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Clark TM 12, 25, 36 Volt EV-100 Supplement Forklift Service Manual

687 pages · Publication SM-555

$69.67
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Models
TM 12, 25, 36 Volt EV-100 Supplement
Manual type
Service Manual
Pages
687
Publication
SM-555
Condition
Brand new
Clark TM 12, 25, 36 Volt EV-100 Supplement Forklift Service Manual, publication SM-555

What's inside

From the manual's own table of contents: 80 sections, 148 entries. See sample pages (PDF, 282 KB)

INTRODUCTION
HOW TO USE THIS MANUAL
SUBJECT/PICTORIAL INDEX
SAFETY INFORMATION
DRIVER'S DAILY CHECKLIST
PM REPORT FORM
PM - PLANNED MAINTENANCE PROGRAM7 topics
  • VISUAL INSPECTION
  • OPERATIONAL CHECKS / TEST DRIVE
  • AIR CLEANING
  • CRITICAL FASTENER TORQUE CHECKS
  • CHASSIS COMPONENTS MAINTENANCE / INSPECTION
  • LUBRICATION, FILTERS & FLUID LEVEL CHECKS
  • ELECTRICAL TESTS
01-01 PLANNED MAINTENANCE SCHEDULE
01-02 PLANNED MAINTENANCE AND LUBRICATION CHARTS
12-01 BATTERY REMOVAL
12-02 BATTERY MAINTENANCE
13-01 LIFT PUMP MOTOR MICROSWITCH ADJUSTMENT
13-02 SERVICE BRAKE MICROSWITCH ADJUSTMENT
13-03 PARKING BRAKE MICROSWITCH ADJUSTMENT
13-06 ACCELERATOR CONTROL
14-01 ELECTRICAL SYSTEM
16-01 ELECTRICAL MOTOR MAINTENANCE
16-02 DRIVE MOTOR BRUSH REPLACEMENT
16-04 STEER MOTOR BRUSH REPLACEMENT
16-22R STEER PUMP AND MOTOR ASSEMBLY REMOVAL
16-22 STEER PUMP MOTOR OVERHAUL
16-23R DRIVE MOTOR REMOVAL
16-23 DRIVE MOTOR OVERHAUL
16-24R LIFT PUMP AND MOTOR ASSEMBLY REMOVAL
Show all 80 sections
16-24 LIFT PUMP MOTOR OVERHAUL
17-04 STEER AXLE TRUNNION MICROSWITCH ADJUSTMENT
19-01 CONTROL PANEL6 topics
  • CONTROL PANEL DESCRIPTION
  • CONTROL PANEL MAINTENANCE
  • CONTROL PANEL TROUBLESHOOTING
  • CONTROL PANEL REMOVAL
  • CONTACTOR INSPECTION
  • CONTROL PANEL INSTALLATION
19-02 EV-100M SEQUENCE OF OPERATION AND TROUBLESHOOTING41 topics
  • OPERATION SEQUENCE DRIVE CONTROL
    • DRIVE CONTROL
    • BATTERY
    • BATTERY INDICATOR AND PUMP MOTOR
    • HOUR METER, STEERING & SRO
    • FWD/REV CONTACTORS
    • CONTACTOR OPERATION & CAPACITOR PRECHARGE
    • 8 1C CAPACITOR CHARGING & REACTOR OPERATION
    • FLYBACK
    • ACCELERATOR MODULE, THERMAL PROTECTOR & PMT
    • 12 1A CONTACTOR OPERATION
    • PLUGGING
  • CHECKING COMPONENTS
    • SPECIFIC GRAVITY TEST
    • CHECK CAPACITOR (1C)
    • CHECK FILTER MOUNTING BLOCK
    • CHECK SENSOR
    • CHECK THERMAL PROTECTOR
    • CHECK REACTOR/CHOKE MODULE
    • CARD ADJUSTMENTS
    • CARD VOLTAGE CHECKS
    • CONNECTOR PLUG A, B, Z
  • RECOMMENDED TEST, TEST EQUIPMENT AND PROCEDURES
    • GROUND FAULT CONDITION
    • POWER STEER IDLE CURRENT
    • SCR CURRENT LIMIT
    • 4 1A FREE WHEELING CURRENT
    • 5 1A TIME DELAY
    • CREEP SPEED MOTOR VOLTS
    • PLUGGING FUNCTION
  • SYMPTOM CHARTS
    • CONTACTORS WILL NOT CLOSE
    • CONTACTORS CLOSE, NO POWER, NO HUM, TRUCK INOPERATIVE IN SCR RANGE
    • CONTACTORS CLOSE, NO POWER, SCR HUM, TRUCK INOPERATIVE IN SCR RANGE
    • CONTACTORS CLOSE BUT POP OPEN, PMT TRIPS
    • ONE CONTACTOR CLOSES, OTHER WILL NOT
    • STIFF PLUG AND/OR PLUGGING DISTANCE NOT ADJUSTABLE
    • 7 1A CONTACTOR WILL NOT CLOSE
    • PMT TRIPS WHEN HYDRAULIC SWITCHES ARE ACTIVATED
    • POWER STEER MOTOR DOES NOT OPERATE
    • LIFT/TILT/ATTACHMENTS DO NOT OPERATE
SUPPLEMENT4 topics
  • EV100 LXT CONTROL PANEL
  • EV100 LXT CONTROL PANEL - STATUS CODES
  • REPLACEMENT OF EV-100 COMPONENTS
  • EV100-LXT CARD FUNCTION SET-UP
20-01 DRIVE AXLE MAINTENANCE
20-10R DRIVE AXLE REMOVAL
20-10 DRIVE UNIT OVERHAUL
22-01 PNEUMATIC TIRE AND WHEEL MAINTENANCE
BRAKE SYSTEM (CARLISLE BRAKE)10 topics
  • BRAKE SPECIFICATIONS
  • BRAKE SYSTEM BLEEDING
  • BRAKE PEDAL REMOVAL, REPLACEMENT, AND ADJUSTMENT
    • INTRODUCTION
    • PEDAL REMOVAL
    • PEDAL REPLACEMENT
    • PEDAL ADJUSTMENT
  • BRAKE REMOVAL AND REPLACEMENT
  • PARKING BRAKE REMOVAL, REPLACEMENT, AND ADJUSTMENT
  • BRAKE OVERHAUL
23-03 BRAKE BLEEDING PROCEDURE
23-04 PARKING BRAKE ADJUSTMENT
23-17R SERVICE BRAKE CALIPER ASSEMBLY REMOVAL
23-17 SERVICE AND PARKING BRAKE, BRAKE CALIPER ASSEMBLY OVERHAUL
23-18R BRAKE MASTER CYLINDER REMOVAL
23-18 MASTER CYLINDER OVERHAUL
25-05 PYLON RELEASE LEVER ADJUSTMENT
25-10R POWER STEERING CONTROL UNIT REMOVAL
25-10 STEERING GEAR
26-01 STEER AXLE TRUNNION BEARINGS CHECK AND ADJUSTMENT
26-02 STEER WHEEL BEARING MAINTENANCE
26-03 POWER STEERING SYSTEM RELIEF PRESSURE CHECK
26-04 STEER CYLINDER LINKAGE CHECK AND ADJUSTMENT
26-08 STEER AXLE, STEERING LINKAGE, AND STEER AXLE TRUNNION OVERHAUL
26-09R STEERING CYLINDER REMOVAL
26-09 POWER STEERING CYLINDER OVERHAUL
26-14R POWER STEERING PUMP REMOVAL
26-14 POWER STEERING PUMP OVERHAUL
29-01 HYDRAULIC SYSTEM FLUID AND FILTER CHANGE
29-10R LIFT PUMP REMOVAL
29-10 LIFT PUMP OVERHAUL
30-01 HYDRAULIC SYSTEM RELIEF PRESSURE CHECK AND ADJUSTMENT
30-09R MAIN HYDRAULIC VALVE REMOVAL
30-09 MAIN HYDRAULIC VALVE OVERHAUL
31-01 HYDRAULIC SYSTEM SCHEMATIC DIAGRAM
32-01 TILT CYLINDER ADJUSTMENT
32-02 TILT CYLINDER DRIFT TEST
32-11R TILT CYLINDER REMOVAL
32-11 TILT CYLINDER OVERHAUL
34-01 UPRIGHT LIFT CHAIN CHECK AND ADJUSTMENT PROCEDURE
34-03 UPRIGHT DOWNDRIFT TEST
34-04 FORK MAINTENANCE
34-07 LIFT CHAIN MAINTENANCE
34-09R UPRIGHT REMOVAL
38-01 COUNTERWEIGHT REMOVAL
38-02 FRONT BATTERY PLATE ADJUSTMENT
38-03 MACHINE JACKING AND BLOCKING
39-01 OVERHEAD GUARD REMOVAL
39-02 HOOD REMOVAL
40-01 TRUCK DATA PLATES AND DECALS
40-02 SUGGESTED EQUIPMENT FOR ELECTRIC TRUCK PM
40-03 FIRE EXTINGUISHER RECOMMENDATIONS
40-04 LUBRICANT SPECIFICATIONS AND RECOMMENDATIONS
40-05 TRUCK DATA AND SPECIFICATIONS
40-17 MEASURING VOLTAGES WITH THE VOLT-OHM METER ( V-O-M )
40-18 MEASURING RESISTANCE WITH THE VOLT-OHM METER ( V-O-M )

Inside this manual

Real pages from this service manual (687 pages). Open the sample pages (PDF, 283 KB)

Sample pages from the Clark TM 12, 25, 36 Volt EV-100 Supplement Forklift Service Manual: Troubleshooting, Diagram, Specifications, Foldout diagram
  • Troubleshooting, page 300: STATUS CODE
  • Diagram, page 550: ClclRK
  • Specifications, page 610: Cl!lRU
  • Foldout diagram, page 687: OPTIONS

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, 687 pages

Quantity one is the manual described above.

Fast free USA shipping

Ships in 1 business day.

60-day returns

Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy

Binder not included

Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.

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).