Format: PDF (Printable Document)
File Language: English
File Pages: 353
File Size: 49.64 MB (Speed Download Link)
Brand: Clark
Model: EC500 20, 25, S30 E-R Control Forklift
Book No: PMA386
Type of Document: Planned Maintenance and Adjustment Procedure Manual
$ 40
These Clark EC500 and S30 electric forklifts spend their lives loading pallets in warehouses, docks, and tight indoor aisles, so when they act up, downtime hurts fast. This planned maintenance and adjustment manual helps you keep the truck predictable—you use it to set up and fine‑tune controls, then verify the systems are responding the way they should. For example, if the pump motor only kicks in intermittently when you hit the operating switch, this guide walks you through the checks and adjustments needed to trace whether you’ve got a switch issue, a control setting problem, or something further down the line.
Applications & Use Cases
FAQ
Q: Can I use this manual on a tablet in the shop?
A: Yes, it’s practical to keep it open on a tablet so you can zoom in on diagrams and follow steps right next to the truck.
Q: Is it worth printing sections of this manual?
A: Many techs print the few procedures they use often, mark notes on them, and keep them in a binder on the service cart.
Safety Note
Always lock out the truck and verify all controls are disabled before reaching into any electrical or hydraulic area.
Pump Motor Operating Switch Check & Adjustment Procedures
Tilt Cylinder Check & Adjustment Procedures
Hydraulic Sump Tank – Fill
Hydraulic Sump Tank Filter Service Procedures
Hydraulic Sump Tank – Drain
Electric Truck Battery Service Procedures – Remove/Replace
Hydraulic System Pressure Checks – Main Hydraulic Pump
Hydraulic Lift and Tilt Lines
Electric Motor Maintenance, PUMP – Commutator Check Chart
Seat Brake Linkage Check & Adjustment Procedures
Electric Motor Maintenance, DRIVE (TRACTION)
Drive (Traction) Motor Brush Remove and Replace
Drive (Traction) Motor Remove and Replace
Drive (Traction) Motor Brake Drum Remove and Replace
Contactor Check & Adjustment Procedures (1A, Pump, For & Rev)
Recommended Tools for Contactor Check & Adjustments
SCR CARDS – SCB / SRN and FW (trucks so equipped)
Steer Gear, Linkage & Axle Check & Adjustment Procedures
Steer Wheel Bearings Clean, Repack and Adjust
Lubrication Charts and Cold Storage Lubrication Charts
Steer Gear Adjustment Procedures
Accumulator Charging Procedures
Upright Carriage Roller Check & Adjustment Procedures
Upright Roller Check & Adjustment Procedures
Upright Compound Cylinder Bleeding Procedures
Upright Downdrift Test
Upright Lift Chain Check & Adjustment Procedures
Hydraulic Sump Tank Breather – Refer to PM-Procedures on
Service Brakes – Pedal Free Travel – Master Cylinder By-Pass
Bleeding the Brake System
Lift Cylinder Service Procedures
SCR Control (Accelerator Linkage, IMS & 2MS)
Electric Drive Motor (BRAKE) Cut-Off Switch
Service Brakes
Axle End Service Procedure
Electric Drive Motor (SEAT BRAKE) Cut-Off Switch
SCR CONTROL: Battery Polarity Voltage and Truck Polarity
SCR Electric Operating Sequence – System Schematic
SCR CONTROL: Supplement
– General Characteristics of the System
– Components used in the Control System
– Circuit Operation
– System Components
– General Maintenance Instructions
– TROUBLE SHOOTING INSTRUCTIONS
– Checking SCR Components Individually
– Installation and Removal of Components
Wheels & Tires – Solid or Cushion Tire Maintenance
SPECIFICATIONS AND REFERENCE DATA
PM-Inspection & Drivers Daily Inspection Forms
PM-Safety and PM-Cautions
SAFETY INSTRUCTIONS for maintaining industrial trucks
Lubrication Specifications & Recommendations / Lube Chart Key
EC500-E235 TRUCKS SPECIFICATIONS
Name Plates, Upright Deck Number and Truck Serial Number Data
Measuring Voltages with the Volt-Ohm Meter
Measuring Resistance with the Volt-Ohm Meter
Suggested Equipment for Electric Truck P.M.
Ammeter Hook-Up Methods
Hoist Chain Data
Table of Weights (in pounds)
P.M. PROCEDURES:
– P.M. Check Sheet
– Visual Inspection
– Operational Tests
– Cleaning, Inspection and Lubrication
– Electrical Tests
– Periodic Electrical Tests
