CLARK FORKLIFT SM 646 EC 90120 SERVICE MANUAL

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CLARK FORKLIFT SM 646 EC 90120 SERVICE MANUAL – PDF DOWNLOAD

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CLARK FORKLIFT SM 646 EC 90120 SERVICE MANUAL – PDF DOWNLOAD

• Before starting to drive truck: a. Be in operating position with seat belt fastened. b . Be sure parking brake is engaged. c. Put direction control in neutral. d . Start engine. e. Check functioning of direction and speed controls, steering, brakes, warning devices, and any load handling attachments. Before leaving truck a. Stop truck. b . Put directional control in neutral.
• c. Apply the parking brake. d . Stop the engine by turning off the key switch. e. Put upright in vertical position and fully lower the forks or attachment. f . Put blocks at the wheels if truck is on an incline. Brakes, steering mechanisms, control mechanisms, warning devices, lights, governors, guards, safety devices, and frame members must be carefully and regularly inspected and maintained in a safe operating condition.
• Special trucks or devices designed and approved for hazardous area operation must receive special attention to ensure that maintenance preserves the original, approved, safe-operating features. Fuel systems must be checked for leaks and condition of parts. Extra special consideration must be given in the case of a leak in the fuel system. Action must be taken to prevent the use of the truck until the leak has been corrected. The truck manufacturer’s capacity, operation, and maintenance instruction plates, tags, or decals must be maintained in legible condition.
• Batteries, motors, controllers, limit switches, protective devices, electrical conductors, and connections must be inspected and maintained in conformance with good practice. Special attention must be paid to the condition of electrical insulation. 17. To avoid injury to personnel or damage to the equipment, consult the manufacturer’s procedures in replacing contacts on any battery connection.
• 18. Industrial trucks must be kept in a clean condition to minimize fire hazards and help in the detection of loose 19. 20. 21. or defective parts. Modifications and additions that affect capacity and safe truck operation must not be done without the manufacturer’s prior written approval. Capacity, operation and maintenance instruction plates, tags, or decals must be changed accordingly.
• This is an OSHA requirement. Care must be taken to assure that all replacement parts, including tires, are interchangeable with the original parts and of a quality at least equal to that provided in the original equipment. Parts, including tires, are to be installed per the manufacturer’s procedures. Always use genuine CLARK or CLARK-approved parts. Use special care when removing heavy components from the truck, such as counterweight, seat deck, upright, etc. Be sure that lifting and handling equipment is of the correct capacity and in good condition. Also, this removal may upset the stability of the truck. The frame must always be safely blocked for major component removal.

Table Of Contents:

CLARK FORKLIFT SM 646 EC 90120 SERVICE MANUAL – PDF DOWNLOAD

SAFE MAINTENANCE
1. Safety
2. Lifting, Jacking, and Blocking
3. Towing
PS PERIODIC SERVICE
1. Maintenance Schedule
2. Planned Maintenance
3. PM Inspection Form
12 BATTERY
I. Battery Service
13 WIRING, SWITCHES, AND INSTRUMENTS
1. Electrical Diagrams
2. General Electrical Service Tips
3. Switches and Sensors
4. Instrument Panel
16 ELECTRIC MOTORS
1. Specifications and Description
2. Inspection and Troubleshooting
3. Drive Motor Overhaul
4. Lift Pump Motors Overhaul
5. Steer Pump Motor Overhaul
19
20
22
MOTOR CONTROLS
1. Specifications and Description
2. Maintenance and Checks
3. Control Panel Removal and Replacement
4. Contactors Overhaul
5. EV-200 LX Handset Operation Supplement
6. EV-288 LX Status Codes Supplement
DRIVE AXLE
I. Specifications and Description
2. Troubleshooting
3. Removal and Installation
4. Overhaul General Practices
5. Drive Axle Ends Overhaul
6. Differential Adaptor Overhaul
7. Differential Overhaul
WHEELS AND TIRES
1. Specifications and Description
2. Cushion Wheels 81 Tires
23 BRAKE SYSTEM
I. Specifications and Description
2. Service Brake Troubleshooting
3. Pedal and Linkage Adjustment
4. Brake System Bleeding
5. Master Cylinder Service
6. Service Brake Overhaul
7. Seat Brake Service
25126 STEER SYSTEM
1. Specifications and Description
2. Troubleshooting
3. Relief Pressure Check and Adjustment
4. Column Removal and Replacement
5. Steering Gear Overhaul
6. Steer Pump Overhaul
7. Steer Axle Service
6. Steer Cylinder Overhaul
29/30 MAIN HYDRAULIC SYSTEM
32 TILT CYLINDERS
1. Specifications and Description
2. Checks and Adjustments
3. Mounting and Overhaul
4. Tilt Lock Valve
34 UPRIGHTS
1. Upright Removal and Replacement
2. Lift Chain Inspection and Service Guidelines
38 COUNTERWEIGHT AND CHASSIS
1. Counterweight Removal and Installation
2. Overhead Guard Removal and Installation
3. Seat and Sheet Metal R&R
40 SPECIFICATIONS
1. Nameplate and Decals
2. General Specifications
3. Hydraulic Fitting Tightening Procedure
I. Specifications and Description
2. Fluids and Filters
3. Troubleshooting
4. Pressure Checks and Adjustments
5. Main Pumps Overhaul
6. Main Control Valve Removal and Overhaul
SM 646, Feb ‘99 Contents

Please Note:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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