switch "OFF" and disconnect
battery from truck receptacle.
NOTE - When suitable equipment is
available, the truck may be raised Refer to
or hoisted up and placed in a level GROUP 38, Section 3,
position on wheel cradles to allow Machine Jacking and
access under the axle. Otherwise, Blocking.
raise the fork carriage only high
enough to provide access clearance
to the axle. Please refer to pro-
cedure described above in "Access
To The Drive Axle", page 2.
Copyrighted Material
GROUP 20, Section 1, Page ci Intended for CLARK dealers only Code: PMA-540, NOV 85
Do not sell or distribute
--- Page 13 ---
CLERK GROUP
22
SAFETY
CAGE
AIR
GAUGE
--
RELIEF
////r--
Y/f
E/_\
SHUTOFF \\ I I I II,\
VALVE
SOURCE
OF AIR
SUPPLY
Fig. 9702 Typical Tire Filling Procedure
Filling Tires With Air 3. At intervals, close the control
valve and check the pressure in the
All wheel and tire assemblies must be tire by reading the gauge. Do not
filled in a safety cage. The airhose put too much pressure into the tire.
and components should be arranged as
shown in Fig. 9702. The hose must 4. Continue to fill the tire to the
have an adapter that can be connected correct caoacity.
to the valve stem.
I M PO RT Ai'lT
1. Attach an air hose to valve stem.
2. Open the control valve which will PUT EQUAL AIR PRESSURE IN BOTH
let compressed air into the tire. TIRES OF A DUAL ASSEMBLY. DO
NOT PUT AIR INTO A TIRE THAT IS
FLAT WITHOUT FIRST INSPECTING
IT AND THE WHEEL FOR DArqAGE.
Copyrighted Material
Code: PMA-270, REV FEB 84 Intended for CLARK dealers only Section 1, Page 9
Do not sell or distribute
--- Page 14 ---
CLflRl4 GROUP
23
BRAKE BLEEDING PROCEDURE
NOTICE - The service brake system on this truck model uses conventional
SAE/DOT 3 heavy duty automotive hydraulic brake fluid only.
Normally a minimum of brake bleeding will be required. The brake system is
designed to place the master cylinder reservoir at the highest point in the
circuit. This ensures that the major part of any air that has entered the
system will flow upwards and vent into the reservoir. The recommended
brake bleeding procedure outlined below is intended to dislodge and remove
any entrapped air from the circuit.
IMPORTANT - Service brake pedal free play must be correctly adjusted
before bleeding brakes.
Check frequently and keep master cylinder reservoir filled during bleeding.
Refer to Page 7 for illustration of brake lines installation.
1 Iiemove floorboard.
NOTICE - More space will be available
if brake bleeding is performed when
battery is removed and front battery
plate is adjusted for service access.
Refer to GROUP 38, Section 2,
Front Battery Plate Adjustment.
‘,
85M506
2 Remove access cover from pylon.
85M510
Copyrighted Material
Code: PMA-540, NOV 85 Intended for CLARK dealers only GROUP 23, Section 3, Page 3
Do not sell or distribute
--- Page 16 ---
cL!ww GROUP
26
GROUP
26
SECTION
1
STEER AXLE TRUNNION BEARINGS
CHECK AND ADJUSTMENT
To perform this service procedure, it is
recommended that you first:
l Park the truck on a level surface and
fully lower the upright.
l Return all controls to neutral, and turn
key switch to the "OFF" position.
l Apply the parking brake.
l Lift and block the truck up to raise the
steer axle wheel off the floor.
Refer to GROUP 38, Section 3, Machine
Jacking and Blocking.
85M775
Copyrighted Material
Code: PMA-540, NOV 85 Intended for CLARK dealers only GROUP 26, Section 1, Page 1
Do not sell or distribute
--- Page 17 ---
GROUP
26
STEER WHEEL BEARING MAINTENANCE
1 Be sure that truck is parked and blocked up
correctly to raise the steer wheel off the
floor. NOTE - It is optional to raise and
block up entire truck.
See CAUTION, Page 1.
Refer to PM section, Page 6.9, for addi-
tional steer axle inspection notes.
26520
2 To check the steer wheel bearings for exces-
sive free play or looseness, hold the wheel
with both hands and try to move it by a rock-
ing motion from side to side. Also, try to
pull it in and out along the wheel spindle.
There should be a small amount of free move-
ment. The maximum allowable end play is
[0,08 mm] -003 inch. If the wheel has
excessive end play, the bearings require
additional service and/or adjustment.
85M747
Steer Wheel Bearing Adjustment
The steer wheel bearings are retained and
adjusted by a self-locking bearing nut.
Step 1: Remove hubcap by tapping lightly
on the outer edge of hubcap. (Reference
Figure 85M883, shown here with wheel
removed).
85M883
Step 2: Loosen spindle (bearing adjusting)
nut.
NOTICE - After spindle nut is loosened, hit
the top of wheel (tire) to loosen (unseat)
the bearings. This moves the bearings free
of their seated, running position.
IMPORTANT - Spindle nut should be replaced
with a new one each time it is removed because
holding torque capability is partially 85M892
destroyed with each removal.
Code: PMA-540, NOV 85 Copyrighted Material GROUP 26, Section 2, Page 3
Intended for CLARK dealers only
Do not sell or distribute
--- Page 18 ---
GROUP
26
13 When the relief pressure reading has been
obtained:
14 Turn key switch "OFF".
15 Move direction control lever to neutral.
16 Apply parking brake.
17 Disconnect pressure gauge, remove the
temporary Tee fitting, and install elbow
and steer line as initially installed.
Be sure to correctly tighten all fittings.
85M635
18 Install access cover on pylon.
20283
19 Remove blocking from under the upright.
NOTICE - If steering system relief pressure
setting is not correct, refer to Overhaul Manual
OH-540, for correct maintenance procedures.
Copyrighted Material
GROUP 26, Section 3, Page 4 Intended for CLARK dealers only Code: PMA-540, NOV 85
Do not sell or distribute
--- Page 19 ---
GROUP
29
3 Remove the snap-on cap and connect a suit-
able drain hose line to the diagnostic
check port fitting located on side of main
hydraulic valve. NOTE - Use quick-disconnect
adapter fitting, Clark Part No. 3797029.
85M552
4 You will need a drain pan of [9.8-17 L]
'2.6-4.5 gal minimum capacity, or other method
of disposal, for collecting the used oil.
Be sure the outlet end of the drain
line is directed into the drain pan
and held from moving when pressurized.
NOTICE - If battery is removed, use an
adapter cable connected between battery
and truck receptacle to power hydraulic
system.
5 Turn key switch to "ON" position.