Free download - clark npr-17 electric service manual

Remove adjustor screw and lock washer securing the switches, switch adjustors, lock washers and springs to the switch bracket. Installnew switch, switch adjustors, lock washers and springs in the reverser order of removal. Secure the sub-assembly with adjustor screw s and lock washer s. Route switch wires as shown in illustrations on Page 1 and Page 4.

Remove clamp screw and remove transducer clamp assembly harness from the clamp. Remove fastener switch securing the transducer and transducer plate to the bracket. Remove nut and washer securing transducer to transducer plate. Wear eye protection and protective clothing when cleaning or drying with air pressure.

Discharge capacitors using a ohm, 10 watt resistor connected between the Positive and Negative power terminals on the SCR control. Hold the resistor in place for2 seconds before removing. A planned maintenance program of regular, routine inspections is important for long life and troublefree operation of electric motors.

Make and keep records of your inspections. Use these records to help establish correct P. Inspection Procedures To perform these service procedures, mended that you first: Park truck safely.

Fully lower upright. Apply parking brake. Turn key switch OFF. Disconnect battery from truck recepatacle. The presence of any oil on or near motor could indicate either bad bearings or leaking hydraulic system. Determine cause and repair problem before extensive motor damage occurs. Motor Insulation If a reduction in motor performance has been noted, it may be due to breakdown in motor insulation causing internal grounding or a short circuit. Failures of motor insulation are due to: l. Motdr Cleanliness Electric motors should be kept clean at all times to prevent shorting, minimize wear, and for best cooling.

Wipe off all dust, dirt, oil, water, etc. Remove any debris from cooling air vents and around motor frame to prevent overheating. Air clean blow out open motors using clean, dry moisture-free compressed air at [ kPa] 30 psi. Air clean all inner areas around commutator and brushes, including cooling air vents and fan. Wear safety glasses.

Contamination includes dirt, moisture, oily vapors, metal chips, carbon dust from brushes, etc. Mechanical factors include shock, vibration, over speed, etc. Operation at prolonged or excessively high temperature will cause insulation to become brittle and crack leading to premature failure.

The insulation condition can be judged both visually and by test measurement. Regular, periodic measurements of insulation resistance can give a useful indication of the rate of insulation deterioration.

A sudden drop or consistent trend toward low values of insulation resistance give evidence that insulation is deteriorating and that failure may be imminent.

Discharge the capacitors. Refer to Group This test may be made with motor in the truck. Connect the positive lead of the VOM to all terminal studs of test motor.

Use jumperwires to connectbetweenmotorterminals. ConnectVOM negative lead to motor frame. Connect one lead of a volt megger to any motor terminal.

Connect other lead to motor frame. Apply voltage. If less than this, motor should be air-cleaned or dried to attempt to increase insulation resistance. Test all terminals individually, or joined together, as noted. If less than 1 megohm is measured, air clean motor and repeat test. If cleaning does not make an improvement, the motor will have to be removed from the truck and disassembled for a closer inspection.

The key to planned maintenance of the brush and commutator is recognizing the undesirable brush and commutator conditions. If this is done, corrective action can be taken before a major component is damaged beyond serviceability. The brushes and commutator should be inspected for even wear and good commutation. Good Commutation: Poor Commutation: or coloring A dark uniform coloring pattern at the brush wearing surface. The surface of the commutator appearing rough, pitted, scored signs of burning or heavy arcing between bars.

The pattern will be:. Streaky film with commutator Bar edge burning. Uneven film. Carbon dust bridging between bars wear. Different Grade Brushes; When the brushes being fitted are of a different grade from those previously by the previous used, then it is advisable to remove the film left grade brushes.

This film removal should be done by scouring with a strip of abrasive cloth do not use emery cloth while the armature is rotating. Do not finish with a lapped, highly polished surface. A surface will help moderately abraded commutator the new brushes to run in and the commutator will acquire more readily the film appropriate to the new brush grade. Operating Conditions Operating environment of lift truck motors varies widely: The following recommendations should be applied as actual conditions dictate.

Normal Service: Basically an eightSevere Service: Extended operating hour day of indoor hours, or constant usmaterial handling. Remove brush cover s and remove brushes from brush holders. Clean brushes and holders. Check brush holders for damage.

Inspect condition of brushes. Remove each brush from brush holder and inspect brushes and commutator for worn condition and uneven wear. Clean commutator surface. Wipe commutator with a dry, lint-free cloth. Motors 7. Check brush shunt for good contact with brush holder.

Be sure shunt is not damaged or burned since this may cause brush spring to carry current and lose tension. Clean and check brush box and connector screws. Tighten if loose. Be sure brush box shunt connection is tight. If brushes do not need to be replaced, and commutator is in good condition, install brushes and brush springs into brush holders. Check appearance of commutator surface where brushes ride Inspect commutator bars for burned, damaged or raised areas. The best signs of good commutation are a dark brown highly-polished commutator and uniform glossy brush-wearing surfaces.

Be sure brush spring is correctly placed on brush holder and that brush isfree to slide in brush box. Install brush cover on motor case. Check and tighten all motor bolts.

Check lower nut on each terminal post. It should be installed finger-tight, then tightened another turn with a wrench. Measure and make a record of brush length at each inspection. The record will verify amount of brush wear and indicate if there is enough brush length remaining until next scheduled inspection. Observe how brushes are assembled in brush holders, and position of brush lead pigtail. New brushes must be installed in same manner. Use an appropriate torque wrench and tighten all fasteners to the torques specified in the illustation on the following page.

Motor Reassembly. Wear eye protection and protective clothing when drying with air pressure. Debris remoJed with air pressure can cause injury. Use a Torque Wrench to tighten Terminal Connections. Typical Inch Pound Torque Wrench. GENERAL Routine Maintenance Schedule with Recorded Findings is the best way to reduce costly shut-downs and repair of equipment during operating hours The goal of any maintenance program, long-life and trouble-free operations, is related to the time spent making inspections and correcting minor problems as they occur.

Thekeytoplannedmaintenanceofthebmshandcommutatoris recognizingundesirablebrush and commutator conditions. Good Commutation: Poor Commutation: A dark uniform coloring pattern at the brush wearing surface.

The surface of the commutator appearing rough, pitted, scored or signs of burning or heavy arcing between bars. The coloring pattern will be:. Streaky film with commutator wear. Bar edge burning. Carbon dust bridging between bars. Operating Conditions Operating environment of lift truck motors varies widely: The service frequency shall depend upon the severity of operating conditions.

Normal Service: Basically an eighthour day of indoor material handling. Severe Service: Extended operating hours, or constant usage. Use a brush hook to reach into the motor and lift the brush springs. Pull the brushes out of the brush holders. Eitherpositionthebrushesoutsidethemotor or remove the brush retaining screws and remove the brushes from the motor.

Although locating marks are not always necessary because of locating pins in some motors, they can save a lot of time when the motor does not have locating pins. Remove the commutator end head retaining screws or bolts. Almost all motors have a slip fit bearing at the commutator end, andtheend head canberemovedwithverylittletrouble. Remove end head. Remove bearing from head. Remove the drive end head retaining bolts or screws, itnecessary.

Remove the drive end head the bearing may or may not remain on the shaft. Pull the armature assembly from the housing and field coil assembly. If the bearing remained on the armature shaft, remove bearing from shaft with a bearing puller. When a puller is used, protect the end of the armature shaft with a nut or a thick flat washer. If theshaft, or spline is damaged when removing the end head, the armature or the drive spline usually has to be replaced. Use caution and do not damage the armature.

Theventilating fan is, for the most part, cast iron or cast aluminum. Once the fan has been pressed onto the armature, it must be heated to be removed without damage. Remove Fan A puller is installed and a slight pressure exerted against the fan. Use a small propane torch to heat the area of the fan around the shaft. When the fan becomes loose on the shaft, as evidenced by the puller becoming loose, it should be removed as quickly as possible. Remove Retainer Pin l.

If the bearing remained in the end head, remove bearing from end head. On some motors the bearing is retained with a snap ring. Remove the snap ring, then press the bearing out of the end head.

After the motor components have been thoroughly cleaned and dried, they should be inspected for the following:. Drive End Head 1. Check bearing recess for any signs of wear. Checkmountingholesforany strippedorcmsed threads or broken studs.

Bearings 1. Check bearings by turning them with your fingers. Feel for binding or gritty effects and excessive looseness or wobble. A good bearing should also have a small amount of drag or stiffness caused by the lubrication but should turn smoothly. If the bearing turns very freely, it should be replaced. Bearings should also be changed, if worn out, damaged or removed from armature shaft. Armature 1. Check security of fan. Check for loose commutator bars. Loose commutator bars will usually be indicated by excessive wearorbumingonone bar.

The commutator can be checked for loose bars by lightly tapping all of the bars with the handle of a plastic or wooden handled screwdriver. A contrasting dull thud or vibration will indicate a loose barin which case, the armature must be replaced. Ball bearings that have been pulled off of shafts, pressed out of end heads, or side loaded in such a way as to apply pressure on the balls and races must be replaced. Although the bearing may appear or feel good, the bearing races have been brinelled and will fail within a relatively short period of service.

Check for grounded circuits using a test light. Most commercial growlers incorporate a test light as shown in illustration below. Check the armature for grounded circuits by placing one test lead of the test lamp on the commutator and the other test lead on the armature shaft. If the test light lights, the armature is grounded.

Brush and Commutator The brushes and commutator should be inspected for even wear and good commutation. Good Commutation: A dark uniform coloring pattern at the brush wearing surface.

Poor Commutation: The surface of the commutator appearing rough, pitted, scored or signs of. Motors 4. Standard Winding Armatures are tested on a growler see illustration below using a steel strip or hacksaw blade to locate any shorted. Check for shorted windings by slowly rotating the armature in the growler while holding the strip or blade so that it passes over each armature core slot. If a winding is shorted, the strip or blade will vibrate and the blade will get hot.

Hacksaw Blade. Check the condition of all insulation. If the insulation on the field coils appears blackenedor charred, the serviceability of the coils is questionable. Burned or charred insulation is a result of coil overheating due to overloading conditions, groundedor shortedcoil windings. Check condition of all other insulation such as brush rigging, under coil connections and around terminal studs.

After thorough inspection, the Frame and Field Assembly should be checked for grounded, open or shorted circuits. Grounded and open circuits can be checkedusinga test light. Most commercial growlers incorporate a test light as shown in opposite illustration. Ifthearmaturehasbeenturnedand undercut prior to testing, check for and remove any copper buildup or filings between commutator bars and at the commutator riser.

This condition will cause an armature tocheckshortedandusuallyresults from a dull undercutting tool. Check commutator bars for any signs of burning.

If deep burned sections are evident, either in the brush track or on the riser ends of the commutator bars, an open or short circuit in the armature windings is indicated. Touch one test lead to a clean bare metal spot on the frame and check all terminals with the other lead. If a grounded condition exists, the test light will light. Check between all connecting terminals with test leads.

Ifthe bulb fails tolight, anopencircuit is indicated. Shorted windings in series coils are very difficult to detect. Generally, if the coil insulation is sound and these are no signs of overheating, the coil can be presumed good. Red glyptol can be used if a better material is not available, however, we recommend using a class H Polyurethane air drying insulating varnish.

This is readily available under various brand names from electrical repair or parts houses in aerosol type dispensers. Before spraying field coils, make sure they are absolutely clean anddry. Protect brush rigging, pole shoe faces and end head seats to keep varnish off. Bearing Installation 1.

Whenever ball bearings are pressed into an end head or onto a shaft, always press against the race that is absorbing the pressure. Press on the outer race when installing into end heads. Press against the inner race when installing onto a shaft. EndHeads having slip-fit bearings are normally retained by a snap ring. Always install new snap ring s.

After Assembly. The motor should be connected as specified in trouble shooting, and tested to the specifications. When testing motors, the voltmeter connections must be made at the motor terminals. Prior to installing thejield coils, the connections which require soldering should be buffed or wire brushed clean to remove any oxidation.

The connections should then be tinned with a soldering iron. When changing brushes When changing brushes the commutator serviced as follows: l. We do not recommend using a soldering gun or torch. Soldering guns cannot provide the heat concentration required and soldering torches can damage the insulation. Resurface the commutator by taking only light cuts each time, 0. After field coil installation, connect the solder joint making sure the solder is flowing properly to avoid a cold soldered joint.

This motor is equipped with Standard Winding Connections and meets latest revision of U. MaximmDiameter, NEW 2. Length of Worn Brush 0. Force per New Brush 29 oz. Force per Worn Brush 12 oz. Frame Size: 6. Debris remo2ed with air pressure can cause injury. The key to planned maintenance of the brush and commutator is recognizing undesirable brush and commutator conditions. If this is done, corrective action canbe takenbefore amajor component is damaged beyond serviceability.

Severe Service: Normal Service: Extended operating Basically an eighthours, or constant ushour day of indoor age. Remove the cover band if so equipped from the commutator end of the motor. Either position the brushes outside the motor orremove the brush retaining screws and remove the brushes from the motor.

Scribe or center punch locating marks in the end heads and the frame. The motors have a slip fit bearing at the commutator end, and the end head can be removed with very little trouble. Remove the drive end head retaining bolts or screws. Separate the armature and drive end head as an assembly from the frame and field coil assembly.

Separate the armature from the drive end head. This operation is usually accomplished by pressing the armature out of the drive end bearing. The end head and bearing may have to be removed with a puller.

If the shaft, coupling, or spline is damaged when removing the end head, the armature or the drive spline usually has to be replaced. Separate the bearing from the end head. The bearing is retained with a snap ring. Motors burning or heavy arcing between bars. Checkmountingholesforanystrippedorcrossed threads or broken studs. Discolored brush shunts Discolored brush springs. Refer to the Brush Chart on the following pages. Loose commutator bars will usually be indicated by excessive wearor burning on one bar.

Thecommutator can be checked for loose bars by lightly tapping all of the bars with the handle of a plastic or wooden handled screwdriver. A contrasting dull thud or vibration will indicate a loose bar in which case, the armature must be replaced. Brush and Commutator The brushes andcommutator should be inspected for even wear and good commutation. Poor Commutation: The surface of the commutator appearing rough, pitted, scored or signs of SM Check for shorted windings by slowly rotating the armature in the growler while holding the strip or blade so thatitpasses over each armature core slot.

Burned or charred insulation is a result of coil overheating due to overloading conditions, grounded or shorted coil windings. Grounded and open circuits can be checked using a test light. Ifthearmaturehasbeentumedand undercut prior to testing, check for and remove any copper buildup or filings between commutator bars and at the commutator riser. Touch one test lead to aclean bare metal spot on the frame and check all terminals with the other lead.

Check between all connecting terminals with testleads. Ifthebulbfails tolight,anopencircuit is indicated. Red glyptol can be used if a better material is not available, however, we recommend using a class II Polyurethane air drying insulating varnish.

After Assembly l. Prior to installing thefield coils, the connections which require soldering should be buffed or wire brushed clean to remove any oxidation. NOTE l. Bearings are double sealed and lubricated with high temperature grease for the life of the bearing. Motor Counlinz A coupler is used to connect the motor to the pump. One half the coupler attaches to the motor and the other half to the pump. Trouble Shooting Prior to Disassembly GENERAL Routine Maintenance Schedule with Recorded Findings is the best way to reduce costly shut-downs and repair of equipment during operating hours The goal of any maintenance program long-lifeand trouble-freeoperations is related to the time spent making inspections and correcting minor problems as they occur.

Operating Conditions Operating environment of lift truck motors varies widely: The service frequency shah depend upon the severity of operating conditions. The permanent magnet motor differs from conventional D. Do not. Try to turn the shaft by hand. Keep motor leads separated while doing this. If the shaft turns freely go to item 3. If the shaft wont turn, proceed to item 2A. If it does turn, then hold the motor leads on the power supply for a longer time.

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