Clark NPR-345, NPR-17, NPR-20 Forklift Service Manual
491 pages · Publication SM-587
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- Models
- NPR-345, NPR-17, NPR-20
- Manual type
- Service Manual
- Pages
- 491
- Publication
- SM-587
- Condition
- Brand new
What's inside
From the manual's own table of contents: 50 sections, 299 entries. See sample pages (PDF, 310 KB)
Title Page
Pictorial Index #1
Index 1 of 2 Pictorial Index
Pictorial Index #2
Cautions
Foreword
Planned Maintenance Procedures13 topics
- P.M. CHECK SHEET
- Visual Inspection
- Operational Tests
- CLEANING
- Adiusting for Lining Wear When to Replace Brake Linings
- Checks 81 Minor Adjustments
- Upright Lift Chains
- Chain Lubrication
- Lift Chain Adjustment
- Carriage Chains
- Carriage Stop - to - Upright Stop
- Adjusting For Brake Lining Wear
- Every 1,000 Operating Hours
01 - 1 Lubrication Chart & Illustrations16 topics
- Lubrication Chart Key
- Every P.M. (250 operating hours maximum) Corrosion Protection
- COLD STORAGE LUBRICATION
- WARNING
- BATTERY HANDLING
- Battery Removal
- Battery Vents
- Battery Cleaning
- Battery Charging
- Battery Electrolyte
- Clean Battery Compartment
- Install Battery
- KEEPING BATTERY RECORDS
- These records should contain
- BATTERlES
- HOW TO GET MAXIMUM LIFE OUT OF YOUR BATTERY
13 - 1 Multi-Function Control Handle Switches3 topics
- REACH, TILT AND AUXILIARY
- UP (LIFT) AND DOWN (LOWER)
- TRANSDUCER, FORWARD AND SWITCHES
16 - 2 Electric Motors General20 topics
- Electric Motor Maintenance
- Inspection Procedures
- Motdr Cleanliness
- Motor Insulation
- TEST FOR MOTOR INSULATION "RESISTANCE TO GROUND" (Using a 500 Volt Megger)
- TEST FOR MOTOR INSULATION "RESISTANCE TO GROUND" (Using a Simpson Volt-Ohmeter)
- BRUSH AND COMMUTATOR INSPECTION
- Operating Conditions
- General Brush & Commutator Inspection
- Brush Inspection Chart
- GENERAL
- Disassembly
- Component Inspection & Trouble Shooting
- TESTING
- When changing brushes
- 24-Volt Motor Specifications
- 36-Volt Motor Specifications
- Brush Inspection Chart
- 24-Volt Pump Motor Specifications
- 36-Volt Pump Motor Specifications
16 - 7 Auxiliary/Steer Pump Motors 24 & 36 Volt4 topics
- TROUBLE SHOOTING PRIOR TO DISASSEMBLY
- MOTOR DISASSEMBLY
- 24-Volt Auxiliary/Steer Pump Motor Specifications
- 36-Volt Auxiliary/Steer Pump Motor Specifications
17 - 17 Contactors6 topics
- Forward I Reverse Contactors
- Disassemble the contactors
- Forward / Reverse Contactors
- Parts Inspection
- Reassembly
- I-A, Line & Pump Contactors
19 - 2 Electrical Sequence of Operation22 topics
- OPERATIONAL SEQUENCE #l
- Connect the Battery
- Close the Key Switch
- Steering Function
- Brake Switch & Static Return to Off (SRO) Checks
- Energizing the Directional Contactors
- Turning ON the Transistors
- Turning ‘OFF’ the Transistors, Capacitor Charging and Flyback
- Accelerator, Thermal Protector and Pulse Monitor Trip (PMT)
- IA Contactor Operation
- Plugging
- Plugging (continued)
- Travel Speed Limit
- Solenoid Functions
- Lift
- Lower
- Reach / Retract
- Reach / Retract (Continued)
- Tilt
- Tilt (Continued)
- Side Shift (Optional)
- Side Shift (continued)
Status Codes
19 - 4 Oscillator Card Settings2 topics
- NPR (24 Volt Truck) EV-T15 Card Factory Settings
- NPR (36 Volt Truck) EV-TIS Card Factory Settings
19 - 5 Steering Control Adjustments EV-T5PS4 topics
- Steer Control Adjustments Steps 1-3
- Steer Control Adjustments Steps 4-5
- Steer Control Adjustments Steps 6-7
- Steer Control Adjustments Step 8-9
19 - 6 Wiring Diagrams NPR-345
19 - 7 Forward & Reverse Switches, Up (Lift) & Down (Lower) Switches and Transducer Adjustments3 topics
- Forward, Reverse, Up (Lift) & Down (Lower) Switch Adjustment
- TRANSDUCER ADJUSTMENT
- FORWARD AND REVERSE SWITCH ADJUSTMENT
19 - 8 Periodic Electrical Checks8 topics
- Periodic Electrical Inspection
- Electrical Inspections
- Power Cables
- Cables & Wiring
- Solenoid Control Card
- Multi-Function Control Handle
- Cables must be routed as shown
- Install truck battery
19 - 10 Oscillator Card Remove & Replace3 topics
- Truck Preparation
- Oscillator Card Removal
- Installation
19 - 16 Solenoid Control Card Trouble Shooting4 topics
- Voltage Data Sheet
- RH5 Voltage Checks
- Lift Function ONLY Disabled
- NEW SOLENOID CONTROL CARD INSTALLATION
20 - 20 Axle, Articulation Adjustment21 topics
- Illustration
- Check Adjustment of Axle Stop Bolts
- LUBRICATION
- Removing the top of the gear unit (300) from the basic gear unit (100)
- Dismantling the housing lid
- Dismantling the crown gear (104) and wheel shaft (119)
- Dismounting the outer race
- Dismantling the inner race
- Dismounting the helical spur gear (201) and the conical pinion shaft (104)
- Mounting the gear unit
- Measuring the assembly dimension of the conical pinion shaft (104)
- Pre-assembly of the wheel shaff
- Pre-assembly of wheel shaft bearing in the housing
- Checking the tooth pattern
- Setting the conical pinion shaft (KM), helical gear (201) and setting the bearing clearance
- Adjustment of bearing clearance
- Checking the bearing clearance of the pinion shaft
- Mounting the wheel shaft (119), crown gear (104), and setting the bearing clearance
- Mounting the housing lid (134)
- Mounting the top of the gear unit (300)
- Special Tools
22 - 22 Traction Wheel & Tire2 topics
- Illustration, exploded view
- Replacing Traction Wheel Tire
22 - 2 Caster Wheel & Tire6 topics
- Replacing Caster Wheel Tire
- Check Caster Wheel Bearings
- Adjustment
- Motor Brake Service
- Brake Adjustment
- Final Adjustment Specification
Show all 50 sections
23 - 2 Caster Brake3 topics
- Caster Brake Service
- SLAVE CYLINDER
- BRAKE BACKING PLATE
23 - 3 Brake Bleeding Procedure1 topic
- Bleeding Brake System
23 - 4 Brake Pedal Adjustment1 topic
- Pedal Up-Height Adjustment
26 - 1 Hydraulic Pressure Checks NPR-3453 topics
- HYDRAULIC PRESSURE CHECKS
- Relief Valve Adjustment
- Check Lift Control Circuit Relief Valve Setting
29 - 1 Hydraulic Sump Tank Filter and Strainer2 topics
- Drain Hydraulic Sump Tank
- Check Sump Tank Fluid Level
29 - 2 Hydraulic Schematic NPR-345
29 - 4 Hydraulic Pump Overhaul2 topics
- Pump Disassembly
- Pump Reassembly
30 - 1 Hydraulic Control Valves and Solenoid Control Valves8 topics
- Control Linkage
- Removal of Hydraulic Lines
- Lift, Auxiliary, Reach & Tilt Control Valves
- Flow Regulator
- Auxiliary and Lowering Solenoid Valves
- REASSEMBLY SUGGESTIONS
- Mounting the Lift and Tilt Control Valve Assemblies
- Hydraulic Tube Installation
30 - 2 Auxiliary, Reach & Tilt Control Valve7 topics
- Valve Cut-A-Way with Specifications
- Cleaning and Inspection
- Valve Reassembly
- Port Plug
- Valve Spool
- Spool Spring Assembly
- Check Sump Tank Level
30 - 3 Lift Control Valve5 topics
- Specifications
- Pilot Operated Relief Valve Assembly with Schematic
- Cut-A-Way View of Valve
- LIFT CONTROL VALVE
- Valve Disassembly
30 - 4 Lowering Solenoid Valve2 topics
- Specifications, Warnings and Caution
- Hydraulic Schematic
30 - 5 Auxiliary Solenoid Valve (Reach and Tilt Control)
30 - 6 Reach & Tilt Selector Valve9 topics
- Discharge Capacitors
- Hydraulic Plumbing Diagram
- Specifications and Hydraulic Schematic
- REACH 81 TILT SELECTOR VALVE
- REMOVAL
- Location and Mouting Illustration
- Removal, Disassembly & Reassembly
- Mounting Selector Valve
- Installing clamps, connect wire plugs, tighten nuts and bolts
30 - 7 Side Shifter Solenoid Control Valve (Optional Equipement)2 topics
- Truck Make Ready
- Route Hosing As Shown
32 - 2 Tilt Cylinder Overhaul3 topics
- Safety
- Preparation Cleaning & Inspection Suggestions
- Cleaning & Inspection
32 - 3 Reach Cylinder Overhaul
34 - 1 Upright & Pantograph Remove & Replace Roller Shim Adjustments15 topics
- PANTOGRAPH
- UPRIGHT REMOVAL
- Cable, Hose & Chain Sheaves
- Free Lift Cylinder Cylinder
- Cable and Chain Sheaves
- Pantograph Assembly
- PANTOGRAPH CARRIAGE ROLLERS
- Upright Rollers
- Upright Rails to Rollers
- Triple Stage Upright
- Roller Clearance Inspection
- Checking Lower Rollers
- Checking Upper Rollers
- Determine Number of Shims needed to make roller adjustments
- Shim Adjustment
34 - 2 Pantograph & Fork Carriage Assembly5 topics
- Preparation
- Fork Removal
- Servicing Fork Carriage
- Fork Carriage Removal
- SERVICING PANTOGRAPH ARM ROLLERS
34 - 3 Rail Lift Cylinder Overhaul
34 - 4 Free Lift Cylinder Overhaul
34 - 5 Lift Fork Inspection3 topics
- Inspection Procedure
- Fork Wear Calipers
- Fork Inspection Illustrations
34 - 6 Upright Chain Inspection, Adjustment & Replacement12 topics
- Periodic Inspections
- Elongation
- Edge Wear
- Turning or Protruding Pins
- Cracked Plates
- Chain Length Adjustments
- Triple-Stage Upright (TSU) Chain Length Adjustments
- Chain Removal and Replacement
- General Guidelines
- Lift Chains (Standard and TSUs)
- Primary Cylinder/Carriage Chains(TSUs)
- Other Chain Service Notes
35 - 1 Load Wheels3 topics
- Remove & Replace
- Inspection
- Installation & Lubrication
Specifications NPR-34513 topics
- Wiring Color Code
- Ikavel Speeds with Capacity Load
- Lift Speeds
- Wheels & Tires (Type & Size)
- Fork Spread
- Overall Dimensions
- Lift Cylinder Downdrift Test
- Tilt Cylinder Drift Test
- Service/Parking Brake(s)
- Caster Brake
- ELECTRICAL SYSTEM SPECIFICATIONS
- Hydraulic System Specifications
- Critical Fastener Torque Specifications
40 - 2 Service Weights1 topic
- SERVICE WEIGHTS IN POUNDS
40 - 3 Lubricants and Shop Supplies Easy Reference Listing12 topics
- ADHESIVE PRODUCTS
- CLEANERING PRODUCTS
- LUBRICANTS
- THREADLOCKER PRODUCTS
- Detailed Product Descriptions
- Lubricants
- Sealants
- Gasket Materials
- Threadlocks and Threadsealers
- Adhesives
- Cleaners
- Miscellaneous Shop Supplies
Inside this manual
Real pages from this service manual (491 pages). Open the sample pages (PDF, 310 KB)
- Diagram, page 71: Motors
- Troubleshooting, page 232: GROUP 22
- Specifications, page 463: Specifications, Truck
This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 491 pages
Quantity one is the manual described above.
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Ships in 1 business day.
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Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).