1994 Clark NPR 17, NPR 20 & NPR-345 Electric Stand-Up Reach Forklift Service Manual (P/N SM-587)

Clark service manual P/N SM-587, December 1994, covers the NPR 17, NPR 20, and NPR-345 narrow-aisle electric stand-up rider reach trucks.

• Maintenance and batteries: Planned maintenance inspections, operational tests, lubrication charts, battery handling, charging precautions, and battery service procedures.

• Electric motor service: Traction, lift-pump, and auxiliary/steer motor disassembly, component inspection, electrical testing, brush replacement, and reassembly.

• Electrical controls: EV-T15 status-code troubleshooting, oscillator-card settings and replacement, EV-T5PS steering adjustments, and multi-function control handle switch and transducer adjustments.

• Drive unit and axle: Gear-unit overhaul, crown-gear and pinion setup, bearing-clearance checks, tooth-contact-pattern inspection, and axle articulation adjustment.

• Brakes and wheels: Motor and caster brake service, manual and pressure bleeding, pedal adjustment, tire replacement, and load-wheel bearing service.

• Hydraulics: Circuit pressure checks, pump and control-valve overhaul, optional side-shift controls, and tilt, reach, rail-lift, and free-lift cylinder repair.

• Upright and pantograph: Removal and installation, carriage and upright roller shimming, pantograph arm service, fork inspection, and lift-chain inspection and adjustment.

This manual is intended for mechanics and service technicians trained and authorized to perform lift-truck maintenance.

Planned Maintenance and Battery Service

Walk-around inspections lead into operational tests for steering, acceleration, controlled plugging, and hydraulic functions. The PM check sheet distinguishes minor adjustments from conditions requiring shop repair.

Battery coverage includes removal and installation, electrolyte checks, charging precautions, and maintenance records. Lubrication charts distinguish standard service from cold-storage applications.

Follow the documented battery-handling, electrical-isolation, and blocking precautions when working around electrical components or raised upright assemblies.

Electrical Diagnosis and Motor Repair

EV-T15 status-code charts connect operating symptoms with possible causes, circuit sketches, and electrical test criteria. Wiring diagrams and the electrical sequence-of-operation section trace brake interlocks, contactors, plugging, and hydraulic commands. Together, these references help technicians distinguish an input or wiring fault from a control-panel problem.

Factory oscillator-card settings differ between the 24- and 36-volt trucks. Steering adjustments cover idle output and compensation settings, while the handle section explains directional-switch timing and accelerator transducer alignment. Changes to the EV-T15 function settings require the EV100/EV-T15 handset.

Motor coverage goes beyond brush replacement, with armature and field-circuit tests, bearing inspection, and checks after reassembly. The Brush Inspection Chart and Commutator Check Chart illustrate wear patterns and surface conditions.

The capacitor-discharge cautions explain how using a shorting device without a resistor load can damage the solid-state control.

Drive Unit, Brakes, and Wheels

Drive-unit overhaul covers crown-gear and conical-pinion assembly, bearing clearance, shim selection, and tooth-contact-pattern checks. Dimensioned special-tool drawings accompany the gear-unit procedures.

The brake sections explain the spring-applied, hydraulically released motor and caster assemblies. Coverage extends to brake shoes, slave-cylinder alignment, spring adjustment, and pedal checks, with separate manual and pressure-bleeding methods.

Wheel service addresses traction and caster tire replacement, bearing adjustment, and load-wheel installation.

Hydraulic Valves, Cylinders, and Pantograph

Pressure checks distinguish the lift circuit from the steering and auxiliary circuits. Pump inspection covers gears, wear plates, bushings, and seals; valve sections address lift, reach/tilt, selector, and optional side-shift controls.

The lowering-solenoid cartridge is not internally serviceable. Its section covers removal, coil and seal replacement, and reinstallation.

The Hydraulic Schematic and Pilot Operated Relief Valve Assembly with Schematic show circuit and valve relationships. Cylinder procedures address gland inspection, seal orientation, and reassembly, with hydraulic cylinder seal tools 1801783 and 1801784 identified.

Upright service distinguishes rail and carriage roller shimming from pantograph arm rollers and pivot bushings. Carriage rollers and inner/outer arm bushings require pantograph removal. Fork and lift-chain inspections include wear and damage criteria.

The chain-anchor cautions explain how restricted anchor movement can twist and overstress the lift chains.

A Preview of Steering and Gear-Setting Data

These examples represent a small selection of the adjustment data in the manual.

For EV-T5PS steering-control idle adjustment, motor-output voltage across M+ and M- is specified as 9.2 ±0.2 V on 24-volt trucks and 13.6 ±0.2 V on 36-volt trucks.

The drive-unit overhaul section specifies allowable crown-gear circumferential backlash of 0.10–0.15 mm (0.004–0.006 in.), with related shim-selection and tooth-pattern checks.

Text Search, Bookmarks, and Diagram Viewing

Search and diagram detail: Service chapters contain searchable text, with embedded bookmarks for the main groups and subsections. Some wiring and cylinder-service pages lack searchable body text. Dense wiring labels require zooming, and one wiring layout is sideways.

The manual is supplied as a printable, English-language 492-page PDF in one file. This total already includes the two opening cover/title pages, front matter, service sections, and reference listings.