Clark TW125, TW235 EV1 Control Forklift Planned Maintenance and Adjustment Procedure Manual (PMA422)

Clark TW125, TW235 EV1 Control Forklift Planned Maintenance and Adjustment Procedure Manual (PMA422)

Clark TW125, TW235 EV1 Control Forklift Index:

page 8 VISUAL INSPECTION
pages 8 through 11 PM-CHECK SHEET
Pages 12 through 15 OPERATIONAL TESTS
page 16 BATTERY CHECKS
Pages 17 through 34 CLEANING, INSPECTION & LUBRICATION
pages 35 through 40 ELECTRICAL TESTS
Pages 41 through 49 PERIODIC ELECTRICAL TESTS
DESCRIPTION
LUBRICATION CHARTS – TW-235
LUBRICATION CHARTS – TW-125
BATTERY
PUMP MOTOR OPERATING SWITCH
SCR CONTROLLER (ACCELERATOR) 1MS & 2MS & Linkage Adjustments
DRIVE MOTOR (BRAKE) CUT-OFF SWITCH
ELECTRIC DRIVE MOTOR PARKING BRAKE CUT-OFF SWITCH
DRIVE MOTOR (STEER) CUT-OFF SWITCHES
ELECTRIC MOTOR MAINTENANCE
PM-PROCEDURES 48 FIELD WEAKENING PMT/SRO
17 P.S. Sec. 8, pages 1-2; Tools Sec. 13, Pages l-3; pump Sec. 14, Pages l-3; and
17 Interlocks Sec. 15, Paqes 1-2; FA & RB, RA & RB. lA-A Fr lA-B Sec. 17, Paqes 1-4
19 17 1 throuqh 10 CHECKING SCR COMPONENTS WITH VOLT OHM METER
SCHEMATIC BREAKDOWN – TW-125
SCHEMATIC BREAKDOWN – TW-235
SCR SYSTEMS TROUBLE SHOOTING GUIDE
CHECKING BATTERY POLARITY & VOLTAGE CHECKING TRUCK POLARITY
CHECKING EV-1 COMPONENTS
DRIVE UNIT
WHEELS G TIRES (PNEUMATIC)
SAFETY TIPS (RIMS AND WHEELS)
SAFETY TIPS (RIMS AND WHEELS)
WHEELS/TIRES (SOLID & CUSHION)
BRAKE PEDAL FREE TRAVEL CHECK & ADJUSTMENT
BRAKE BLEEDING PROCEDURE
PARKING/SERVICE BRAKES
STEERING ADJUSTMENTS – TW-125
POWER STEERING – TW-23.5
STEER FORK BEARINGS
STEER WHEEL BEARINGS
STEER SYSTEM HYDRAULIC PRESSURE CHECKS
HYDRAULIC SUMP TANK & FILTER
HYDRAULIC SYSTEM PRESSURE CHECKS
HYDRAULIC SYSTEM SCHEMATIC
HYDRAULIC ACCUMULATOR CHARGING PROCEDURES
TILT CYLINDER DRIFT TEST
TILT CYLINDER ADJUSTMENT
4 AND 6 ROLLER CARRIAGE CHECK AND ADJUSTMENTS
UPRIGHT ROLLER CHECK & ADJUSTMENTS
UPRIGHT LIFT CHAIN CHECK & ADJUSTMENT PROCEDURE
BLEEDING COMPOUND LIFT CYLINDERS
UPRIGHT DOWNDRIFT TEST
FULL FREE LIFT TRIPLE STAGE UPRIGHTS EQUIPPED WITH 6-ROLLER
CARRIAGES USED ON TRUCKS RATED FROM 2,000 THROUGH 12,000
LBS CAPACITY UPRIGHTS BEGINNING WITH “M” DECK NUMBERS
FULL FREE LIFT TRIPLE STAGE UPRIGHTS EQUIPPED WITH 6-ROLLER
CARRIAGES USED ON TRUCKS RATED FROM 2,000 THROUGH 12,000
LBS CAPACITY UPRIGHTS BEGINNING WITH “M” DECK NUMBERS
PM-INSPECTION & DRIVERS DAILY INSPECTION FORMS
PM-SAFETY AND PM-CAUTIONS
LUBRICATION SPECIFICATIONS & RECOMMENDATIONS d CHART KEY
TRUCK SPECIFICATIONS
DECALS, NAME PLATES & UPRIGHT DECK NUMBER & SERIAL NUMBERS
SUGGESTED EQUIPMENT FOR ELECTRIC TRUCK P.M.
MEASURING VOLTAGES WITH THE VOLT-OHM METER (V-O-M)
MEASURING RESISTANCE WITH THE VOLT-OHM METER (V-O-M)

REF. ITEM
NUMBERS
1, UPRIGHT –
GROUP
Standard & Hi-Lo Carriage Rollers Check & Adjustments 34
Standard & Hi-Lo Rollers 34
Lift Chains 34
Bleeding Compound Lift Cylinders 34
Downdr ift Test 34
Full Free Lift Triple Stage Operational Checks & 34
Adjustments, Carriage Chain Adjustments, Load Testing,
Lift Cylinder & Tilt Cylinder Drift Tests &
Carriage Roller Check & Adjustments
Full Free Lift Triple Stage Roller 34

Clark