CLARK FORKLIFT SM 643 PWDHWD 30-40SE SERVICE MANUAL

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CLARK FORKLIFT SM 643 PWDHWD 30 40SE SERVICE MANUAL – PDF DOWNLOAD

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CLARK FORKLIFT SM 643 PWDHWD 30 40SE SERVICE MANUAL – PDF DOWNLOAD

• Clark arranges parts and service procedures by standardized Groups. In this manual, Groups are similar to “chapters.” Groups are listed in the table of contents on the next page.
• Each Group begins with a table of contents that shows the Sections contained within the Group. Lengthy Sections also begin with a table of contents showing the topics contained within the Section.
• Each Group and Section has an identifying name and number, or “ID.” Each page also has a unique ID. The page ID consists of three numbers separated by hyphens. The three numbers represent the Group number, the Section number, and the page number.
• For example, “00-1-2” on the lower comer of the page indicates Group 00, Section 1, Page 2. You can quickly locate a specific point in the manual by using the headers and footers that appear on every Section page.
• The following illustration points out these areas. Group ID -f–j–t Group ID Section ID’ Manual ID ’ Section ID This manual is intended for the use of trained service personnel. Please read Group SA, “Safe Maintenance,” and the Operator’s Manual before working on or operating the truck.

Table Of Contents:

CLARK FORKLIFT SM 643 PWDHWD 30 40SE SERVICE MANUAL – PDF DOWNLOAD

SM-643 PWD/HWD 30-40SE....................................  1
Arrangement and Use of this Manual........................  2
Contents..................................................  3
PERIODIC SERVICE..........................................  4
	P.M. CHECK SHEET......................................  5
	Visual Inspection.....................................  6
	Operational Tests.....................................  9
	Maintenance Schedule.................................. 15
	“Planned Maintenance”................................. 16
		Determining Maintenance Intervals................. 16
		P.M. CHECK SHEET.................................. 17
		Visual Inspection................................. 18
		Operational Tests................................. 21
	PM Inspection Form.................................... 27
Group 12 Battery.......................................... 29
	BATTERY HANDLING...................................... 30
	Battery Cleaning...................................... 33
	Keeping Battery Records............................... 35
Group 14 Wiring Diagram................................... 37
	PWD Wiring Diagram.................................... 38
	HWD Wiring Diagram.................................... 41
Group 16 Electric Motor Service........................... 44
	Electric Motor Maintenance............................ 45
	Inspection Procedures................................. 45
	Drive Motor........................................... 49
		Disassembly....................................... 51
		CLEANING & INSPECTION............................. 52
		Commutator Undercutting........................... 53
		TESTING........................................... 54
		FRAME AND FIELD SERVICE NOTES..................... 55
		ASSEMBLY AND TESTING.............................. 56
Group 17 Line Contactor................................... 57
GROUP 19.................................................. 58
	Card Factory Settings................................. 59
	PWD Controller........................................ 60
		OVERVlEW.......................................... 61
		CONNECTIONS....................................... 63
		PROGRAMMABLE PARAMETERS........................... 70
		INSTALLATION CHECKOUT............................. 72
		BENCH TESTING WITH THE 1307 PROGRAMMER............ 74
		PROGRAMMER OPERATION.............................. 75
		DIAGNOSTICS AND TROUBLESHOOTING................... 84
			TROUBLESHOOTING CHART......................... 85
			LED DIAGNOSTICS............................... 86
		MAINTENANCE....................................... 87
	HWD Controller........................................ 89
		OVERVIEW.......................................... 89
		INSTALLATION AND WIRING........................... 92
			CONNECTIONS................................... 94
			CONTACTOR, SWITCHES, and OTHER HARDWARE.......101
		PROGRAMMABLE PARAMETERS...........................102
		INSTALLATION CHECKOUT.............................108
		PROGRAMMER OPERATION..............................110
			PROGRAMMER MENUS..............................116
			Special Program Menu..........................117
			Diagnostics and Special Diagnostics “Menu”....118
		DIAGNOSTICS AND TROUBLESHOOTING...................119
			TROUBLESHOOTING CHART.........................120
			LED DIAGNOSTICS...............................121
		MAINTENANCE.......................................122
Group 20 Drive Unit.......................................123
	Description...........................................123
	Removal...............................................124
	Specifications........................................132
	DISASSEMBLY...........................................134
	Cleaning and Inspection...............................139
	REASSEMBLY............................................140
	Adjustment Specifications.............................146
	Ring and Pinion End Play..............................148
	Installation..........................................151
Group 23 Drive Motor Brakes...............................161
	Description...........................................161
	Inspection............................................163
	Brake Installation....................................165
	Brake Linkage Installation............................166
	Brake Switch Adjustment...............................168
Group 23 Coast Control....................................170
Group 25 Caster Assembly..................................171
Group 28 HYDRAULIC SYSTEM.................................172
	HYDRAULIC UNIT........................................174
Group 34 Lift Cylinder....................................176
	Lift Cylinder Removal.................................177
	Block Lift Frame......................................177
	Disconnect Hoses......................................178
	Disconnect Lift Cylinder..............................178
	Disconnect Cylinder Base..............................179
	Disassembly...........................................179
	Inspection............................................179
	Reassembly............................................179
Group 35 Lift Linkage and Load Wheels.....................181
	OPERATIONAL CHECK.....................................182
	Pull Rod Adjustment Check.............................182
	Pull Rod Adjustment...................................183
	BUSHING IDENTIFICATION................................185
	LIFT LINKAGE REMOVAL..................................186
	Cleaning and Inspections..............................191
	Bushing Installation..................................192
	Dual Load Wheels......................................194
	Single Load Wheels....................................194
	Lift Linkage Installation.............................195
	Pallet Entry Skids....................................196
	Pallet Entry/Exit Rollers.............................196
Group 39 Sheet Metal......................................197
	PWD Standard Sheet Metal..............................198
	HWD Standard Sheet Metal..............................199
Group 40 Truck Specifications.............................200
	BATTERY...............................................201
	BRAKE.................................................202
	CURTIS 1242/1244......................................202
	ELECTRICAL............................................203
	Travel Speeds:........................................203
	HYDRAULIC SYSTEM......................................204
	Lifting Speeds:.......................................204
	TIRES.................................................204
	Truck Service Weights.................................205
	Torque Specifications.................................205

Please Note:

• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
• You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
• Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted

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