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NPR 17/20
CLRRK
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Service
Manual
SM -587
NPR-345 NPR-17
NPR-20
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
TABLE OF CONTENTS
w Group No-Section No.-Page No. Item Groun No-Section No.-Page No.
01 Planned Maintenance Procedures PM-l thru 29 3 1 Hydraulic Control Valves & Solenoid
02 Lubrication Charts 01-1-l Control Valves, Remove & Replace30- l- 1
03 Battery Service 12-1-1 32 Auxiliary Reach & Tilt Valve Overhaul 30-2- 1
04 Multi-Function Control Handle Switches 13-1-1 33 Lift Control Valve Overhaul 30-3- 1
05 Electric Motor Service -- General 16-2-1 34 Lowering Solenoid Valve 30-4- 1
06 Traction Motor Service 16-3-1 35 Auxiliary Solenoid Valve
07 Pump Motors 16-5-1 ( Reach & Tilt Control Valves) 30-5-l
08 Auxiliary/Steer Pump Motor Service 16-7-1 36 Reach & Tilt Selector (Solenoid) Valves 30-6- 1
09 Contactor Service 17-1-1 37 Side Shifter Solenoid Control Valve 30-7- 1
10 Electrical Sequence of Operation 19-2-1 38 Tilt Cylinder Overhaul 32-2-l
11 EV-T15 Solid State Control Status Code 19-3-1 39 Reach Cylinder Overhaul 32-3-l
12 Oscillator Card Settings and Tests 19-4-1 40 Upright & Pantograph Remove & Replace
13 Steering Control Adjustments (EV-T5PS)19-5-1 and Roller Shim Adjustments 34-l-l
14 Wiring Diagrams 19-6-1 41 Pantograph & Fork Carriage R&R
15 Directional, Lift & Lower Switches and and Roller Shim Adjustments 34-2-l
Transducer Adjustment 19-7-1 42 Rail Lift Cylinder Overhaul 34-3- 1
16 Periodic Electrical Checks 19-8-1 43 Free Lift Cylinder Overhaul 34-4- 1
17 Oscillator Card, Remove & Replace 19-10-l 44 Lift Fork Inspection 34-5- 1
18 solenoid Control Card Troubleshooting lo- 16- 1 45 Lift Chains 34-6-l
19 Axle Articulation Adjustment 20-l-l 46 Load Wheels 35-l-l
20 Drive Unit Overhaul 20-2- 1 47 Specifications 40-l-l
21 Traction Wheel & Tire 22-l-l 48 Service Weights 40-2- 1
22 Caster Wheel & Tire 22-2- 1 49 Lubricants and Shop Supplies 40-3-l
23 Motor Brake 23-l-l
24 Caster Brake 23-2- 1 NOTE
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Table of Material
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INDEX Pictorial Index
Pictorial Index #1
NPR-345
/ 23
Index 1 of 2
Pictorial Index
Contents
PM Planned Maintenance Procedures ........................... PM-01 thru 29
PM Caster Brake: Adjusting for Lining Wear; When to
Replace Brake Linings ........................................................... PM- 16
Motor Brake: Adjusting for Lining Wear When to
Replace Brake Linings ........................................................... PM-28
Group ........................................................................ Group-Section-Page
01 Lubrication Chart and Instructions.. ................................ .01-l-01 thru 07
12 Battery Service Instructions ............................................. 12-l-01 thrllO8
13 Multi-Function Control Handle Switches ....................... .13-l-01 thru 05
16 Electric Motor Service - General .................................... .16-2-01 thru 09
16 Traction Motor Service ................................................... 16-3-01 thru 11
16 Pump Motors 24 & 36 Volt.. .......................................... .16-5-01 thm 11
16 Auxiliary/Steer Pump Motor Service .............................. .16-7-01 thru 12
17 Contactors, Control Panel.. ............................................. .17-l-01 thru 09
19 Electrical Sequence of Operation .................................... .19-2-O 1 thru 5 1
19 Instructions - Status Codes for EV-T15 Control.. ............ .19-3-01 thru 15
19 Oscillator Card Settings ................................................... 19-4-01 thnlo4
19 Steering Control Adjustments.. ....................................... .19-5-01 thru 06
19 Wiring Diagrams ............................................................ 19-6-01 thru 03
19 F&R Switches, Up & Down Switches, Transducer Adjl . .19-7-01 thru 10
19 Periodic Electrical Checks .............................................. .19-8-01 thru 16
19 Oscillator Card Remove & Replace .............................. .19-lo-01 thru 04
19Solenoid Control Card Trouble Shooting.. ..................... .19-16-01 thru 06
20 Axle Articulation Adjustment .......................................... 20-l-01 thru 03
20 Drive Unit Disassembly & Reassembly .......................... .20-2-01 thm 19
22 Wheel & Tire, Traction ................................................... 22-l-01 thnlo3
22 Wheel & Tire, Caster ...................................................... 22-2-01 thru 04
23 Brake, Traction Motor ..................................................... 23-l-01 thru 08
23 Brake, Caster ................................................................. .23-2-01 thru 09
23 Bleeding Procedure, Brake ............................................. .23-3-01 thru 02
23 Brake Pedal and Cylinder(s) Check & Adjustment ........ ..23-4-O 1 thru 02
Index 2 of 2
Pictorial Index
Contents
Group .............................................................................................. Group-Section-Page
26 Pressure Check & Adjustment -Steering, Auxiliary, Reach & Tilt,
and Side Shift (If so equipped) ...................................... 26-l-l thru 05
29 Hydraulic Sump Tank, Filter and Strainer Service .......... ...29-l- 1 thru 07
29 Hydraulic Schematic Diagram ........................................ ..29-2- 1 thru 02
29 Hydraulic Pump Overhaul.. ............................................. ..29-4- 1 thru 05
30 Hydraulic Control Valves and Solenoid Control Valves,
Remove & Replace ..................................................... .30-1-l thru 14
30 Auxiliary, Reach/Tilt Control Valve Service ................... ..30-2- 1 thru 07
30 Lift Control Valve Service Procedures .............................. 30-3-l thrlll0
30 Lowering Solenoid Valve Service Procedures ................. ..30-4- 1 thru 06
30 Auxiliary Solenoid Valve (Reach/Tilt Control) ................. .30-5 1 thru 06
30 Reach & Tilt Selector Valve Service Procedures ............. ..30-6- 1 thru 13
30 Side Shifter Solenoid Control Valve (Optional Equipment) 30-7-l thru 09
32 Tilt Cylinder Overhaul Procedures .................................... 32-2-l thru 07
32 Reach Cylinder Overhaul Procedures ............................... .32-3- 1.thru 07
34 Upright, Pantograph Remove & Replace Procedures and
Roller Shim Check & Adjustment Procedures.. ............ .34-l- 1 thru 40
34 Pantograph & Fork Carriage Service Procedures ............. ..34-2- 1 thru 12
34 Lift Cylinder, Rail - Overhaul Procedures.. ....................... .34-3-l thru 05
34 Lift Cylinder, Free Lift - Overhaul Procedures.. ............... ..34-4- 1 thru 05
34 Lift Fork Inspection ......................................................... .34-5-l thru 04
34 Lift Chain Inspection, Lubrication and Specifications.. .... ..34-6- 1 thru 06
35 Load Wheel Service Procedures ....................................... .35-l- 1 thru 02
40 NPR-345 Specification Listing ........................................ ..40-l- 1 thru 13
40 Service Weights ............................................................... .40-2-l thru 04
40 Lubricants and Shop Supplies ........................................... 40-3-l thru 14
Lubrication
Charts & Specifications 01-1-l
Valves
Remove & Replace 30-l-l
Auxiliary Reach & Tilt 30-2- 1
Lift Control 30-3-l
Lowering Solenoid 30-4- 1
Auxiliary Solenoid Valve
( Reach & Tilt) 30-5-l
Reach & Tilt Selector 30-6-l
Side Shifter Solenoid Control 30-7-l
Specifications 40-l-l
Service Weights 40-2- 1
Lubricants and Shop Supplies 40-3-l
Sump Tank
Fluid Level 29-l-l
Filter and Strainer(s) 29-l-l
Wheel & Tire
Traction 22-l-l
Caster 22-2- 1
Load 35-l-l
The following is a list of CAUTIONS connected with the operation andmaintenance of trucks
equipped with Solid State Control Panels.
IMPORTANT This message is used when special precautions should be taken to ensure a correct
action or to avoid damage to or malfunction of the truck or a component.
A! CAUTION This message is used as a reminder of safety practices which can result in personal
injury if proper precautions are not taken.
A WARNING This message is used when a hazard exists which can result in serious personal
if
injury or death, proper precautions are not taken.
A WELDING ON TRUCKS
1. Make sure the truck has no grounds.
2 Disconnect truck battery.
3. Protect electrical wiring and components from weld spatter with
a shield.
4. Ventilate battery or remove battery from truck.
If the above is not followed, damage can result to wiring and electrical
components on a solid state control truck.
Solid State Controls should be cleaned at regularintervals. Blowing dirt off with an air hose (that
is restricted to 30 psi [207 kPa]) periodically will, for the most part, eliminate any serious
cleaningproblems. Should the need arise for a more thorough cleaning, water may be hosed over
the control and if necessary a mild detergent applied such as that used in washing dishes in our
home. The detergent should be rinsed off and the controls must be thoroughly air dried before
putting truck into service.
Periodic cleaning, such as those mentioned above, should preclude the need for using a
degreaser. However, if a degreaser is used we recommend the following:
Only approved solvents should be used to clean Solid State Control Components. Use Clark
#I1801146 Degreaser, or the equivalent to MS- 180 Freon TF Degreaser and Cleaner.
A CHECK POLARITY
Battery Polarity must be correct or the truck will not
operate.
Appropriate servicemethodsandproperrepairproce- This manual cannot possibly anticipate all such varia-
dures are essential to the safe, reliable operation of tions and provide advice or precautions as to each.
industrial trucks as well as the personal safety of the Accordingly, anyone departing from the instructions
individual doing the work. This Service Manual provided in this manual through procedures used or
provides general directions for accomplishing service choice of tools, materials, and parts may jeopardize
and repair work with tested, effective techniques. his or her personal safety and/or the safety of the
Following them will help assure successful repair and vehicle user.
reliable truck operation.
Improper or careless techniques cause accidents. Dont
There are numerous variations in procedures, tech- take chances with incorrect or damaged equipment.
niques, tools and parts for servicing industrial trucks, Read and understand the procedures for safe opera-
as well as in the skill of the individual doing the work. tion and maintenance outlined in this manual.
Drive and work safely and follow the safety signs and their messages
displayed in the work area, on the truck and in this manual.
Dee 94 ii SM-587
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Cautions
GENERAL PRECAUTIONS
Thefollowing list contains general precautions that should be followed when working
on a lift truck.
Service Electric Truck Batteries in a well-venti- Set the parking brake. Place chocks to the front
lated area to avoid the danger of lighting explo- and rear surfaces of the tires to provide further
sive gases, clear of pedestrians and with ad- restraint from inadvertent vehicle movement.
equate overhead clearance and on a flat, level Use safety stands or blocks whenever a proce-
surface. dure requires you to be under the vehicle.
Always wear safety glasses for eye protection. Follow the Safety Instructions outlinedin Group
Remove rings, watches, loose jewelry and open 12, Handling Storage Batteries.
clothing before working on a vehicle, to avoid Always Discharge the Capacitors prior to work-
serious injury. ing on or around electrical components. Refer to
Do not smoke while working on a vehicle. the instructions outlined in Group 19, Dis-
charging Capacitors.
Putpowerkey switchintheOFFposition,unless
otherwise required by the procedure.
A! CAUTION
Avoid contact with Battery Acid. The battery contains corrosive acid which
can cause injury. Follow the instructions outlined in Group 12 Handling
Storage Batteries and those instructions received with your battery and
charger.
...
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Foreword
This Service Publication provides information Procedures have been made easier to use by
covering normal service, maintenance and repair of providing specific steps only when necessary and
the Clark industrial lift trucks noted on the cover. It general instructions required to explain the activity,
has been specifically prepared to help owners and component, assembly, or process being worked on.
service personnel maintain these trucks in efficient The technician is expected to include obvious addi-
and safe operating condition. tional steps of standard procedure for removal, disas-
This manual is intended for use by persons who sembly, cleaning, inspection, reassembly, installa-
are trained and authorized to do lift truck mainte- tion, etc., as needed.
nance. It is designed to provide essential information Tobe better prepared to do the necessaryservice
about the correct and safe service maintenance and work, take time to completely read the entire proce-
repair of the truck by trained mechanics or service dure, including any special instructions, before start-
technicians. ing any work.
The information is organized by use of the The technician is cautioned and expected
Basic Group Numbering System used in the to...
Master Parts Book and the Customer Parts Manuals.
The manual includes:
... before beginning to work.
P.M. *Take time to completely read (entire) procedures,
including any special instructions.
Planned Maintenance Procedures
including precautions and safe
maintenance recommendations.
ABOUT PLANNED MAINTENANCE
01-40
Service specifications, adjust- The Planned Maintenance Procedures
ments, maintenance and overhaul located in the front of this manual provide a basic step
procedures including lubrication by step guide which should be followed in servicing
charts, recommended lubricants the vehicle. Adjustment Procedures, Specifications,
and service weights, etc. Lubrication Guides, Overhaul Procedures and other
data are found in the rear of this manual listed under
General and detailed service and repair Group and Section Numbers. Refer to the index.
procedures are outlined (as required) for each Regular, correct maintenance and care of
component or subsystem. Some procedures include
industrial trucks is not only important for long and
explanations that are common to several components
efficient truck life but it is essential for safe operation.
or subsystems. The importance of proper maintenance through
The Pictorial Index lists components or systems planned service, inspection and qualified repairs can-
by Basic Group Number of Major Parts. Additional not be emphasized too strongly. Preventive mainte-
content listings are placed at the beginning of each nance instructions are provided for reference in set-
Section in the manual. ting-up and conducting a recommended periodic
Planned Maintenance (PM) program.
The Table of Contents list the pages in this
manual.
NOTICE
The descriptions and specifications included in this manual were in effect at the time of
printing. Clark reserves the right to discontinue models at any time, or make improvements
and changes in specifications or design without notice and without incurring obligation.
Specifications, torques, pressures, measurements, adjustments, illustrations and other
items may change at any time. Contact your authorized CLARK dealer for information on
possible updates or revisions.
Dee94 iv SM-587
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Foreword
Visual Inspection
1. Insuect Batterv Plugi BzTruck Receutacle Battery Plug 7
5. Batterv Retainers
. Check battery retainers for damage. Make cer-
tain retainers are locked in position at each end
of the battery compartment.
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Planned Maintenance Procedures
Fastener Tightening
Sequence
D
F
B
A
G
@ C
E
TORQUE FASTENERS
TO:
124 - 139 LB. FT.
(168 - 188 N*M)
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Planned Maintenance Procedures
I
Wrenchkymb
d. Check the hour meter. Turn the key switch to
the OFF position. The hourglass symbol light Battery Symbo
should come on. The hours registered on the
truck should appear on the digital readout for
about four seconds. Record this hour meter
reading on the PM check sheet.
h. Check Steerin
. While moving the truck at a slow rate of speed
in a forward direction of travel, turn hand wheel
slowly both clockwise and counterclockwise
while listening for unusual steering noise. The
steering should be smooth without hesitation. Direction of Travel
Next, turn the hand wheel rapidly in both direc-
tions. Note on P.M. Check List if steering locks
momentarily. This may indicate a malfunction
in the hydraulic steering system.
CLEANING
IMPORTANT
Do not clean electrical components with steam. Only approved solvents should be used to clean Solid
State components. Scheduled cleaning (as outlined) should preclude the need for using a degreaser. Not
all degreasers are acceptable. If a degreaser is to be used, we recommend Clark #1801146 degreaser or
the equivalent to MS-180 Freon TF degreaser and cleaner.
A WARNING
When cleanina with cornDressed air:
l Wear eye protection and protective clothing when cleaning or drying with air pressure.
l Reduce air pressure to 30 PSI (207 kPa). Debris removed with air pressure can cause injury.
Normal Cleaning
Blowing dirt off with an air hose periodically will, for the most part, eliminate any serious cleaning problems.
Should the need arise for a more thorough cleaning, water may be hosedover the control and if necessary a mild
detergent applied such as that used in washing dishes in the home. This detergent should be rinsed off and the
control dried with an air hose. The control must be thoroughly dry before putting the truck back
into service.
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Planned Maintenance Procedures
c. Discharm?the CaDacitors
. Be sure the battery is unplugged.
. Discharge capacitors using a 100 ohm, 10 watt
resistor connected between the Positive and
Negative power terminals on the Transistor
Control. Hold theresistorinplacefor2 seconds
before removing.
A CAUTION
Using a shorting device
without a resisfor/oadcould
cause damage to the control.
A WARNING
Discharging the capacitors
without using specified
resistor could cause serious
injury to yourself and
bystanders.
A Warning
When cleanina with
compressed air:
. Wear eye protection and protective clothing
when cleaning or drying with air pressure.
. Reduce air pressure to 30 PSI (207 kPa).
Debris removed with air pressure can cause
injury. Battery Roller
d. Air Clean
Battery RetainerL
. Using clean, dry air, and a nozzle extension on
the air compressor hose, air clean truck and
components.
Steer Control-! /-%I
e. Air Clean Batterv Comuartment
. Blow off rollers and roller wells.
. Inspect rollers for damage. Replace any that are
unfit for further service.
Be sure battery retainers are not damaged and fit
properly in their respective grooves.
Air Clean Lower Comnartment
Completely air clean the compartment. Blow
off the steer control, steer pump & motor, drive
motor, brake, cylinder and reservoir.
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PM-l 1 Dee94
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Planned Maintenance Procedures
Make certain that all dust is removed from both the outside and inside of the motor.
I I
Artkula ting
Axle
Brake ComnonentS
l Air clean master cylinders located beneath the
brake pedal. Blow off the brake lines in the
operators compartment. If there is leakage at the connections, tighten the
fittings. If leakage still exists, replace darnaged
l Check brake cylinders, lines and fittings for
parts. If brake cylinder leakage exists, report
damage and leakage. Be certain the brake line
condition to designated authority.
retainer brackets are in place and tightened
securely. Tighten all fasteners and replace any
that are damaged or missing.
h. Axle Mounting
. Be sure the axle to frame retainment
bolts are in place and tightened se-
curely.
......
.>>F.. . . . . .. .. . . . . . . . . . . .. . . ..~.~......
:~:~:::::jj,::~.~.~.~.::::~.~~.~:~:~
.-
b_
Make certain retainer plate is properly located
against the brake line fitting. \
Fa
Hvdraulic Comnartmen$
l Blow off the valves, pump and motor. horn,
and steering sensor. Air clean the complete
compartment.
l Blow off the filter, sump tank and hydraulic
lines.
l Be sure area around the sump breather fill cap
is clean.
l Clean area around the fluid level indicator.
l Visually inspect hydraulic hoses and clamps
for damage, leakage and security of mounting.
Tighten loose clamps and/or fittings. Note any
damage on the P.M. Check List. Valve & Lines
Puma Motor
l If the motor is equipped with a brush cover, remove the cover.
l Remove the brushes and inspect them for wear. Refer to the Brush Inspection Chart in Group 16.
l Inspect commutator bars for bridging dust (copper material) while slowly rotating armature. If bridging
exists, gently remove the bridging dust using a sharp pointed tool such as a scribe or ground off hacksaw
blade. Air clean the commutator after removing bridges.
l Reinstall brushes and brush cover (if applicable).
l Record commutator condition and brush lengths on the P.M. Check List.
Contactors
A WARNING
When clean with compressed
air:
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Planned Maintenance Procedures
Umight
. Blow off the safety screen (or glass), upright
chains, lift cylinders and carriage.
. Check screen/shield for security of mounting.
. Air clean the packing glands on all cylinders.
. Air clean the pantograph, valves and piping.
. Air clean the cylinders and piston rods.
. Blow off the piston rods.
. Check rods and glands for obvious damage,
nicks, marring, scratches that might damage the
cylinder packings. Checkcondition of hydraulic
plumbing and connections. Tighten connec-
tions if loose. If the cylinders are leaking or rods
are damaged note condition on the P.M. Check
List.
* Check lift chains for damage.
. Check the chain anchor pins (7). Be sure the
cotter pins (6) are in place and not damaged.
. Examine the hydraulic plumbing and connec-
tions (5). Tighten loose connections.
. Check rods and glands for obvious damage,
nicks, marring, scratches that might damage the
cylinder packings. Checkcondition of hydraulic
plumbing and connections. Tighten connec-
tions if loose. If the cylinders am leaking or rods
are damaged note condition on the P.M. Check
List.
. Check theharness hold-down clamps (4), brack-
ets (2), andconnectors (3) for security of mount-
ing and damage.
1
l Note condition on P.M. Check List.
1. Fastener
2. Bracket
3. Connector
4. Clamp
5. Fitting
6. Cotter Pin
7. Chain Anchor Pin
-
Snap Ring
Fork
RetainmentPin
+ Fork
IMPORTANT
Anchor Cotter Pin Heads
must be to the inside of
A CAUTION
Never tighten Chain Anchor against
weldment. To do so will result in
chain carnage.
+ Spherical Bushing
+ Chain Adjustor Nut
+ Jam Nut 4-b Torque Specifications
Using two wrenches, a torque wrench
on the Jam Nut and a second wrench
to hold the Chain Adjustor Nut, (A
third wrench on the chain anchor is
helpful) . .. Torque Jam Nut to:
100 - 200 N*m (74 - 148 Ib.ft.)
l With the upright fully lowered and the panto- 2. Rotate chain adjustor nut on each chain anchor
graph fully retracted, check to see if there is l/2- the same number of turns until there is l/2-inch
inch clearance between the heel of the forks and clearance between forks and floor, see illustra-
the floor, see insert below. Check both forks. tion insert below.
Ifclearance is as specified, check tension of both 3. Once the l/2-inch clearance has been accom-
chains on the longest span. Chain tension should plished, check for equal chain tension ... they
be the same. should be the same. If not, make a minor adjust-
ment to the chain that has the least tension.
l If the above checks are as specified, follow the
carriage instructions outlined in Step 5 on the 4. Finger tighten jam nuts against chain adjustor
next page. nuts . Make sure the chains are not twisted and
then torque the nuts as instructed in the illustra-
l If any one of the above checks are not as speci-
tion below. Again, check to be sure chains are
fied, adjust the chains as instructed on this page
straight and not twisted.
and then continue to Step 6 on the next page.
u w Chain Anchor
+ Spherical Bushing
o + Chain Adjustor Nut
8
0 + Jam Nut 4-k Toraue Soecifications
f&a
[ Using two wrenches, a torque wrench
on the Jam Nut and a second wrench
Lift Chains connect to
to hold the Chain Adjustor Nut, (A
Pantograph Carriage. third wrench on the chain anchor is
helpful) ... Torque Jam Nut to:
100 - 200 Nom (74 - 148 Ib.ft.)
Elevate upright to maximum fork height. Rotate chain adjustor nut on each chain anchor
the same number of turns until there is l/8- inch
Check to see if there is clearance between the clearance between these stops. Adjust no more
stop weldment on the Inner Rail and the stop than necessary to provide this clearance.
weldment on the Pantograph Carriage. For loca- Now, torque jam nuts as previously described.
tion of these stops, see illustration below. There
Again, check to be sure chains are straight and
must be some clearance ... approximately 15 mm
not twisted.
(S9 inch) ... between these stops.
If the carriage stop contacts the rail stop, adjust
chain anchors as outlined in next column .
Carriage stops must not make contact when upright is elevated to maximum
fork height.
l/O
Chain Anchor
+ Spherical Bushing
+ Chain Adjustor Nut
+ Jam Nut 4-k Toraue Specifications
Using two wrenches, a torque wrench
on the Jam Nut and a second wrench
to hold the Chain Adjustor Nut, (A
third wrench on the chain anchor is
helpful) ... Torque Jam Nut to:
100 - 200 Nom (74 - 148 Ib.ft.)
1. use nrotectivelubrication fluid. Clark Part Number 1803827. to coat terminals of followirw 111119s;
l EV-T15 A,B,Y and 2 Plugs (OSC or Traction Control Card)
l EV-TSPS PL4 Plug
l DashDisplay Plug - PL - DP Plug
l Key SwitchTerminals - Wire Spades 10 & 1OC and 12 & 12B
l HornTerminals - Wire Terminals 13 (or 13B) and 26
l Relay Terminals (for optional equipment only)
2. Check Contactor Tips for the following:
l Cleanliness
l Wear
l Metal transfer between stationary and movable tips.
3. Check Harness/Cable/Fuse Connections for securitv of mounting and condition of terminals,
l Check for frayed/broken cable strands at termi- l Check for oxidation (white/blue) and discolora-
nal crimp, see below. tion of cable edge on terminal barrel end. This
reflects high resistance joint
Broken Wires
Notice:
AS Brake Linings Wear:
l Brake Arm & Rod move
inward.
9 Pressure Spring Length
increases.
NOTE
RefertoGroup 19,Section
Forward Switch Reverse Switch
7ofthismanualforspecific
procedures.
Transducer
Brake Reservoir -1
Caster Pivot Bearings
Motor Brake Linkage A
Section 1
NPR-345
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Copyrighted Material Dee 94
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GROUP 01 Lubrication
Lubrication Chart Key
L18l L2 A multi-purpose grease of refined mineral oil
NLGI #I Grade blended with a lithium soap thickener or equal
Clark Spec. MS-107B
General Purpose Grease containing anti-wear, anti-rust and anti-oxidants
L3 with EP additive with EP additives, per Clark Specification MS-
NLGI #2 Grade Ir
107.
Clark Spec. MS-107C
B
Clark Part No. 885385 Use only high quality hydraulic fluid with Zinc
of 24 one qt. cans
l-case
or equivalent Anti-Wear additive which meets
L7
Clark Part No. 885382 the requirements of ASTM D-2882 pump wear
l-caseof 6 one gal. cans
test with 50 mg total weight loss maximum per
Hydraulic Fluid Clark Spec. MS-68
Caster Brake Linkage: Lubricate with engine oil at every PM Brake Inspection.
Note
Lubricate length of rails at point of roller Contact first P.M. only on new trucks.
c;I
Ground Wire -
Apply to wire con-
nections any time
they are discon- Pump Motor
nected. Note: ReaD-
plybeforemakingthe c
Threaded Areas
I
improved viscosity-temperature characteristics.
r
-
3
B
,
\
-
-T-
Grease Fittings
Sr>ecifications: Use an extreme low temperature aircraft quality grease meeting ML-G-23827A, or equivalent
product. Temperature range: - 100 to +250F.
for
SECTION 1
Battery
Contents
Battery Service Area .................................................................. 12-1-3 & 4
Handling Storage Batteries ........................................................ 12-1-3 & 4
Battery Removal & Installation ......................................................... 12-1-5
Battery Maintenance ......................................................................... 12-1-6
Battery Installation ........................................................................... 12-1-7
Battery Records ................................................................................ 12-1-8
(....i
, ...., / BATTERY
.- .._.___
_
:::;.y
SERVICE
;Y
L.
nnrr
I.. ._._.,
,<\
~. -.&.._..~.-;..
-.
Y\
,.,
D
A WARNING
SULFURIC ACID
THE BATTERY CONTAINS CORROSIVEACID WHICH CAN
CAUSE INJURY. IF ACID CONTACTS YOUR EYES OR SKIN,
FLUSH IMMEDIATELY WITH WATER AND GET MEDICAL
ASSISTANCE.
1147748
l l
A WARNING
A DANGER
Explosive gas is always present around batteries,
especially when they are being charged. The fol-
lowing should be adhered to.
l No smoking shall be allowed in the charging
area.
l Battery electrolyte shall never be checked
with an open flame.
l Open flame, sparks, or electric arcs shall
never be allowed in the battery charging
area.
Persons maintaining storage batteries must wearpro-
tective clothing such as:
l Face and head shields
l Long shirt sleeves.
l Gaunlet gloves.
SM-587 Copyrighted12-1-3
Material Dee 94
Intended for CLARK dealers only
Do not sell or distribute
GROUP 12 BATTERY
Be sure the battery service area is equipped with Overhead Hoist
- Safetv Hook /
material handling equipment designed for the pur-
pose of removing and replacing batteries, such as a
conveyer or overhead hoist equipped with safety
hooks
l When using an overhead hoist, be sure to use an
insulated spreader bar or similar lifting device.
To prevent side forcesfrom damaging the bat-
tery, the distance between the lifting hooks (of
the spreader bar) must be adjusted to the same
dimension as between the battery lijiting eyes.
Make sure the lifting hooks are the correct size
tofit the lifting eyes of the battery.
Plyw~ -
l If the battery does not have a cover of its own,
cover it with a non-conductive material such as (Non-Conductive Cover)
plywood-
Typical Illustration
Typical Illustration
* Never lay tools or other metal objects on a
battery. Metal objects contacting battery termi-
nals will cause short circuits. The shorted cir-
cuits could ignite battery fumes and cause the
battery to explode.
Battery Disconnected
.
Uncovered Batteries:
Cover With
FVywood or Heavy Cardboard
../....
L
---I=
-
lad
:A =
-
---_
-ze
-_
Battery Vents
l When ChargingBatteries:Theventcapsmust
be kept in place to avoid electrolyte spray. Care
must be taken to assure that vent caps are func-
tioning. The cap vents must be open to allow the
battery to breath. The battery cover must be
removed/opened to dissipate heat and explosive
gas.
l When Cleaning Batteries: The vents must be
tightly in place.
Battery Cleaning
The easiest and most satisfactory method of cleaning
a battery is to wash it with a low pressure cold water
spray. The battery top can also be washed with a
baking soda solution and rinsed with clear water.
l Check to be sure all vent caps are tight before
washing the battery.
l Fill a bucket with cold water while adding a box IMPORTANT
of baking soda to the pail. Stir the solution until Vent Caps must be free of obstruction and in good condition
dissolved. It is advisable to have this solution Battery top should be clean and free of cracks or breaks.
Battery terminals must be clean and solidly mounted.
around the battery service area at all times.
Damaged batteries should be repair or replaced.
l After washing battery, thoroughly rinse with Consult your battery vendor.
clear cold water.
Battery Charging
Follow theinstructions suppliedby theBattery Charger
Vendor.
I Battery Maintenance
To obtain maximum performance and
Battery Electrolyte battery life, the instructions supplied
l Always use a carboy tilter or siphon when by your Battery Vendor should be
handling battery electrolyte. adhered to.
l When mixing electrolyte, always pour acid into
water - never pour water into acid. Pouring
water into acid will cause a dangerous chemical
action.
A WARNING
- Air Hose -
Wear eye protection and
protectiveclothing when drying
with air pressure. Reduce air
pressure to 30 PSI (207 kPa).
Debris removed with air
pressure can cause injury.
1Fl
::,..
l Blow off the compartment walls and floor with .P,...
Install Battery
If the battery is uncovered, cover the battery with a
non-conducting material (i.e.., plywood, heavy card-
board, etc.) prior to installation.
l Push battery into battery compartment.
l Install battery retainer.
l Remove non-conductive material from battery.
l Connect battery to truck.
SM-587 Copyrighted12-1-7
Material Dee 94
Intended for CLARK dealers only
Do not sell or distribute
GROUP 12 BATTERY
KEEPING BAlTERY RECORDS BAllERlES
Records should be kept to get the best service out of Industrial Batteries are used to supply the electrical
your battery and truck. power to operate an Electric Industrial Truck. Their
voltage depends on the number of individual cells
These records should contain: they contain. There are approximately 2 volts for each
cell in the commonly used lead-acid type battery.
l Test Date. Each test should be dated for future
Batteries normally range from 6 volts to 72 volts.
reference and comparison.
Their capacity varies depending on the application.
l Specific Gravity and Temperature readings. Only use batteries that comply withfactory spec@ica-
Each battery cell should be checked and re- tions as to size and capacity and weight.
corded before and after charging. The specific
gravity reading of the electrolyte should not be HOW TO GET MAXIMUM LIFE OUT
less than 1.260. If below 1.250, the battery OF YOUR BAITERY
should be recharged and tested.
. Do not add acid to a battery. Only qualified
l Variation between each cell tested. The varia- Battery Representatives should determine ijlhis
tion in specific gravity reading between cells
is necessary.
should not be greater than 15 points (.015). If
. When lifting a battery, use a lifting device
readings are greater, this indicates there are
defective cells. designed for this purpose
. Check the electrolyte level before placing a
Thepilotcellshould be changed occasionally to
distribute any electrolyte loss over the battery battery on charge. Add water, if required, before
when taking readings. charging the battery. The electrolyte level in a
battery should be slightly below the lower lip of
l Load Voltage Tests should be performed and the filling hole vent. Do not over fill. Over
recorded indicating the condition of a battery
flushing causes loss of electrolyte.
while it is performing work.
. Keep the battery clean, dry and in good condi-
l Actual Operating hoursof the battery.Record
tion.
the actual time the battery is in use before
. Keep metal objects and tools away from the top
putting it on charge..
of the battery. Short circuits will cause battery
l Charging Time. Keep an accuraterecordof the damage and could ignite battery fumes, explod-
actual time the battery is on charge. After each
ing the battery.
charge, check to see if the battery is fully
. Maintain good battery cable connections.
charged. Test the battery before placing it back
into service. Record these results. . Check power cables and wiring for damage.
l Visually Inspect for loose terminal connec- . Do not over charge a battery.
tions or posts, a cracked case, or damaged cell
. Do not under charge a battery.
vent caps and excessive corrosion. This data
should be noted to help ascertain work environ- . Follow the instructions provided by your
ment and possible trouble areas. supplier(s) of the battery and battery charging
For further information, refer to Croup 19, Section 4 equipment.
in this manual. . Maintain accurate battery records. If battery
Check with your local battery supplier for complete troubles occur, these records will help you and
battery maintenance procedures and their expertise. your battery representative determine the nature
of the problem.
Section 1
Multi-Function Control Handle
Switches
Contents
Reach, Tilt and Auxiliary Switches, Remove and Replace . .. .. . .. . .. .. .. .. . 13-l-2
Lift and Lower Switches, Remove and Replace . ... . .. .. .. .. .. .. .. .. .. ... . .. .. .. 13-1-3
Transducer; Forward and Reverse Switches, Remove and Replace..... 13-1-4
PL-9
so-i0
Transduce- \\> Harness
so-7 sq7
Lift/Lower
Switch ~,
A CAUTION
If disconnected, match plug number with appropriate receptacle number before
making a connection. If not, electrical shorts and possible damage to equipment
may result. i.e., Plug #PL-6 plugs into pin socket ##SO-6,etc.
IMPORTANT
Cables must be positioned so all tape markers
are aligned with or hidden under clamps or guides.
L Washer
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 13 Switches
-#oG
ml -Y /
4
I IIl-I
Assemble horn switch
Route Harness
as shown -W
Route Harness
hidden under
to bracket.
Remove & Replace
l Route the transducers wire assembly through
Two adjustable switches mounted to a
the clamp and securely fasten the socket clamp
bracket at the rear of the multi-function control pro-
as shown in illustration on page 1.
vide forward and reverse direction of travel. A trans-
ducer and adjustor plate are attached to a mounting l Connect transducer harness Socket SO- 10 to the
plate at the rear of the control. The transducer provides main wire harness Plug PL-10.
variable speed control. Refer to GROUP 19, Section 7 for switch and
Switch Removal transducer adjustment procedures.
Section 2
Electric Motors
General
Contents
Safety . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . ... . . .. .. .. .. .. .. .. . . .. . 16-2-2
Motor Inspection, Cleaning and Insulation . .. .. .. .. .. .. .. .. .. .. . ... .. .. .. .. .. . . .. .. 16-2-3
Testing Procedures . .. .. .. .. .. .. .. .. .. .. ... . .. .. .. .. ... . .. .. .. .. .. .. .. .. .. .. .. . .. . .. .. .. .. . .. . . 16-2-4
Brush and Commutator Inspection . ... . .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. . .. .. .. .. .. .. .. .. 16-2-5
Brush Inspection Chart . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . ... . .. . .. .. .. .. .. .. .. .. .. .. . 16-2-7
Cable and Clamp Inspection . . ... .. .. .. .. .. .. .. .. .. .. .. .. . . ... ... . .. . .. .. .. .. .. .. . .. . .. .. . 16-2-9
Refer to:
Group 16, Section 7
A WARNING
Wear eye protection and
protective clothing when
cleaning or drying with air
pressure. Reduce air pressure
to 30 PSI (207 kPa). Debris
removed with air pressure can
cause injury.
........ :.:
........ :.:~:::::::::::::::::.
.....................................
........ . . .. . . . . . . . . . . . . . . . . ..j.....:~:::::~::::::.
. . . . . . . . . . . . ::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::
:::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::
..:.:.:.:.:.:.:.:.:.:::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::
:.:.:.:.:.:.:.:.:.:.....~.......:.:~.~.:~~~.:.:.~.:.!.:.:.~.:.:.~.~.:.:.:.:.~.~.:.:~.~~.~
:: :::: ::::::::<
.............. ..
A CAUTION
Using ashorting devicewithout
a resistor load could cause
damage to the control.
A WARNING
Discharging the capacitors
unplugged. _
without using specified resistor
could cause serious injury to
yourself and bystanders.
A planned maintenance program of regular, routine inspections is important for long life and trouble-
free operation of electric motors. Make and keep records of your inspections. Use these records to help
establish correct P.M. intervals and to indicate maintenance required to prevent major problems from
occurring during operation.
Inspection Procedures 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
To perform these service procedures, it is recom- motor damage occurs.
mended that you first:
Motor Insulation
Park truck safely.
Fully lower upright. If a reduction in motor performance has been
Apply parking brake. noted, it may be due to breakdown in motor insu-
lation causing internal grounding or a short circuit.
Turn key switch OFF.
Failures of motor insulation are due to:
Disconnect battery from truck recepatacle.
l (1) contamination
Discharge capacitors, see page 2.
l (2) mechanical factors
l (3) high temperatures
Motdr Cleanliness
Contamination includes dirt, moisture, oily va-
pors, metal chips, carbon dust from brushes, etc.
Electric motors should be kept clean at all times to
prevent shorting, minimize wear, and for best cool- Mechanical factors include shock, vibration, over
ing. speed, etc.
Operation at prolonged or excessively high tem-
l Wipe off all dust, dirt, oil, water, etc., from perature will cause insulation to become brittle and
outer surface of motor. crack leading to premature failure. The insulation
condition can be judged both visually and by test
l Remove any debris from cooling air vents and measurement. Regular, periodic measurements of
around motor frame to prevent overheating. insulation resistance can give a useful indication of
the rate of insulation deterioration.
SM-587 Copyrighted16-2-3
Material Dee 94
Intended for CLARK dealers only
Do not sell or distribute
GROUP 16 Motors
TEST FOR MOTOR INSULATION TEST FOR MOTOR INSULATION
RESISTANCE TO GROUND RESISTANCE TO GROUND
(Using a 500 Volt Megger) (Using a Simpson 260-6~ Volt-Ohmmeter or
equivalent calibrated on the RxlO,OOOScale).This
(Test must be made with motor out of truck).
test may be made with motor in the truck.
1. Disconnect battery from truck receptacle. 1. Disconnect battery from truck receptacle.
2. Discharge the capacitors. Refer to Group 19. 2. Discharge the capacitors. Refer to Group 19.
3. Disconnect power cables from all motor termi- 3. Disconnectpowercablesfrommotorterminals.
ll&.
4. Connect the positive lead of the VOM to all
4. Connect one lead of a 500-volt megger to any terminal studs of test motor. Use jumperwires to
motor terminal. NOTE: Test ALL terminals connectbetweenmotorterminals.ConnectVOM
individually or by interconnecting with jumper negative lead to motor frame.
wires. Connect other lead to motor frame. Apply
NOTE
voltage.
Test all terminals individually, or
5. Resistance should be measure at least 1,OOO,OOO joined together, as noted.
ohms (1 megohm). If less than this, motor
should be air-cleaned or dried to attempt to 5. VOM must show 1,OOO,OOO ohms ( 1 megohm)
increase insulation resistance. resistance or higher for a good motor insulation.
6. 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.
SM-587 Dee 94
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Motors GROUP 16
BRUSH AND COMMUTATOR 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: A dark uniform coloring pattern at the brush wearing surface.
Poor Commutation: 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.
. Uneven film.
. Carbon dust bridging between bars
Different Grade Brushes; When the brushes being fitted are of a different grade from those
previously used, then it is advisable to remove the film left
by the previous 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
moderately abraded commutator surface will help
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 recommen-
dations should be applied as actual conditions dictate.
Normal Service: Basically an eight- Severe Service: Extended operating
hour day of indoor hours, or constant us-
material handling. age.
IMPORTANT
NEW BRUSHES MUST BE OF
Shunt-\ \ f-Cross Connector
SAME SIZE AND GRADE
PressureSpring--+\A I~rBrush Box
(MATERIAL
SPECIFICATION)
REPLACED
AS T!/ 1
.I
Retainer
Screw
BRUSHES.
AWAYS REPLACE BOTH
Brush Box- CBrush Box
BRUSHES AND SPRINGS. DO p_
Brush - II I Brush 1
NOT REUSE OLD SPRINGS. I III
- 6rus.h BOB
AI
J
Retainer
Screw
Hammer Plate FJI-2
Observe how brushes are assembled in brush hold-
ers, and position of brush lead (pigtail). New
brushes must be installed in same manner.
rypical lllustation
REPLACE BRUSH
-i
REPLACE BRUSHES
WHEN WORN TO
Typical Illustration
Typical
Inch Pound
Pointer
Typical
Foot Pound
Pivoted
Torque Went h
Scale Handle
Pointer
IMPORTANT
Improperly Torqued Fasteners Can Cause Damage.
. Use an appropriate torque wrench and tighten all fasteners to the torques specified
in the illustation on the following page.
IMPORTANT
Xamps must be
jositioned so all
rAPE MARKERS
ire aligned with
)r hidden under
he clamps or
:able guides.
\ /I i ! i \\
IL
2
Wire
Harness \
:;:>g#:;
::::::::::::::::
:::
j:::::::::::
::::::::::::::::
::::::::::::::::
y:::::::::::::
::::::::::::::::
::::::::::::::::
::::::::::::::::
::::::::::::::::
y:::::::::::::
TM- ?.Z.W:
IJ1Torque
------__--
Drive Motor Cable Fasteners
to: 150 Ib.in. (I 6.9 N*m)
Al
Torque Cable Guide Nut
to 100 Ib.in. (11.3 Nom)
-
Section 3
Traction Motors
24 & 36 VOLT
Contents
General Information . .. .. .. .. .. .. .. .. .. ... . .. . .. . .. ... . .. .. .. .. .. .. .. .. .. .. .. . .. . .. .. .. .. .. .. . 16-3-3
Motor Disassembly . .. .. .. .. .. .. .. .. .. .. .. ... . .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. .. .. .. .. .. .. .. . . . . 16-3-5
Component Inspection & Trouble Shooting . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... . 16-3-6
Testing . .. .. ...I..................................................................................... 16-3-7
Changing Brushes . .. .. ...f.................................................................... 16-3-8
Motor Reassembly . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. .. .. .. .. . . .. . 16-3-8
Specifications .. ... .. .. .. . ... .. .. . ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . ... . .. . .. .. .. .. .. . . 16-3-9 & 10
Inspection Charts . .. .. .. .... .. .. .... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 16-3-11
24 & 36 Volt
Ventilated and Enclosed Motors
Dee 94 Copyrighted16-3-1
Material SM-587
Intended for CLARK dealers only
Do not sell or distribute
GROUP 16 Motors
A WARNING
Wear eye protection and protective clothing when drying with air pressure. Reduce
air pressure to 30 PSI (207 kPa). Debris remoJed with air pressure can cause injury.
Pointer
SM-587
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 16
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. 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: A dark uniform coloring pattern at the brush wearing surface.
Poor Commutation: 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.
. Uneven film.
. 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 eight- Severe Service: Extended operating
hour day of indoor hours, or constant us-
material handling. age.
Extreme Service:
7. Remove commutator
end head and .... Q
Brush Holder
>ommutator End Head Motor Housing Armature Assembly Drive End Head
Disassembly
Remove the cover band (if so equipped) from
the commutator end of the motor. Use a brush
hook to reach into the motor and lift the brush
springs. Pull the brushes out of the brush hold-
ers.Eitherpositionthebrushesoutsidethemotor
or remove the brush retaining screws and re-
move the brushes from the motor.
Scribe or center punch locating marks in the end
heads and the &me. Although locating marks IJ YJ II
If the bearing remained in the end head, remove l Use a hammer and chisel or drift punch to drive
bearing from end head. On some motors the spline out of shaft.
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 burning or heavy arcing between bars. The
cleaned and dried, they should be inspected for the coloring pattern will be:
following:
l Streaky film with commutator wear.
Drive End Head
l Bar edge burning.
1. Check bearing recess for any signs of wear.
l. Uneven film.
2. Checkmountingholesforany strippedorcmsed
l Carbon dust bridging between bars.
threads or broken studs.
Brushes should be inspected for uneven wear and
Commutator End Head
signs of overheating, i.e.
1. Check bearing recess for any signs of wear.
l Discolored brush shunts
2. Check brush holder insulation for cracks or any
l Discolored brush springs.
signs of burning.
Refer to the Brush Chart on page 16-3-11.
3. Check brush holders and springs for wear.
Armature
Bearings
1. Check security of fan.
1. Check bearings by turning them with your fin-
gers. Feel for binding or gritty effects and 2. Check for loose commutator bars. Loose com-
excessive looseness or wobble. A good bearing mutator bars will usually be indicated by exces-
should also have a small amount of drag or sive wearorbumingonone bar. The commutator
stiffness caused by the lubrication but should can be checked for loose bars by lightly tapping
turn smoothly. If the bearing turns very freely, all of the bars with the handle of a plastic or
it should be replaced. Bearings should also be wooden handled screwdriver. A contrasting
changed, if worn out, damaged or removed from dull thud or vibration will indicate a loose barin
armature shaft. which case, the armature must be replaced.
l Ball bearings that have been pulled off of shafts, 3. Check for grounded circuits using a test light.
pressed out of end heads, or side loaded in such Most commercial growlers incorporate a test
a way as to apply pressure on the balls and races light as shown in illustration below.
must be replaced. Although the bearing may . Check the armature for grounded circuits by
appear or feel good, the bearing races have been placing one test lead of the test lamp on the
brinelled and will fail within a relatively short commutator and the other test lead on the arma-
period of service. ture shaft. If the test light lights, the armature is
Brush and Commutator grounded.
TESTING
Grounded Circuit
l Touch one test lead to a clean bare metal spot on
NOTE the frame and check all terminals with the other
Ifthearmaturehasbeenturnedand lead. If a grounded condition exists, the test light
undercut prior to testing, check for will light.
and remove any copper buildup or
filings between commutator bars Open Circuit
and at the commutator riser. This
l Check between all connecting terminals with
condition will cause an armature
test leads. Ifthe bulb fails tolight, anopencircuit
tocheckshortedandusuallyresults
is indicated.
from a dull undercutting tool.
SM-587 Dee 94
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Motors GROUP 16
Motor Specifications
l Frame Size: 6.7 (165.1 mm) Diameter
.
l Weight (Approx.): 43 lbs. (19.51 kg)
l Internal Bearings are sealed and lubricated with high temperature grease for the
life of the bearing.
Motor Insulation
l Armature components, Class H
l Commutator components, Class H
.
C.C.W.D.E.
Brush Data
1 Brush per Holder
4 Brushes per Motor
Min. Length of Worn Brush
0.42 (10.67 mm)
Max. Force per New Brush
29 oz. (825 gm)
Max. Force per Worn Brush
12 oz. (340 gm)
Brush Drop Grade: H803
Motor Specifications
l Frame Size: 6.5 (165.1 mrn)Diameter
l Weight (Approx.): 43 lbs. (19.51 kg)
l Internal Bearings are sealed and lubricated with high temperature grease for the life of the
bearing.
Fsulation
l Armaturecomponents, Class H ROTATION: REVERSIBLE
l Commutator components, Class H
C.W.D.E.
CommutatorServicing Diameters
Forward Vehicle Direction
Maximum Diameter, NEW: 2.92
I
Minimum Diameter for RESLOTTING: 2.80
Min. Diameter for REPLACEMENT: 2.75 C.C.W.D.E.
Brush Data
l 1 Brush per Holder
l 4 Brushes per Motor
l Min. Length of Worn Brush
0.42 (10.67 mm)
l Max. Force per New Brush
29 oz. (825 5)
l Max. Force per Worn Brush
12 oz. (340 5)
l BrushDrop Grade H803
Motor Brush
1.0 Volts @ 71 Amps
REPLACE BRUSH
I
IF SPRING TENSION IS NOT THE SAME
FOR EACH BRUSH, REPLACE SPRINGS. II
I I
REPLACE BRUSH IF OIL SOAKED
0.42"
REPLACE BRUSHES
WHEN WORN TO
Copyrighted Material
16-3-l 1 SM-587
Intended for CLARK dealers only
Do not sell or distribute
GEA-7
LIGHT TAN FILM over entire commutator MOlYLED SURFACE with random film pot- BLOT BAR-MARKING, o sfiihdy do&f HEAVY FILM cpn oppeor over entire
swfoc* is one of many normal condtionl tam is pmbabfy most heqwdy obrmed fffm, pppmn on bon in o d&k panem preo of efficient and normal commute-
ohen seen on (I well-functioning machine. condition of rommutatorr in industry. nl0t.d to numb.l of condumm per dot. tar and, if uniform, b quite occ.ptobfc.
STREAKING on the commutator swfoce sipnols Ihe THREADING al tommutm~r whh firmlims rowIts GROOVING b o mechanical condition cowed
beg8nnmg of s*rios met01 nand*r to Ihe carbon whan lxmsiva mudnansfnoccum h usually kodr by abrasive motwiol in the brush or otmor-
brush. Check the chart below for possible muses. to rwnfocing of commutotw and mpid bwsh weor. phere. lf grooves form, start corrective action.
- --\ .
COPPER DRAG, on obnormol build-up of commutator PlYCH BAR-MARKING produces bw w burn... spots .- HEAVY SLOT BAR-MARKING con involve
mattiol, forms most often at Iroiling +* of bar. Con- on lh* commutota surfor*. The number of these mork- atching of hailing edgo of rommutotor bar. Pot-
dition is rare bui ton covu flashover if not hked. ingr equolr half or all 410 numbw of pohr on the motor. tern b r&ted to number of conductors per dot.
Carbon Products
General Electric Company
East Stroudsburg. Pa. 18301
Copyrighted Material c
Section 5
Pump Motors
24 & 36 VOLT
Contents
General Information . . . .... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 16-5-3
Motor Disassembly . .. .. .. . ... .... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . ... .. .. .. .. .. .. . . .. .. 16-5-5
Component Inspection & Trouble Shooting . .. .. .. ... . .. .. .. .. .. .. .. . ... .. .. .. .. . . 16-5-6
Testing . . ... .. . ... .. .. .. .. .. . ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. .. .. .. .. . .. . . 16-5-7
Changing Brushes . .. .. .. .. . .. ... .. .. .. .. .. ... . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... . .. .. .. .. .. . . 16-5-8
Motor Reassembly . . .. ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. . . 16-5-8
Specifications . ... . .... ... . .... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. .. .. .. .. .. . .. . . 16-5-9
Inspection Charts . .. .. .. .. .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. 16-5-11
24 & 36 Volt
Ventilated and Enclosed Motors
3/8-l 6 UNC-2A -
Bearing Bearing
I .;-. 17 -
Name Plate
0 0
Snap
-t
112-l 3 UNC-2B A - Mounting Bracket 3/8-24 UNF-2B -1
A WARNING
Wear eye protection and protective clothing when drying with air pressure. Reduce
air pressure to 30 PSI (207 kPa). Debris remo2ed with air pressure can cause injury.
Pointer
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.
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. 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 burning or heavy arcing between bars. The coloring
pattern will be:
. Streaky film with commutator wear.
. Bar edge burning.
. Uneven film.
. 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: Severe Service:
Basically an eight- Extended operating
hour day of indoor hours, or constant us-
material handling. age.
1. Remove brushes. +
4
3. Remove
screws from
2. Remove screws-b
drive end
from commutator
head.
end head.
4. Remove
drive end
head with
bearing.
Screw
Disassembled View
T Bearing Bearing
Field Coils & Pole Shoes
Housing
Disassembly
l Remove the cover band (if so equipped) from
the commutator end of the motor. Use a brush
hook to reach into the motor and lift the brush
springs. Pull the brushes out of the brush hold-
ers. Either position the brushes outside the rush I prin! s
c-
heads and the frame. 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.
l Remove the commutator end head retaining
screws or bolts. The motors have a slip fit
bearing at the commutator end, and the end head
can be removed with very little trouble.
l 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.
l Separate the armature from the drive end head.
This operation is usually accomplished by press-
ing the armature out of the drive end bearing.
The end head and bearing may have to be
removed with a puller. When a puller is used,
protect the end of the armature shaft with a nut
or a thick flat washer. If the shaft, coupling, 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.
l Separate the bearing from the end head. The
bearing is retained with a snap ring. Remove the
snap ring, then press the bearing out of the end
head.
Dee 94 Copyrighted18-5-5
Material SM-587
Intended for CLARK dealers only
Do not sell or distribute
GROUP 16 Motors
Component Inspection & Trouble Shooting
After the motor components have been thoroughly burning or heavy arcing between bars. The
cleaned and dried, they should be inspected for the coloring pattern will be:
following:
l Streaky film with commutator wear.
Drive End Head
l Bar edge burning.
1. Check bearing recess for any signs of wear.
0. Uneven fti.
2. Checkmountingholesforanystrippedorcrossed
l Carbon dust bridging between bars.
threads or broken studs.
Brushes should be inspected for uneven wear and
Commutator End Head
signs of overheating, i.e.
1. Check bearing recess for any signs of wear.
l Discolored brush shunts
2. Check brush holder insulation for cracks or any
l Discolored brush springs.
signs of burning.
Refer to the Brush Chart on the following
3. Check brush holders and springs for wear.
pages.
Bearings
Armature
1. Check bearings by turning them with your fin-
1. Check security of fan.
gers. Feel for binding or gritty effects and
excessive looseness or wobble. A good bearing 2. Check for loose commutator bars. Loose com-
should also have a small amount of drag or mutator bars will usually be indicated by exces-
stiffness caused by the lubrication but should sive wearor burning on one bar. Thecommutator
turn smoothly. If the bearing turns very freely, can be checked for loose bars by lightly tapping
it should be replaced. Bearings should also be all of the bars with the handle of a plastic or
changed, if worn out, damaged or removed from wooden handled screwdriver. A contrasting
armature shaft. dull thud or vibration will indicate a loose bar in
which case, the armature must be replaced.
NOTE
Ball bearings that have been pulled 3. Check for grounded circuits using a test light.
off of shafts, pressed out of end Most commercial growlers incorporate a test
heads, or side loaded in such a way light as shown in illustration below.
as to apply pressure on the balls . Check the armature for grounded circuits by
and races must be replaced. placing one test lead of the test lamp on the
Although the bearing may appear commutator and the other test lead on the arma-
or feel good, the bearing races
ture shaft. If the test light lights, the armature is
have been brinelled and will fail
grounded.
within a relatively short period of
service.
TESTING
L Switch
/
Grounded Circuit
Growler
l Touch one test lead to aclean bare metal spot on
NOTE the frame and check all terminals with the other
Ifthearmaturehasbeentumedand lead. If a grounded condition exists, the test light
undercut prior to testing, check for will light.
and remove any copper buildup or
filings between commutator bars Open Circuit
and at the commutator riser. This
l Check between all connecting terminals with
condition will cause an armature
testleads. Ifthebulbfails tolight,anopencircuit
tocheckshortedandusuallyresults
is indicated.
from a dull undercutting tool.
Motor Specifications
l Frame Size: 6.5 (165.1 mm) Diameter
l Weight (Approx.): 43 lbs. (19.51 kg)
l Internal Bearings on Pump End and Commutator End. Bearings are double
sealed and lubricated with high temperature grease for the life of the bearing.
Motor Insulation
l Armature components, Class H
l Commutator components, Class H
.Commutator Servicing Diameters
l Maximum Diameter, NEW 2.92
l Minimum Diameter for RESLOTHNG: 2.80
l Min. Diameter for REPLACEMENT: 2.75
Brush Data
l 1 Brush per Holder
l 4 Brushes per Motor
l Max. Length of Worn Brush
0.42 (10.67 mm)
Length
l Min. Force per New Brush 11.13(28.7n n>
7
29 oz. (825 gm)
l Max. Force per Worn Brush
12 oz. (340 gm)
l Brush Drop Grade: H803
Motor Specifications
l Frame Size: 6.5 (165.1 mm) Diameter
l Weight (Approx.): 43 lbs. (19.51 kg)
l Internal Bearings on Pump End and Commutator End. Bearings are double sealed and lubricated
with high temperature grease for the life of the bearing.
Motor Counlinz
l 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.
Circuit and Rotation
Jnsulation
Single Rotation
l
l Armature components, Class H
CCWDE, -
l to Battery Negative,
l Commutator components, Class H
+ to Battery Positive.
Commutator Servicing Diameters
l Maximum Diameter, NEW: 2.92
l Minimum Diameter for RESLOITING: 2.80
l Min. Diameter for REPLACEMENT: 2.75
Brush Data
l 1 Brush per Holder
l 4 Brushes per Motor
l Min. Length of Worn Brush
0.42 (10.67 mm)
Length-6
l Max. Force per New Brush 1.13(28.7mm)
l
29 oz. (825 gm)
Max. Force per Worn Brush
12 oz. (340 gm)
BrushDrop
1.0 Volts @ 71 Amps
7 Grade H803
Motor Brush
REPLACE BRUSH
v
CHECK TENSION
OF EACH SPRING
0.42"
1
REPLACE BRUSHES
WHEN WORN TO
HERE.
NEW BRUSHES
LIGHT TAN FILM ov.r entire commutator MOYYLED SURFACE wf+ft mndom film pat- SLOT IAR-MARKING, a sfiphdy darker HEAVY FILM <on oppeor ov.r weire
surfoc* is one of many nomwl conditions +em is probably mod fmqwn+fy observed fib, appmm
onbanin a dafinih panem or.0 of efficient and normal commvto-
ohen seen on a well-funaioning machine. condition of commu+q+orr in industry. nl.a+ed +o numkr of <onduc+urI par Jo+. +or and, if uniform, is quite accep+abfc.
STREAKING on the ~ornrn~t~+or wrbre sign& the YHREADING of tommu+~+or with fine liner roruhs GROOVING is o mechanical condition caused
begmmng of r.riow m.+al nondw to the carbon whan lxcwsiw me+ol hondw occur. h usually fwdr by abrasive material in the brush or o+mos_
brush, Check the chart b4o.v for possible
cousm. +o resurfacing of ~ommu+a+w and rapid brush wear. pherm. If grooves form, s+w+ correc+iw action.
COPPER DRAG, on abnomwl build-up of comnw+&o~ PIYCH BAR-MARKING +x&w bw or burn... spo+s -- HEAVY SLOT BAR-MARKING can involve
mottiol, forms mos+ okm 01 boiling edgo of bar. Con- on +fw commu+a+or wfoc*. The numbw of +ft.s, mark- nching of hailing edge of ~ommu+a+or bar. Pot-
din is ram but can couw Rashorn if no+ &ted. ings wuofs half or all +fta numk of p&r on +fw motor. +em is r&+ed lo numbw of conductors per Jo+.
Carbon Products
General Electric Company
East Stroudsburg. Pa. 18301
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Material Handling
CMRK Company
GROUP 16
Section 7
Auxiliary/Steer Pump Motors
24 & 36 VOLT
Contents
General Information .......................................................................... 16-7-3
Trouble Shooting Prior to Disassembly ............................................. .l6-7-5
Motor Disassembly ........................................................................... 16-7-6
Component Inspection & Trouble Shooting ....................................... 16-7-8
Changing Brushes ............................................................................. 16-7-9
Motor Reassembly ............................................................................ 16-7-9
24-Volt Specifications and Brush Data ............................................ .16-7-10
36 Volt Specifications and Brush Data ............................................ .16-7-11
Brush Inspection Chart .................................................................... 16-7-12
24 & 36 Volt
Ventilated and Enclosed Auxiliary/Steer Motors
Post
Nut
Washer
Insulator
Motor Frame
-&-Terminal Kit
01 Armature Shafi
Bearing
Brush
Cover
Copyrighted Material
16-7-l SM-587
Dee 94
Intended for CLARK dealers only
Do not sell or distribute
GROUP 16 Motors
AWARNING
Wear eye protection and protective clothing when drying with air pressure. Reduce
air pressure to 30 PSI (207 kPa). Debris removed with air pressure can cause injury.
Typical
Inch Pound
Torque Wrench
Pointer
SM-587 Dee 94
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Motors GROUP 16
GENERAL
Routine Maintenance Schedule with Recorded Findings is the best way to reduce costly
shut-downs and repair of equipment during operating hours
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 burning or heavy arcing between bars. The coloring
pattern will be:
. Streaky film with commutator wear.
. Bar edge burning.
. Uneven film.
. Carbon dust bridging between bars.
Operating Conditions
Operating environment of lift truck motors varies widely: The service frequency shah
depend upon the severity of operating conditions. w
e
Br,ush Cover f
r1
, Name
+-
---
plate
L _--
*
Matching half of coupler
attaches to hydraulic pump
Dee 94
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Motors GROUP 16
The permanent magnet motor differs from conven- impact, drop or squeeze the motors as this can
tional D.C. motors in that the field winding has been cause damage to the ceramic pole pieces and it will
replaced with ceramic magnet pole pieces. Do not make motor unfit for further use.
1 Read the nameplate to become familiar with the enough to observe if the shaft turns. If it does
motor, especially the rated voltage. turn, then hold the motor leads on the power
supply for a longer time. If the motor sounds
2 Try to turn the shaft by hand. Keep motor leads
normal, go to item 3. If the motor sounds noisy,
separated while doing this. If the shaft turns
it should be taken apart as described herein.
freely go to item 3. If the shaft wont turn,
proceed to item 2A. 3. If the motor turned freely, connect an ammeter
in thecircuit as shown below. Withratedvoltage
2A The shaft could be tight for a number of reasons.
applied and the shaft running free, the ammeter
This check is to determine if the tightness is of a
should read less than 20% of the nameplate full
temporary nature only. Obtain a power source to
load current. If the motor meets the above con-
produce the rated voltage. Do Not Make A
ditions then it can be assumed the original
Permanent Connection. First touch the motor
problem is external to the motor. A higher
leads quickly to the power supply just long
current indicates a faulty armature.
Ammeter
PoDwcer
SUPPlY
16.:
16.208
16 .258 J
1. Check bearing recess for any signs of wear. l Streaky film with commutator wear.
r Hacksaw Blade
2. 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
Jre
trouble shooting, and tested to the specifications.
Lights . When testing motors, the voltmeter connec-
tions must be made at the motor terminals.
REASSEMBLY
Reassembly is the reverse of disassembly.
Motor Specifications
l Frame Size: 6.5 (165.1 mm) Diameter .
l Weight (Approx.): 43 lbs. (19.51 kg)
l Internal Bearings on Pump End and Commutator End. Bearings are double
sealed and lubricated with high temperature grease for the life of the bearing.
l Grade: M-8 Magnets l 4-Magnets l 4 Poles
MotorInsulation
l Armature components, Class H
Circuit and Rotation
l Commutator components, Class H.
l Single Rotation
CommutatorServicing Diameters
l CCWDE, - to Battery Negative,
l Maximum Diameter, NEW 2.92
+ to Battery Positive.
l Minimum Diameter for RESLOTTING: 2.80
l Min. Diameter for REPLACEMENT: 2.75
++
--
Brush Data
1 Brush per Holder
4 Brushes per Motor
Min. Length of Worn Brush
0.42 (10.67 mm)
Max. Force per New Brush
29 oz. (825 gm)
Max. Force per Worn Brush
12 oz. (340 gm)
Brush Drop
Grade: H803
1.0 Volts @ 71 Amps Motor Brush
Brush Data
.
Width
1 Brush per Holder
,
0.812 (20.8 mm)1
l 4 Brushes per Motor
l Min. Length of Worn Brush
0.42 (10.67 mm)
l Max. Force per New Brush
29 oz. (825 gnI)
l Max. Force per Worn Brush
12 oz. (340 gm)
l Brush Drop Grade HO03
Motor Brush
1.0 Volts @ 71 Amps
I I
REPLACE BRUSH
0.42"
1
REPLACE BRUSHES
WHEN WORN TO
HERE.
NEW BRUSHES
LIGHT TAN FILM over entire commutator MOTTLED SURFACE with random film pat- SLOT BAR-MARKING, a slightly darker HEAVY FILM con appear over entire
surface is one of many normal conditions tern is probably most frequently observed film, appears on bon in a definite pattern areo of efficient and normal commute-
ohen seen on a well-fundioning machine. condition of related to number of conduc+ors per slot. tar and, if uniform, is quite acceptable.
STREAKING on the oxnmutctor surface signals the THREADING of commutator with fine lines resuhs GROOVING is a mechanical condition cowed
beginning of serious metal trander to the carbon when excessive metal transfer occurs. h usually leads by abrasive moteriol in the brush or otmos-
brush. Check the chart below for possible causes. to resurfacing of commutator and rapid brush wear. phere. If grooves form, star+ corrective qction.
COPPER DRAG, on abnormal build-up of commutator PITCH BAR-MARKING produces low or burned spots -- HEAVY SLOT BAR-MARKING can involve
mote&al, forms most ohen at hailing edge of bar. Con- on the ~ommutotor surface. The number of these mark- etching of trailing edge of commuta+or bar. Pot-
dition is rare but can cause Rashover if not checkd. ings equals half or all the number of poles on the motor. tern is related to number of conductors per slot.
Carbon Products
General Electric Company
Copyrighted Material
East Stroudsburg, Pa. 18301
Intended for CLARK dealers only
Do not sell or distribute
Material Handling
Cl!!JRK Company GROUP 17
Section 17
Contactors
Contents
Forward & Reverse Contactor Illustration .................................... 17-1-2
Disassembly ...................................................................................... 17-1-3
Forward & Reverse Contactor Illustration .................................... 17-1-4
Parts Inspection ................................................................................. 17-1-5
Forward & Reverse Contactor Illustration .................................... 17-1-6
Reassembly ....................................................................................... 17-1-7
lA, Line & Pump Contactor Illustration ........................................ 17-1-8
Disassembly ...................................................................................... 17-1-9
Parts Inspection ................................................................................. 17-1-9
Reassembly ...................................................................................... .17-l-9
Control Panel
Bolt
sclE%v-
Insulator
(If Conductor
* &
=;5
f
Support
Spring-&
L ----- J
Coil
Base
r
--------me
Lock Washer
Bolt
s Lock Washer
.z
E3 7 Washer
l- ----------
Conductor
p--
Insulator
L-_-_--l
Coil
Base
SM-587
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Contactors GROUP 17
Forward / Reverse Contactor-continued- 27. Now, secure the Forward Contactor Assembly
Support into the vise using minimumpressure to
22. Inspect spring seats for damage (cracks, breaks,
hold the support.
etc.). Replace damaged parts with new.
. Install spring into coil recess.
23. Inspect the thin washer located on the armature
for cracks, etc., and security of mounting.
. locate white bushing over armature stem and
insert armature thru bottom of support position-
. Material on the armature stem has been up set
ing armature tab into support slot.
in four places to retain the washer. Inspect all
four places to be certain this thin washer is . Install spring and upper spring seat, upper con-
properly retained and free to rotate about the tact, upper insulator, lockwasher and nut onto
armature stem. armature stem.
. Inspect the cone surface of the armature and IMPORTANT
the corresponding surface in the base plate for Torque Nut to: 18 to 20 lb. in. (2.0
scoring, etc. to 2.4 N*m).
. Inspect the small white bushing for wear. The 28. Remove support and movable contact assembly
bushing I.D. must be perfectly round. If the from the vice.
bushing becomes egg shaped (out-of-round),
it should be replaced with a new bushing.
29. Assemble the Reverse Contactor Support and
Movable Contact Assembly in the same man-
24. Inspect coil for damage. ner.
IMPORTANT 30. Now locate the Forward Contactor Support and
The coil has four blind alignment Movable Contact Assembly over Bracket (D).
holes in the top and two in the
IMPORTANT
bottom These holesmustproperly
Be certain the armature tab is
align with the off-set pins in the
pointing inward toward the center
bracket and contactor base at
of the contactor base when
reassembly.
positioning support over bracket.
. Inspect alignment holes to be certain they are Refer to the boxed illustration on
perfectly round and not egg shaped (dam- opposite page.
aged).
31. Now locate the Reverse Contactor Support and
. Inspect coil terminals for damage. Movable Contact Assembly over its bracket.
. Replace damaged parts with new ones. Again, be certain the armature tabispointing
inward toward the center of the contactor base.
25. Reassemble the contactors. Install both coils
onto contactor base. Terminal connectionsmust 32. Install the long lower buss bar and stationary
point outward - away from cent of base. Be contacts (having threaded holes in one end) into
certain the coils are properly located over the the grooves located on the top side of each
base alignment pins. contactor support The cable end of the buss bar
should extend outward on the right hand side of
26. locate Brackets (0) on each coil and onto the the forward contactor support and extend out-
base. Be certain the bracket alignment pins wardon thelefthandsideofthereversecontactor
properly seat in the holes on the top side of each support. Be certain the notches in the buss bar
coil. and stationary contacts properly seat with the
screw guides of each contactor support.
Bolt
Conductor
III-
!
Insulator
k+ Fastener
m Lock Washer
Insulator
Contact
Spring Seat
17-l -6 SM-587
Dee94 Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Contactors GROUP 17
&-Lock Nut
_ockWasher
Washer
Spring Seat
----
r 1
k
Insulator
-Armature Assembly
I
I
I
I
I tT----
I g-Spring
I
I
I
I
I Retainer
I
I
I
I
L -----
Base
I-A, Line & Pump Contactors 7. Remove lock nut, contact set, insulating washer
A WARNING
and spring fi-om armature stem. Be careful not to
disassemble or loose other parts under contact
Disconnect battery before tips on armature assembly.
working on contactor tips.
8. Install spring, washer, new contact set onto stem
Before attempting to disassemble a contactor and secure with lock nut.
to mstall a new contace set, carefully observe 9. Assemble contactor by putting moving contact
ti
location and orientation of each part. assembly armature shaft into coil plunger with
1. Check armature tid movable contacts for free- return spring on top of armature shaft.
dom of movement by depressing movable are 10. Put top cover over spring and install cover
with a screwdriver or small rod. Refer to illustra- mounting screws. Be sure return spring is in the
tion on page 8. cover recess.
. Check for any restrictions to movement and for IMPORTANT
return of parts by action of the spring. When assembling cover to base
2. Inspect contact tips. Look for any worn or (frame) make sure it is installed
eroded surfaces. Look for evidence of tip weld- with thepositive sign (+) markings
ing. Inspect for evidence of any contaminants on located properly.
tips (paint, dirt, paper or cloth material, etc.)
Use a bar or rod to move contacts
which would impair operation.
and be sure movement is free of
. Do not use sandpaper or file tips. Any damage binding. Be certain contact tips are
must be corrected by tip replacement. in correct orientation and tips
. Tips must be replaced before they wear through contact correct mating parts.
and damage copper base.
SECTION 2
ELECTRICAL
SEQUENCE OF OPERATION
Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..Page
TRACTION CONTROL
HYDRAULIC CONTROL
ACCESSORY
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
2
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I f-
);
I j
;
li
12
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:.......................:
................... 2 .................... 2 .................... * ..............)* pB, TB,
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t.........., $
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, ; SWITCH>;,
12
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1111111111111111__11I
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lo- -45 45 ; cT810 FUNCTION
. . . . . . . . . . . . .. . . . . . .. .
_NO,D CONTROL
12
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. ..,. . . . . -... .,O . . .. . . . .+...%. _.:I . . . _.. . . . . ., 58 ,. . . . . ./.z CcnrrRcc
_..___.____.._......., ._.__.____._..........
l2 I
I
... .
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
OPERATIONAL SEQUENCE #2
H. The horn is operated by pushing the horn button which will supply
battery voltage to the horn through wire #25, and negative through
wire #13.
J. Battery Positive is supplied through wire #2, control fuse 2FU and
wire #12 to the key switch.
Voltages Present:
A. Battery positive
B. Battery negative
C. Battery positive
D. Battery voltage across 1C capacitors
E. Battery positive
F. Battery negative
G. Approximately 3.7 Volts with handle in neutral
H. Battery positive on wire #25
J. Battery positive on wire #12
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
r2
24/M VOLTS
:......................... 20 ..............
.
i i i
;.............
40.. .......................... .
...................... i30
i i
;3 304b ;O 61
j----- 10 -/*
IA
PB6 pyo JlG
i
q, .: ..... ...4 o ........................ 4 o ................... .
SL-1
5 ......................................
, 5 .................. , 5 .............
{.*m3 PA6
,.j................. +-+........., 3 ........................
,4 ......... ...........
i.. ......., 5 ............... %. ............... . 5 .................. ,5 ............. j.* TB.2 pA,,_;. ........... 34 ..... Sk2 ...... . 3 __________I____
SL-3
; * TBS ,,,+_____ 54 ___+.&.____,3 ................. t.. ....
6-----6
................ 8 ................... 6 ............... i.* T86 PA3 -.I.. ............... 2 o ........................ 2 o ........................ i,
4.. ........ , 5 .............. ,,A!. ................ 27 .................. 27 .............. I.* p&( PAZ -_I.. .............. 26 ....................... 26.. ........ . j
26 20 .13
. ..____.__._.
,/,...% . . . . . . . . 46
1_________._._.______------,
0 . . . . . . . . . . . . . v4_..?.! . . . . . . . . 46
12-25 13
Copyrighted
SWITCH
19-02-05
Material
K)RN
l-cm 94
Intended for CLARK dealers only
Do not sell or distribute
OPERATIONAL SEQUENCE #3
D. The closing of the line contactor power tips will release (close)
the steer lock switch.
E. The closure of the steer lock switch will supply battery positive
through wire #SO to terminal 4PLl of the EV-TSPS steer control.
Voltages Present:
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
BATTERY
._ l_,. ._
24/36 VOLTS
1 FU
2FU
0
D
61
l-l0
12 10
12 10 10 2 !O 61
lx6
.................
.E?....................
........................
. ...........
w:
I
12 10 10 2
yfxI-;=.i 12v13J 1 1
SL-1
15 ...................................... , 5 .... .... .... ... .. , 5 4 4 ....... .iw& ....... 13
-i_
t ......... 15 5 .... .... ... ...... , 5 .............j.* TB*
...... .. .. ...._FwD ___.____.___.., PA4,.j .. . . .. . . .34 . . . .-.... . .,a ,. . . . . . .i- ..
SL-3
i--_l5A 6-6 iaT PA+____ 54 ---..?a&.___., 3 . . . . . . . . . .t. ..
* .................. B...............i.* TB6 pAa*_I.__..._..........
;......... 1fj ..............F!0 ........_..._.... 20 ................._.....
2. .....................f
i .____..._., 27 ............_...2..............i.* pB4 ,,A*-_I..... .......... 26 ...._._.______.____....
5 ..............\$7 ......._......... 26 .........
R
:- 15 ,-p 23 -23
~
Ii 10 26 2; 13
.
I
1 i
- 1o ,&s6________.
4; ___..__.
i
46 .......0 .... ... ...... 46 .. .......... .;.+TBa
,~ :.......................;
112 12
SM-587 Copyrighted
H3RN SWITCH Material Aug 94
Intended for CLARK dealers only
Do not sell or distribute
OPERATIONAL SEQUENCE #3
J. The closure of the line contactor power tips will keep the 1C
capacitors charged to battery volts.
K. The BV-T15 control card will monitor the capacitor charge on the
white wire at terminal PZ-14.
L. The EV-T15 control card will send data signals on wires #80, #81,
#82, #83 and #13 to the dash display to light all the display
segments as a visual check for the operator. If all the segments
are working, 8888 will be displayed for about 1 second.
M. After the 1 second segment check, the EV-T15 control card will
sense the absence of battery voltage at terminal TB-2 indicating
that the brake switch is not closed. It will send a signal to the
dash display to show a -01 Status code representing an open brake
switch.
Voltages Present:
H. Approximately 10 volts.
J. Battery volts across the 1C capacitors.
K. Battery positive.
L. NA
M. NA at dash display, approximately 2/3 battery volts at terminal
TB-2.
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
BATTERY
r2 *HIwe
2 24136 VOLTS
S FUM?hKITORA
2FU
P \... . .. . .. . .. . . .. . . . .. . . . . . . . . .
PS-IC 61
:::::::::::%;:I PS-TP I
I
PSNEG
2 10 50 61
SrE ER m :......................... 2(J............
... .
TRAN>- :
CUXR s;
............................ i
. -.,
.....................
r
I I I
t
2
$FlELd
]
2
-12-12~12
:.EVT
.......15
....CARD
.. . ..:
t -2 2 2 j .PB1 TBI . ; 29-
10
AL
24-----24 ; .PE* pwc.j................ 3. _....____...............~~............
A i
IA pyg *.; . .._________.._._
4. ,....................... 4. . . . . . . . . . . . . . . . . . . ..
10 -/% 41-4, -----j-p86
10 lo-lO+TB4 PY13 0 : 61 61
3RAK!z
F
y . . . . . . . , 5 . . . . . . . . . . . . . . ,, A. . . . . . . . . . . . . . . . . . . . 2, . . . . . . . . . .._......2. . . . . . . . . . . . . . i.* m
80 81 82 13 83 26
c 10 10 10 ---+TBlS~ 26 -26
,O_, -J--w
* . . . . . . . . . . . . . . 55 . . . . . . . . . . . . . . . . . . . . . . 55 . . . . . . . . . . . . . f.cTB,,
1. TILT
lo- -45 45 ;snwo
10 P
\h .._._._..._..... 28 ._.___................ 28 . . . . . . . . . . . . . ;.oTBa
li
SOLENOID
12 18 FUNCTION
lO----v~ s1 18 j*TBs
a?NTRci.
___________,O . -58 . . ..-. . . . 58 . . . . .j..T&
_____+...S.?...
, ,, _~/_..__._........
55 48 .......f ............. 48 .............+,a
I r
112
, 0 _v4 S6
.__..._........ 48 . . . . . . . i
II
:.. . . ........... ... ...;
12- l - 131
SM-587 Copyrighted
HORN SWITCH
Material
I&-09 - Rev Aug 94
Intended for CLARK dealers only
Do not sell or distribute
OPERATIONAL SEQUENCE #4
Steering Function
D. Current will also flow from PS-1C capacitor through the current
sensor, steer motor armature, transistor and back to battery
negative. The amount of current flowing out of the capacitor will
depend on the percent ON-Time of the EV-T5PS control.
H. This voltage forces current through the PS-3REC, PS-sensor and the
armature. This current, called Flyback Current, continues to
drive the Steer Motor Armature during the transistor's OFF-Time.
Voltages Present:
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
r2
2
STEER
SXK
2FU
SWITCH
_,
t rI
12
12
ITCH
i 1
c
12 10
-10
12 10
12 10
12 10
1 -t LL
12
c 10 24-24 i.F-32 Fwrj 30 30- /
IA
-1 0 -/+ 41-41 ; * PB6 pyo*.!................ 4. .............___.__.....
4o ..................i
10
, 0 _, o+ Tm py,3*.I.................61 .............___._......
6, .....................
R4KE 0
PITCH>!<
SL-1
12
, 5 ......~...............................
~.________ m3 p*G+. .............__.
, 5 ................. , 5 _._____._____~.~ &++;...... , 3 ......................
44 ._......
m2 PA4,.j
5 ................. , 5 ________.._._~..
~...___.._, 5 ....""..""._..&...'............... .-.....,..,34 . . . iy3 __....13 ________-
; * TB5 pA5+______ 54 ___-"___.,3_________
6------6
1
i ~~~~~~~__.~ 5 . . . . . . . . . . . . . $ .__.__..._.__.___2, .____._.._.._.._..2, . . . . . . . . . . . . . i.* m PA2 ; 26 26
i R
,5w& 23-23
$iEf$-l
12 60 61 62 13 63 26
, 0 _, IFEACH
*_..__._.......'55
...................... 55 .............& TB,,
,0-G-GE45 45 i_cTBlO
P I?
, 0 _--L/c...............26 ...................... 26 .............+
.saENOlD
12 FUNCTDN
10-k s1 16 16 VT=
Cm-ma
___________,O ______,,4.__5?..._., 56 .. . ..+.._...._.
56 .. . .... ..~.r~~
I r
112
, 0 __yI\ ...S6
........... 46 .......i
I
5...__.
. . ... ......
12 -L 13 1
SM-587 KIRNSWITCH
Copyrighted Material Rev Aug 94
Intended for CLARK dealers only
Do not sell or distribute
OPERATIONAL SEQUENCE #4
K. The EV-T5PS card controls the transistor's ON-time to vary the RPM
of the steer motor. The percent ON-time depends on the signal s)
the control receives from one or more of the following:
Note: When more then one signal is present, the highest RPM
demand signal has the- priority on ON-time demand.
P. Removal of the signal from the Steer Transducer (stop turning the
steer tiller) will cause the EV-T5PS control and the Steer Motor
to shut OFF in 2-3 seconds.
Voltages Present:
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
r2
2
2FU
B 1 FU
MC 6:l
TPS-TP
.I )R '+-m
*. I m s
r-i
12
SWITCH
12 10 6'1
12
rlo c
10 10
.
+---15A 6------6 lbTB5 PAS*:------ 54 L ^- - _ _ _., 3 ................. ...
2..0 ...............
i..........15.............. 8 ...................
B...............
i.. TB6 PA3
_.I.................
2o .....................
...20 ........................
F
f___._.,l5 ................. 27 ..................
................... . 7 ..............
..*pB4 PM* : 26 261
li 1; 8 i
lo----+-- .,_____.___.._...5
5 ................_._...
5 5 _.._____.....~.~
TB(,
d._ TILT
, lo- -45 45 +%TEWJ
1,, _\/.. P
_____._........
28 ..........__.__.___...
28 .............j.+TBa
SOLENOID
12
10 -4% s1 18 18 ;+T86 FUNCTION
CONTROL
,,___________10_____+..??,_...58 "'"r'..."'. 58 . . . . . .i.(TBS
s5
1 0 -~~,...............48 .......y........48 .............& T&,
S6 K...................
1 0 -+._.___..____.4* .___..._i
I
12 12 131
HORNSWITCH
Copyrighted Material Rev Aug 94
SM-587
Intended for CLARK dealers only
Do not sell or distribute
OPERATIONAL SEQUENCE #5
C. The control will not allow the truck to start until the following
SRO checks are satisfied:
2) Checks for open F & R switch inputs, terminals TB-5 and TB-6
must be less than 50% battery volts. (Status Code -02 or -03)
Note: The EV-T15 control will repeat the above SRO checks
any time that the brake switch remains open for more
than 1.5 seconds.
D. If all of the above SRO checks are satisfied, the EV-T15 control
card will send a signal to the dash display to show the state of
battery charge.
E. The EV-T15 control card will send a Drive Ready signal from
terminal PB-3 through wire #30 to terminal 4PL3 of the EV-T5PS
steer control card.
F. The E!V-T5PS steer control will turn on the steer motor at idle
speed (825 - 875 RPM).
Voltages Present:
A. Battery Positive
B. Battery Positive
C. See explanations l-3 above.
D. NA
E. Battery Negative
F. 9.0-9.4 volts across the steer pump motor on 24 volt trucks.
13.4-13.8 volts across the steer pump motor on 36 volt trucks.
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
24/36 VOLTS
mER IFU s WM'PM3TORA
ax ........................................................................*.~~~.....
,......................................
2FU <\ f..!u
SWITCH
t r-r
12 1050
ri
12
%TCH
c
12 10
12
rlo
10 10
12 10 10
Rx
12 10 10 2
ACCELERATOR
7-T 7
li
12
..._............_.2.
23----23
12
,O_, IFEACH
0 . . ..__......._. 55 . . . . . . . . . . . . . . . . . . . . . 55 ..___........ +,(f i
J_e TILT
lo- -45 45 ;-%Ttm
P
,O_$ . .._........_.. 26 ..__._..._..._.__..... 26 ______.......+a
/ SOLENOID
12 i FUNCTKN
lo-~ s1 16 16 ; *Tm
icxzsrrm
,,___________,o _____+..?.? .,.... 56 ..__.? _._...... 56 .. . . . . . . /..TBS
B. The EV-T15 control will now make the following start-up checks:
D. This will energize the forward contactor coil and in turn, open
the normally closed contactor tips and close the normally open
tips.
E. The BV-T15 control card monitors the current flowing through the
directional contactor coil circuits. Status Code -23 will be
displayed if the current is less than a preset value.
Voltages Present:
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
BATTERY
r2 >wilc-<c
24136 VOLTS
EER I FU
_ax .. ..
2FU
SWITCH
t I-f-
10 50
ri
12
ETCH
12 10
12 10
rlo c 10
12 10 10
12 10 10 2 13
EVTl5CARD
........ ............!
__..
li
t
10 I
I
b 10
10 -/IA
*,L 24 -24
41-41
;*Fw
frm
Pea.;
PY8 l :
30
40
12
__________+___
__________e___
15 6-6
REV
15 xs . ... .............. ................... .......................I
1 I
*F
15 * 27-27
t-
15
12 li 1 26 2b
.+82
,311 I
OlSPlAY\
WI
Dpz
:
,.i ; ::
._
,a-,3
-82
_^ -1 I
I
I \Dp5 i&+-+83-83-
1 ,, _$
P
. . . . . . . . . . . . . . . . 28 . . . . . . . . . . . . . . . . . . . . . . 28 . . . . . . . . . . . . . j.oTW
SOLENOID
12 ,a 10 FUNCTION
10-h s1 j+T*6
aavrROL
,p___________,~ _____+...??.,. . .,58 ._. ..?. . . . ., 58 . . .. . . ./.rTBs
,,___________,O ______+.?8 ...___.5 8 .. __.i
SM-587 I , 0 _y4 S6
. . . . . . . . . . . . . . 48 . . . . . ...!
l2 Copyrighted Material
; .... . .. ... ....
,&WiTCH
,&_,7
& l3 Aug 94
A. The W-T15 control senses that the forward contactor has closed
and the motor circuit is not open when it senses that the T2
voltage, through the blue wire at terminal PZ-9, is at battery
positive.
C. The EV-T15 control card applies a gate voltage from terminal PZ-4
and PZ-3, through the red and brown wires respectively, to the
gates of both transistors. The transistors turn 'ON' completing
the drive motor circuit to battery negative.
D. Current now flows from the battery, through the 1FU fuse, the line
contactor, sensor, drive motor armature and field windings, the
closed directional contactor tips and through the transistors to
battery negative.
E. Current will also flow from the 1C capacitors through the same
drive motor circuit to battery negative. The amount of current
flowing out of the capacitors will depend on the percent ON-time
of the control.
Voltages Present:
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
2FU
-;t t t T t I !I
Bu(
I a, 91 92 93 50 30 40 20 6'1
rlo
10
10
_~2+#+~---13- 1 ) ]
EVIlSLAHU
24-24
12
10 10 10 ; .TB15 Twc - 26
A. The control now removes the gate voltage and the transistors turn
'OFF'.
Voltage Sequence:
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
r2T
2 2
STEER I
1 FU
24/36 VOLTS
_ WMMOTOR
2FU
k%
I ri
12 2 105(
r-i
12
SWITCH
12 10 2 10 5(
12 10
rlo -l-P 10 2
12 10 10 2
12
ACCELERATOR
--.- Y
t *L
E
10 24 -24 --+a P83.: 30 301
12 lb
IA
1 0 -/? 41-41 ------+Pfs PY8 . ; 40 40 --I
12 10
10 10 104TB15 TB7* :
,0-/t
P
._.._.____.....28 . ..__.._._.._......... 28 . . . . . .. . .. . . . ;.eTBB 13
j SOLENOID
10-----u s1 16 16-----f+TB6 ; FUNCTtCN
;ccNTRoL
__________,o ______+.5? .._._. 56 . . . .+. . . . . . 56 . . . . . .i.<T85
, 0 -&..S ...........
5 46 ..... ..?. ............ 46 ............. j.eT83
, 0 -v4.. .S6
........... .4a ........ I :.......................
.
- 1
112 12 d 13-
SM-587 Copyrighted
HORN SWITCH
Material
w-2d2-21 i-cm Rev Aug 94
Intended for CLARK dealers only
Do not sell or distribute
OPERATIONAL SEQUENCE #9
C. When the transistors are turned ON, the #3 REC stops conducting.
D. The blue wire to terminal PZ-9 of the EV-T15 control card allows
the control to sense pulsing. If the transistors fail to turn OFF,
the card opens the circuit from terminals PB-4 and PB-5 to battery
negative so the directional contactor coils de-energize, dropping
out (opening) the contactor tips.
Voltages Present:
Others N/A
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
r2 f
2 2 24/36 VOLTS
SEER
LCCK ........................................ .....................................................................
---a.....~ ---
_ PUMtvKITOR
1
r **.a
2FU
SWITCH P ................... ps-ic. 6, ...........................
. , .................................
, ...................
.
L
PS-3REC
t R--
li 2 10 50
ri
12
ETCH
12 10 10 50
Es_ $y. $ 1 1ri;; :......?n
................... 2 0
, ,
.. . . . . . . . . . .
rl c
11 - 50 50 501
I
12 10 10 2
24-24
SL-1
15-15 ;*m PA6 +..... . . . . . . . . . . 441.3......_.................
i.........
. . . . . . . . . u*- . . . . . . . . .
10
SL-2
l5-_15iT62 p*4 *_I. . . . . . . .34 . . 0s.e
_..__.,3 _____-____+____
SL-3
6 F TBS p+_____ 54 ___-____13 _--______+___
6
2 10
10 10 1o+m5 Tw. j 26 26
12
...._____.__.____.._..
38 .............i.+W
._v4 . . . . . . . . . . . . . . . 46
12 - 13
-587 Copyrighted
I-iORN SWITCH Material
19-2d2-23 m Rev Aug 94
Intended for CLARK dealers only
Do not sell or distribute
OPERATIONAL SEQUENCE #10
IA Contactor Operation
B. The control will increase the rate and/or length of pulses at the
preset rate as defined by the Controlled Acceleration (C/A)
setting of the EV-T15 control card.
D. After a short time delay, the card completes the circuit from
terminal PB-6 through wire #41, to the 1A contactor coil negative
terminal. This energizes the 1A coil.
Voltages Present:
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
r2
2 24/36 VOLTS
I
. .. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . . . . . . . . . . .
2FU
.. ..................ps_,c
.......... 6, ...........................
PSBREC I 61
I 1. IPS-TP
t
12 II II
rd
12
STEER
SWITCH
,,Q'
I.
12 10 -
92 93 50 io 40 20
12
r10L
10 10
12 10 10
12 la 61
I-t
12 ia 24 -24
41-41 401
10-10
.............. ... ... 6 , ......................
LRME
WITCH
SL-1
15-15 .._..... iyi . . . . . . . , 3 . .._.___________.___...
,% _.._._..._........ . . . . . . . .. . . .. . . .. . . .. . . . . . .._.............. 2. . . . . . . . . . . . .. . . . . . . . . .
261
26 13
:oTFm TBoa- 2
lo-=5 5 -----20 20
10_+&?z?i..35 . . . . . . . . . . . . . . . . . . . . . . 36 . . . . . . . . . . . . . +j,3 TB1r 13
-13
1
12
-L AUX2
.__________,O _____ * o______65 __---_--- 65 ____+6,*
,0-I * . . .-Ii
. . . . . . . . . . . 55 ,...................... 55 . . . . . . . . . . . . j.*Ts,,
1 TILT
lo- -455-45 ;*TBIO
P 13
,O_,,/% .__.._.....____26 . . . . . . . . . . . . . . . . . . . . 26 . . . . . . . . . . ;.,T@
SOLENOID
12 _ Sl
lo----y4 18 16 j*T66 FUNCTtCN
CCNFRCL
,__________,O . _.58 . . ..f. . . . . 56 . . . . . .j.rTf,5
______,k...? . .
10-$ ...s5
............ 46 .......f ............. 48 .............j.qTB3
i. . . . . . . . . . . . . . . . . . . . . .
,0.-v4 . . .S6
. . . . . . . . . . . 46 .. . . . . . . i
-I
112 12 d 131
SM-587 Copyrighted
I-DRN SWITCH Material
19-2052-25 m Rev Aug 94
Intended for CLARK dealers only
Do not sell or distribute
OPERATIONAL SEQUENCE #11
Plugging
C. The control stops functioning because the voltage has been removed
from terminal TB-5 of the EV-T15 control card.
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
r2
2 24/36 VOLTS
I FU PUwmoR
( A
,...................................... r ;i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .s.>W-k . . . . . (Yi-
2FU
ret P \ . . . .._........................
ps_,c 6, . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, .. . . .. . . . . . . .. . . . ..
1 8 I
61
t
12
12
ro
10
c10
h-J 23 REC
12 10 10 m DRIVEMOTOR I:
A2%1 R
8.l
12 10 10 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 lo 61 13
ACCELERATOR
___- I I I :
-12-12-12
:.EVT15CARD
....................... 12+$f#-13--l 1
II 1-2 2 2----+al TB1 . ; 29-
40
--I;
...................... 61 ..;
-; SL-1
........................f... .. .
;. c ,.; ....._.......... . . . . . . . . . ** . . . . . . . . . ,
P
TB3 44 3
SL-2
---p TBP p$$,
9.;... . . .. . . .3$ . . . .- . . . . , 3 ___-_--___;_ .__
SL-3
,--@ P,+______ 54 ___-*9___.,3 __________;_.__
._......____....... . . . . . . . . . . . . . . . . . . . . . 2. . . . . . . . . . . . . . . . . . .. . . .
12 13
10 10 TB7. - 26 26-
TBo* 2
lo-E5 5 TTB14 -20 20
,9-, -J-Faux
* . . . . . . . . . . . . . . 55 . . . . . . . . . . . . . . . . . . . . . . 55 . . . . . . . . . . . . . ;.* TO,,
,o-G-d=-45 45 j.%TBlO
P 13
, 0 _# ._............. 26 . . . . . . . . . . . . . . . . . . . . . . 26 . . . . . . . . . . . . . j.oT,M
SOLENOID
12 Sl
lo- 16 16 ; *KM FUNCTKZN
s7. . . . ..56 mRcc
______-____,O _____+.. . . . ..L. . . . . 56 t.. . . . .+
SM-587 l2 Copyrighted
wFz-w,TcH Material
,&_*7 H3R\l
Plugging (continued)
G. The control now completes the circuit from the reverse contactor
coil to battery negative through wire #23 at terminal PB-5 of the
EV-T15 control card.
H. This will energize the reverse contactor coil and in turn, open
the normally closed contactor tips and close the normally open
tips. This will change the drive motor circuits to the reverse
direction.
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
l-27
2 2 24/3i VOLTS
STEER 1FU
Loa< ......................................./.......................................................................
2FU
SWITCH P
61 61
t rr
12 2 1050
ri
12
ETCH
c
12 10 61
12
rlo
10 10
li 1IO 10 6i
12 1IO 10
BRAKE
SWITCH
10iTILT45 45 i-%TBlO
,,_________-_10______+..S.?...._.56 .. . ..i
12
10 -h...SB _ __.......
36 .................__...
36 ._..........+
TB, 3
, 0 _\/,...S5 ..........46 .......f.............
46 .............~.~
TB3
S6 :......................
1 0 ~~4...~~..~~~~....4* ........!
I
Plugging (continued)
M. The control also over-rides the 1A timer section and will not
allow the 1A coil to be energized during the controlled plugging
operation.
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
2413.6 VOLTS
STEER 1 FU
_CCK
2FU
SWITCI
PSBREC 61
t n
10 5 I
r-i
PS-POS PSNEG
mm
12
SWITCH
12 10
12 10
roc 10
3 30 40 20 6:l 13
....._..__......'._.6
, ......................
-10 10-10
3M
WITCk
3
SL-1
i . -ma PA6 *_+........___.
44 "'."...g&"'"" 3 ......................
-15 15-15
-62
-63
10 10 10 ; .T81.5 lB7. - 26 26
* . . . . . . . ..__.... 55 . . . . . . . . . . . . . . . . . . . . . 55 . . . . . . . . . . . . . +,,
lO----+- -
J_ TILT
lo- -45 45 i sTB10
P IP
, 0 _,,,L.............. 26 ...._................. 26 .............~ TB8
SOLENOID
104% " 16 la ; **I36 FUNCTlON
Cm-rRcc
___________,o_____.+...S? .. . ..sa . .. . . . . 56 . . . . . .j.(TB~
1 0 _bh...s3........ 36 _____..___.._.........
36 .............~+ To, 13
/Lss..__.. 46 .......f.............
46 ............+ TB3
lo-
S6 !.....................
, 0 __+___________..46 ........1
- I
112 12 - 13A
SM-587 Copyrighted
K)RN SWITCH
Material
w-2052-31 Km Rev Aug 94
Intended for CLARK dealers only
Do not sell or distribute
OPERATIONAL SEQUENCE #12
A. Raising the upright above the free-lift stage will open the SL-1
speed limit switch.
Note: When the speed limit switch is re-closed the truck will
revert to the normal operation and speed.
Voltages Present:
A. Battery negative.
B. Approximately 6 volts.
C. NA
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
r2
2 24/36 VOLTS
STEER _ WtvPPMOTOR
LCCX
2FU SWITCH
61
t n-
I\ _JPS-TP
12 10 50 TFI s
rd
PSNEG
12
SWITCH
12 10
n--l
1 3 3040
..................................................................: 13 3040
ACCELER4TOR
--- 7
12-12-12
24 -24
41-41
6 0 ;-TM PA3..I . ...... ..... .... 2. .__..................... 2. ............... ... ... ...
6 2 13
l2
I
Copyrighted
t0R%flTCH
:................. ..
Material
,&)5z_33
Solenoid Functions
The Solenoid Function Control card in conjunction with the EV-TSPS steer control and
the EV-T15 control provides for lift, lower, extend, retract, tilt and side shift
function control and for lift interrupt.
A. In Operational Sequence #3, closing the key switch applied battery positive to
terminal TB-15 of the solenoid control. The solenoid control is connected to
battery negative through the #13 wire at terminal TB-1.
B. The EV-T15 control card will supply a voltage signal from terminal PA-2 through
wire #26 to terminal TB-7 of the solenoid control indicating the battery
status.
Notes LED #2 (RH5) of the solenoid control will be turned 'ON' if the
lift interrupt Is activated.
C. The solenoid control will not allow any solenoid functions to operate if any of
the following checks are not satisfied:
1) Checks for open hydraulic function switch inputs when the key switch is
first closed. Terminal TB-10 through terminal TB-14 of the solenoid control
must be at 0 volts.
2) Continuously checks for invalid switch inputs. If both the up and down
switches are closed at the same time or if more than one of the tilt, reach or
aux 2 (side shift) switches are closed at the same time.
3) Checks for open solenoid and contactor coils or wires anytime that the
multi-function control handle is in hydraulic function neutral. For solenoid
coils connected in parallel, both coils must be open to be detected as a fault.
Terminals TB-3, TB-4, TB-5, TB-6 and TB-8 must be battery volts.
4) Checks for shorted drivers anytime that the multi-function control handle is
in hydraulic function neutral. Terminals TB-3, TB-4, TB-5, TB-6 and TB-8 must
be battery volts for fault not to exist.
Note: LED #1 (RH4) and LED #2 (RH5) of the solenoid control will
be turned 'ON' if fault exists.
Note: If any of the hydraulic control switches are closed within 1.5
seconds of closing the key switch, the control will not allow any
solenoid functions to operate.
Voltages Present:
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
SAll-ERY
r2 b-w<
2 24/36 VOLTS
STEER I FU
.cxx
2FU
WITCH
...........................6
r-d
12
SWITCH
12 10
I i
12 10 10
12 10 10 ,......................................................................
ACCELERATOR
--- -
li 24 -24
41-41
12
12
to-=5 5 I
,,._?.p~._.,, .........
12
______.___.,o -.-.- + w._____65 _________65
,n--__r
.
..I-0 . . .RZACH
. . . . . . . . . . . c* . . . . . . . .
I < -.._ -
A.. IlLl
lo- -45 45 I
13
, 0 _$...! ........__
28 _____.____............
26 I
12 Sl
lo-----vh 16 16
__.______..,o ___._.,,4._-5-7- . . ..56 . . ..t. . . . . 56
Lift
C. This will energize the pump contactor coil and in turn, 'close the
normally open tips.
E. Current will now flow from battery positive, through the 1FU fuse,
the now closed pump contactor tips to the pump motor and back to
battery negative. The interaction of magnetic energy between the
armature windings and the field coils will cause the pump motor
armature to rotate.
Voltages Present:
A. Battery positive.
B. 1.2 volts.
C. Battery positive.
D. Battery positive.
E. Battery positive at the S terminal, battery negative at the A
terminal.
F. 0 volts at TB-14 and battery positive at TB-8.
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
r2
2 24/36 VOLTS
STEER
2FU
cacti
t ir
12 10 50
12 61
12
r
1IO
1
12 10 61
12 10 LT...; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : i0 61 13
ACCELERATOR
H-T
7-i 7
-12-12-12
/.Ry$q 12y-q-13J
2 2 2
12 10
10
VAL *IA
24-24 i'"2 m*; 30 301
1
12 10 1:
. . . . . . . . . . . . . . . . . . . . . 20 .. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
, 0 _&.S5 ___._._._.46
.".."f""""""' 46 .............+
10_+ ...S6
........... 48 .....__.
i :........................
-12 12 - I
CI
SW587 KX=iNSWlTCH
Copyrighted Material
19-262-37 m Rev Aug 94
Intended for CLARK dealers only
Do not sell or distribute
OPERATIONAL SEQUENCE #15
Lower
C. This will energize the Sl solenoid and in turn, open the oil's
path.
Voltages Present:
A. Battery positive.
B. 1.2 volts.
C. Battery volts across the solenoid coil.
D. 0 volts at TB-13 and battery positive at TB-6.
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
r2 t -
2 2 24136 VOLTS
ZEER _ WNPMOTOR
2FU
I CKX
WITCH
61 61-
f
t T-
12 2 50
i 1
mER~q~~ r*i ido
c
2 50
:....._..__._.............
4 D ~ ~ ! I 2 0 ............
1 - 50 50 50-
12
i-l0
10 10
c
2
IC
EG
12 10 10 2
12 10 10 2 h.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCELE,A?
r
*I.
PB3 -i 30
15-15yTTB2 ___
. . . ..- . . . . .
12 1)
, 0 ~_$ ....s ........ 38 .................... . .~a.___._.......
+, 13
. . . . . . . f . . . . . . . . . . . . . 4a . . . . . . . . . . . . . +.T63
, 0 -$ ...S6
............4a ........! :........................
I
131
SM-587 Copyrighted
H;)RN SWITCH Material Rev Aug 94
Intended for CLARK dealers only
Do not sell or distribute
OPERATIONAL SEQUENCE #16
Reach / Retract
A. Depressing and holding the reach button on the side of the multi-
function control lever will close the reach switch. With the
reach switch closed, battery positive will be applied to terminal
TB-11 of the solenoid control through wire #55.
Note: The reach switch must be held closed during the entire
reach/retract operation.
C. This will energize the S3 solenoid coil and in turn, open the oil
path to reach cylinders.
D. Still holding the reach switch closed and pulling the multi-
function control lever towards the operator will close the up
switch or pushing the multi-function control lever away from the
operator will close the down switch. With the up switch or the
down switch closed, battery positive will be applied to terminal
TB-14 or TB-13 of the solenoid control through wire #5 or wire
#35.
Voltages Present:
A. Battery positive.
B. 1.2 volts.
C. Battery voltage across the S3 solenoid coil.
D. Battery positive.
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
r2 f
2 2
STEER
2FU
ILOCK
SWITCH
_.
BPS-TP I
r ir
12 2 I
PSNEG
r
.12
Y SEN-
Pi3 Pi Piipi2 Pi6 pi5 STEER
wEY c_____________________________-_ _Flx
+r
t T ? t 1 I !
12
i
10 2
yE& gz$ I)1loj :......~c
........3c
........... 2 0 .
,
..1.........
,
il
12
r
10
-10
I-w
10 2
-50 50 .^ 5oA
I
12 10 10 2 51
12 10
ACCELERATOR
r-i 7
I-t
12 10
I= 10 " ,.IA
*L 41-41
24-24 ids2
:*I?36 .w.;
PY8 l : 30
40 40
30
lo-l0+TB4 PY13 . ; 61 61
ERAKE
EiWITCH
SL-1
27-27+Pe4 PAZ : 26
261
12 10 1:3
/,P 113
10 " 20 28~T88
10 "" S' 18
,o _@ ...S6
........... 48 .......i
I
12 c=L ,,'i
SM-587 Copyrighted
HORNSWITCH Material
19-&41 mm Rev Aug 94
Intended for CLARK dealers only
Do not sell or distribute
OPERATIONAL SEQUENCE #16
F. When the EV-T5PS steer control senses the signal at terminal 4PL2,
it will turn ON the steer motor at maximum speed.
J. After a short time delay the solenoid control will remove the
voltages from the 53 solenoid coil and the signal from terminal
TB-9 of the solenoid control. The S3 solenoid will open to close
hydraulic oil's path from the reach cylinders. The EV-T5PS steer
control will reduce the steer motor speed to idle speed or coast
to a stop. The EV-T15 control card will stop accumulating time on
the internal hour meter because of reach/retract operation.
Voltages Present:
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
OPERATIONAL SEQUENCE #17
Tilt
A. Depressing and holding the tilt button on the side of the multi-
function control lever will close the tilt switch. With the tilt
switch closed, battery positive will be applied to terminal TB-10
of the solenoid control through wire #45.
Note: The tilt switch must be held closed during the entire
tilt operation.
C. This will energize the S3, S5 and S6 solenoid coils and in turn,
open the oil path to tilt cylinder.
D. Still holding the tilt switch closed and pulling the multi-
function control lever towards the operator will close the up
switch or pushing the multi-function control lever away from the
operator will close the down switch. With the up switch or the
down switch closed, battery positive will be applied to terminal
TB-14 or TB-13 of the solenoid control through wire #5 or wire
#35.
Voltages Present:
A. Battery positive.
B. 1.2 volts.
C. Battery voltage across the solenoid coils.
D. Battery positive.
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
r2
2 24136 VOLTS
SEER _ PUM'PTOR
_ax /I s
2FU
SWITCH P\
61
PS-IC 61 611
61
t
12
li 10 6'1
12
r10c
10 10
~
12 10 10 2 61'
FKE
12 10 10 61
ttH-12-12-12
II t-2 2 2
.EVT!..S.CARD..
i .F%, TBI. i
12cnx-13_J
II 29- I I
10 " *L 24-24 ;*PEt2 Pl33.j 30
/
SL-1
1: 1'0 15-15 j . T03 PI%. j 44-13
SL-2
15-15yTB2 pA4..; . . . . . .. . . 34 .,....-_..__., 3 _________. .___
SL-3
6 6 i . TBS ,,,+____ 54 ___-____,3__________ .___
6-6 + T86 PM. : 20 20
10
Tilt (Continued)
F. When the EV-T5PS steer control senses the signal at terminal 4PL2,
it will turn ON the steer motor at maximum speed.
J. After a short time delay the solenoid control will remove the
voltages from the S3, 55 and S6 solenoid coils and the signal from
terminal TB-9 of the solenoid control. The S3, S5 and S6 solenoids
will open to close hydraulic oil's path from the tilt cylinder.
The EV-TSPS steer control will reduce the steer motor speed to
idle speed or coast to a stop. The EV-T15 control card will stop
accumulating time on the internal hour meter because of tilt
operation.
Voltages Present:
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
BATTERY
r2 bWlk-<(
2 24/36 VOLTS
STEER 1FU s WM'PMOTOR
/I w"
2FU
i%H
L lJ----EFl 61-
I i 161
t R--
12 1050
r/
12
ZTCH
12 lb 10 50
11
rlo I-
12 10 10
12
12
10
10
10
10
Rx
_d L.YG .i
T_Fm
r-3
G
: . . . . . . TR? . . . . . . :
5
i
g
. . . . . . . . . . . . . . . .~
, ai
lo-i-
1.: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . :
ACCELERATOR
--.- -_
i3
SL-1
&
112 12 -
HORNSWITCH 19-262-47 mw
SM-587 Copyrighted Material Rev Aug 94
Intended for CLARK dealers only
Do not sell or distribute
OPERATIONAL SEQUENCE #I8
A. Depressing and holding the side shift button on the side of the
multi-function control lever will close the side shift switch.
With the side shift switch closed, battery positive will be
applied to terminal TB-12 of the solenoid control through wire
#65.
Note : The side shift switch must be held closed during the
entire side shift operation.
C. This will energize the S3, 55 and S6, and S7 and S8 solenoid coils
and in turn, open the oil path to side shift cylinder.
D. Still holding the side shift switch closed and pulling the multi-
function control lever towards the operator will close the up
switch or pushing the multi-function control lever away from the
operator will close the down switch. With the up switch or the
down switch closed, battery positive will be applied to terminal
TB-14 or TB-13 of the solenoid control through wire #5 or wire
#35.
Voltages Present:
A. Battery positive.
B. 1.2 volts.
C. Battery voltage across the solenoid coils.
D. Battery positive.
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
l-27
2 2 24/36 VOLTS
STEER 1 FU ^ PuwIwroR
LOCK
2FU
SWITCH
-p+61 61
611
t rr
12 2 1050
rd
12
SM- L l L 1 1 1
PM PU PLl PI.2 FL6 PL5 STEER
r____-_______________-_________-
SWITCH +_ ;4PL7 ,PLS 4PL6 4PL1 iPL3 4PL. 4PL2
I? T T T 1 7 1
12 10 2 10 50
1A
T2
............................................. 61
ACCELERATOR
--*- 7
I
12
I
10 24 -24
41-41
BFlAK!Z I
61
SWITCH
SL-1
12 10 15-15 44-13 -
SL-2
___&____13 ---------. .__
SL-3
___-____13 ---------. .__
23 -23
1:
SM-587 Copyrighted
HORN SWITCH
Material
Intended for CLARK dealers only
,,i Rev Aug 94
F. When the EV-T5PS steer control senses the signal at terminal 4PL2,
it will turn ON the steer motor at maximum speed.
J. After a short time delay the solenoid control will remove the
voltages from the S3, S5 and S6, and S7 and S8 solenoid coils and
the signal from terminal TB-9 of the solenoid control. The S3, S5,
S6, S7 and S8 solenoids will open to close hydraulic oil's path
from the side shift cylinder. The EV-T5PS steer control will
reduce the steer motor speed to idle speed or coast to a stop.
The EV-T15 control card will stop accumulating time on the
internal hour meter because of side shift operation.
Voltages Present:
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
t-2
2 24/36 VOLTS
STEER 1FU s FuwmToR
/I -4
2FU
%ki P\
Sl-
,
t r-r
12 10 50
ri
12
ETCH
12 10 10 50
12
rlo c
10 10
NZG
12 10 10 I
Fa
12 10 2
3
ACCELERATOR
-->-:
12-12-12 12 13-
EVTl5CARD
~"""""".."...""~
2 2 2*=1 TBI cf
-15
F
-15 "7 ~~~~,~~~~: ::r-_i
R
-15
10
;sMYp&;ggr j3 j3 26 2o
13
10
10
__________,O
II
10
10
131
SM-587 l2 &&/ITCH ,&$_5,
Copyrighted Material & Rev Aug 94
Intended for CLARK dealers only
Do not sell or distribute
Material Handling
CMRIC Company
EV-Tl5
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
MEMORY
STATUS CODE inp~ESCRPToN
-01
brake switch
No
No
RECALL
CIRCUIT Traction
SYMPTOM
Forward or reverse contactor will not pick up.
EVT 15 CARD
2 2 9 PBl
POSSIBLE CAUSE
*Defective brake switch or no brake line pressure. KEy
SWITCH c
/
- Check brake switch to insure proper closure.
- Check that the brakes are releasing and no air in the brake STATUS INDICATION CRITERIA
system. This Status Code will be displayed when TB3 is less than 50%
battery volts.
- Check for hydraulic leaks in the brake system.
SWITCH
4-
POSSIBLE CAUSE
*Forward directional switch closed on initial power up (closure
10 lo --. TB4
of battery receptacle, key switch or brake switch).
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
STATUS CODE DESCRIPTION MEMORY
No
-03
Reverse directional switch is closed on initial power up. RECALL
CIRCUIT Traction
SWITCH
+
POSSIBLE CAUSE
*Reverse directional switch closed on initial power up (closure
10 10 --. TB4
of battery receptacle, key switch or brake switch).
15 --s -4 TB6
-Replace or adjust reverse directional switch to insure that
it opens when directional handle is returned to neutral.
i
*Short circuit between terminals TB2 and TB6.
- Disconnect wire #8 from TB6 and check for short circuit STATUS INDICATION CRITERIA
between TB2 and wire #8. This status code will be displayed when voltage at TB6 is
greater than 60% battery volts at initial power up.
*Defective oscillator card.
DESCRIPTION MEMORY
STATUS CODE
Accelerator input voltage is below threshold before the FWD RECALL No
SYMPTOM ACCE!_ERAKR
TBl 29kci!!r
POSSIBLE CAUSE
*Accelerator (transducer / pot) is misadjusted or defective.
Status code disappears when directional handle is moved away swrr~
-/L
from neutral to close directional switch.
)Open circuit between directional switch(s) and battery positive STATUS INDICATION CRITERIA
or between directional switch(s) and TB5 or TB6. This status code will be displayed when voltage at TB5 and TB6
are less than 60% of the battery volts, and TBl is less than 2.5
- Check all control wires and connections shown in Figure. volts.
SYMPTOM ACCaEFATcFl
POSSIBLE CAUSE
*Accelerator misadjusted or defective. swrrcH
-I,
- Input voltage at TBl should be less than 3.8 volts.
Adjust or replace accelerator to insure that the
voltage at TB1 will vary from 3.8 volts to less than 0.2
volts when the control handle is moved into high speed.
15---p;----6 TBS
*Open circuit between battery negative and TBl.
15~-----8 TB6
- Check for broken wires or loose connections or open :-;1
accelerator / voltage supply in the circuit shown in
figure.
- Check for broken wire or loose or corroded connection at
WHT / BROWN wire to terminal PZl.
STATUS INDICATION CRITERIA
*Short circuit from battery positive to TBl. This status code will be displayed when the accelerator input
voltage at TBl is higher than 3.8 volts.
- Disconnect wire #29 from TBI and measure voltage at wire
#29 to negative. Should be zero volts for potentiometer
type and less than 3.8 volts for transducer type
accelerator.
DESCRIPTION MEMORY
STATUS CODE No
Accelerator input voltage too low on power up after initial RECALL
SYMPTOM ACCELERATOR
Forward or Reverse contactor does not pick up. r.._.._.._..-._.._.._..~
I
i
-12 13 -
EVT 15 CARD
POSSIBLE CAUSE
*Accelerator misadjusted or defective. TBl .
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
STATUS CODE DESCRIPTION MEMORY
Both Forward and Reverse directional switches are closed at RECALL bb
BRAKE
SWITCH
POSSIBLE CAUSE I,
*Forward or Reverse directional switch welded closed or mis-
adjusted to be held closed.
15 d-6 -e TB5
*Short circuit between battery positive and TB5 and / or TB6.
REV
- Disconnect wires #6 and #8 from TB5 and TB6 and check 15----lt-8-~~~6
wires for short circuit to positive side of directional -_
switches.
- Disconnect wires #6 and #8 and measure voltage at TB5 This status code will be displayed when voltage at TB5 and TB6
and TB6. Voltage should be less than 60% of battery are greater than 60% of battery volts at the same time.
volts, if not replace oscillator card.
MEMORY
STATUS CODE Battery
vo,tstoo,o~ESCR~PT~oN No
RECALL
+I1
POSSIBLE CAUSE
*Discharged battery. f
Nominal Minimum
- Check battery for proper open circuit voltage as outlined
Battery Limit Volts
in figure and charge battery if required.
I Volts 0 1.95VICell
BA-TTERY <
*Defective battery.
*Bad wire / connection on terminal PBl. This status code is displayed when the battery volts are less
than 1.95 volts per cell at initial start up. (See table in above
- Check voltage from terminal PBl to battery negative. figure.)
Should be greater than 1.95 volts per cell. Repair or
replace wire or connection.
CIRCUIT Traction
SYMPTOM
Forward and Reverse contactor will not pick up.
Nominal Maximum
Battery Limit Volts
Volts @I 2.4 V / Cell
POSSIBLE CAUSE
*Incorrect oscillator card adjustment.
DESCRIPTION 1 MEMORY
STATUS CODE 1
Invalid card type selection.
-17 i
SYMPTOM
Forward or Reverse contactors will not close.
POSSIBLE CAUSE
*Invalid card type selection.
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
STATUS CODE DESCRIPTION MEMORY
Forward or Reverse contactor coil current low. RECALL No
CIRCUIT Traction
POSSIBLE CAUSE
-Defective F or R contactor coil circuit.
I--
- Remove plug B. Check ohmic value from PB4 to positive
side of F coil. Value should be lo-14 ohms. Make same 15 +L23 - 4 PB5
check for R coil. If value not correct, replace coil.
-24 CIRCUIT
I
Traction
SYMPTOM
Control does not operate. Status code may alternate between
code 23 and code 24. Complete checks for 24, if the problem is
not found, perform code 23 checks.
POSSIBLE CAUSE
*Defective F or R contactor.
- F or R power tips fail to close because:
1) Welded normally closed power tips. BRAKE
2) Binding contactor tip or armature assembly.
3) Defective F or R contactor coil. (See status code 23)
SWITCH
1,
I
4) Loose contactor coil assembly.
a) Coil not locked into position.
-26
SYMPTOM
Forward or Reverse contactor will not pick up. EVT 15 CARD
t
jKc/ SWITCH
I
POSSIBLE CAUSE
*Defective coil driver internal to oscillator card.
-27 CIRCUIT
I
1Traction
SYMPTOM
Forward or Reverse contactors open and close, then can only be
closed by opening and closing the key switch.
POSSIBLE CAUSE
*Discharged battery.
- Insure that the wire connection at terminal PBl is tight and EVT 15 CARD
not corroded.
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
STATUS CODE DESCRIPTION MEMORY
-41
Open Thermal Protector or Control Over Temperature. RECALL No
Cl RCU IT Traction
-
SYMPTOM
Reduced or no power to traction motor in control range. 6 ..-..,,7___..__,
r--- I
ITP 1 \ 1 I
I
I i
I I
POSSIBLE CAUSE i I
I I
*Open thermal protector circuit. I I
i.-..--.-.-.-..-.-.._.._.._I
- Check for loose or corroded connection or broken wire
between:
VI0 wire at thermal protector and PZ2. Q
WHTNIO wire at thermal protector and PZ5. 2
Repair or replace as necessary.
5 0
3 5
*Defective thermal protector (part of transistor).
0 0
PZ5 PZ2 OSCILLATOR CARD
- Disconnect wires from PZ2 and PZ5. At room temperature TCONNECTCR
(25 C or 75 F) measure resistance between VI0 and
WHTNIO wires. Replace transistor if ohmic value is
greater than 1300 ohms.
STATUS INDICATION CRITERIA
control is in thermal cut-back. This status code is displayed when the voltage between PZ2
and PZ5 is greater than 1.8 volts.
- Allow control to cool, status code should disappear. Review
duty cycle, application, motor current, brake drag and
ambient temperature etc.
-42
Motor current sensor input missing. RECALL No
CIRCUIT Traction
SYMPTOM
No power to traction motor in control range.
SENSOR ~2
0; . -
POSSIBLE CAUSE
Qpen sensor wire circuit to PZ12. EVT 15 CARD
- Check for loose or corroded connection at terminal PZ12.
v
- Check for loose connection or broken wire (green wire) l Pi!12
at weld on current sensor and along length of wire.
-43 L
Cl RCU IT Traction
SYMPTOM A
No power to traction motor in control range.
POSSIBLE CAUSE
Qpen sensor wire circuit to PZ13. EVT 15 CARD
- Check for loose or corroded connection at terminal PZ13.
7
- Check for loose connection or broken wire (yellow wire)
at weld on current sensor and along length of wire. + PZ13
DESCRIPTION MEMORY
STATUS CODE
Transistors did not turn OFF properly. RECALL Yes
EVT 15 CARD
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
DESCRIPTION MEMORY
STATUS CODE
Transistors did not turn ON properly RECALL YeS
POSSIBLE CAUSE
*Defective transistor circuit.
- Check for corrosion on plug / pin at terminal PZ9. Repair or EVT 15 CARD
replace.
STATUS INDICATION CRITERIA
*Defective transistors. This-status code is displayed when the transistors fail to gate
ON.
- Intermittent or open transistor gate.
Field test may or may
not show defect. Replace transistors after above checks
show no problem found.
DESCRIPTION MEMORY
STATUS CODE I%
Look ahead test for T2 volts. (Less than 12% of battery RECALL
-46 volts.)
CIRCUIT Traction
SYMPTOM A-t/ A
Forward or Reverse contactor will not pick up. . 0
r-..-_...__.&.-._.._.._,
POSSIBLE CAUSE .
*Defective 1A contactor. I 7 I
:___-..-,,,.G__,~_i
- Check for welded 1A contactor power tips. .I
._.-4. _--_.~_-_-:
f :-- JG i
*Defective transistor. = ! !
I
l.._.._..__x!?__.-.-.-._:
- Check for shorted transistors. Replace transistors. R
.
*Defective oscillator card. j - PZ9 PZ4
-48
Look ahead test for T2 volts (Greater than 88% battery
volts)
Cl RCU IT Traction
l-
SYMPTOM Fg;
Forward or Reverse contactor will not pick up.
POSSIBLE CAUSE
*Defective forward or reverse contactor.
DESCRIPTION MEMORY
STATUS CODE
Capacitor volts low after Line contactor closes. RECALL No
SYMPTOM
Forward or Reverse contactor picks up. Control does not
operate.
POSSIBLE CAUSE
*Defective Line contactor.
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
STATUS CODE DESCRIPTION MEMORY
Capacitor volts low before Line contactor closes RECALL No
-51 (precharge).
Cl RCU IT Traction
SYMPTOM
Line Contactor does not close.
POSSIBLE CAUSE
*Defective capacitor.
- Check capacitor bank per component checking section.
- Check for loose or open connections in capacitor circuit.
*Misadjusted / defective steer interlock switch.
- Check to insure that the steer interlock switch closes after
the line contactoh power tips close. Repair or replace.
-Defective steer control.
- Disconnect the positive cable and 4PL plug from the steer
control. If status code disappears, repair steer control.
-Open circuit in capacitor precharge circuit.
- Check for loose connection or broken wire (WHT) at #3 REC
heat sink or along the length of the wire.
- Check for loose or corroded connection at terminal PZ14.
- Check for loose connection or broken wire (BLACK) at 1 FU
power fuse or along the length of the wire. STATUS INDICATION CRITERIA
- Check for loose or corroded connection at terminal PBl. This status code is displayed when capacitor volts are less than
*Unsuppressed voltage spikes. 85% battery volts at initial start up.
- Check that any and all coils, including horns, that are
present on the truck have the proper voltage suppression.
- Check that the static drag chain is present on the truck and
dragging on the floor so that it keeps static electricity
from building up in the truck.
SYMPTOM
Forward or Reverse contactor opens and closes, then opens and
can only close by opening and closing the key switch.
POSSIBLE CAUSE
*Open T2 circuit.
*Transistors defective.
-54 CIRCUIT
I
Traction
SYMPTOM
Control will not operate
POSSIBLE CAUSE
*Defective oscillator card.
-57
SYMPTOM
Forward or reverse contactors open and close, then can only be
closed by opening and closing the key switch.
SENSOR A2
POSSIBLE CAUSE
*Unsuppressed voltage spikes. *~------- EVT 15 CARD
- Check that any and all external coils that are present on
the truck have the proper voltage suppression.
t
- Check that the static drag chain is present on the truck and
dragging on the floor so that it keeps static electricity
from building up in the truck.
*Reversed yellow and green current sensors wires (if wires are
reversed, truck will not run at all).
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
STATUS CODE DESCRIPTION MEMORY
Maintenance Reminder code. RECALL bb
SYMPTOM
-99 status code is displayed for about 3 seconds when key
switch is first turned ON. Truck may run at a reduced speed and
status code -99 will flash on the display.
-99
POSSIBLE CAUSE
Truck has accumulated the number of hours as preset in
functions #19 and #20. Perform required PM maintenance and
reset functions 19 and 20 to next desired maintenance hour
number.
r
DESCRIPTION MEMORY
STATUS CODE
No display on Dash Display or Handset. RECALL No
SYMPTOM
Display screen on dash display or handset is blank.
F
EVT 15 CARD
POSSIBLE CAUSE
2 2 PBI PZl
*Positive or negative control voltage missing.
.r
SWITCH
i-
- Insure that with the key switch ON, voltage is present
between terminals PBl (positive) and PZl (Negative). f
- Check for broken wire(#2) or loose or corroded
connection from power fuse to terminal PBl.
- Check for open or intermittent key switch. 10 lo -4TB4
- Check for broken wire (#lo) or loose or corroded L
connection from key switch to terminal TB4.
- Check for broken wire (WHT / BROWN) or loose or corroded
connection from key switch to terminal PZl.
Section 4
Oscillator Card Settings
Typical Illustration
Copyrighted Material
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Do not sell or distribute
GROUP 19 Oscillator Card
AWARNING
Typical Illustration
Section 5
Steering Control Adjustments
EV-T5PS
Contents
Preparation and Safety ....................................................................... 19-5-2
Adjustment Steps 1 - 3 ....................................................................... 19-5-3
Adjustment Steps 4 - 5 ....................................................................... 19-5-4
Adjustment Steps 6 - 7 ....................................................................... 19-5-5
Adjustment Step 8 ............................................................................. 19-5-6
SM-587 Dee 94
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 19 Steer Control
A WARNING
Drive wheel must be off the floor
before any adjustments are made.
Raise rear of truck and block it on
both sides.
Typical Illustration
Maximum Speed
Trim Pot
Current Compensation
SC-POS
3. Turn Steer Comp trim pot fully clockwise
0%.
Steer Control
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GROUP 23 Steering EWT5PS
SC-POS
4. Turn Current Comp trim pot fully counter-
clockwise (CCW).
Steer Compensation
Current Compensation
Current Compensation
Trim Pot
SC-POS
5. Measure motor out voltage between M+ and
M- power terminals on steer control.
Steer Compensation
Current Compensation
II III -------------_____
I
L-l l-l
Steer Control
Dee 94 19-5-4 SM-587
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Steering EWT5PS GROUP 19
SC-POS
6. Turn Idle Speed trim pot until motor output
voltage is:
Idle Speed
Trim Pot
Steer Compensation
Current Compensation
Steer Control
SC-POS
8. Turn Current Comp trimpot clockwise (CW)
until motor output voltage is:
12.4 +/-0.2 (24-Volt Truck)
17.5 +/-0.2 (36-Volt Truck)
M+
Steer Compensation
Current Compensation Current Compensation
Trim Pot
Typical Illustration
Section 6
Wiring Diagrams
NPR-345
WY TypicalIkstrario~~
Accelerator 1 , 1
PYl3 81 61
I-
SL-l_
PM 44 13 -
6L-2
PM- ~~~.24~~-~~n~~~ 12 ____a__
PA6r ---.64-----d-B, 12-m-----*
16-=6 PA3 W W
lo-Q=!&6 66 .lBll
10-I -46
TnT 46 lT8l0
10 . .P 26 26 l TB6
10 *6l
.67 16 16 *TM
~~~~~~~~~~.lo-~~~~-~L-----. 61)~_~_~___..~
~-~~_~~~~~.lo-~~---~PL----.~-~~r m
10 .62
I 10 .. s
.
10 rm Horn Switch
: -
. _
. -
6
d
I
b
Lb!%
P
c-
%-
Copyrighted Material
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Do not sell or distribute
GROUP 19
Section 7
Forward & Reverse Switches,
Up (Lift )& Down (Lower) Switches
and
Transducer Adjustments
Contents
Safety................................................................................................ 19-7-2
Switch Adjustments ..... .......... ................................ .... .. .............. ........ 19-7-3
Transducer Adjustment ......................... ............ ................................. 19-7-4
Forward, Reverse Switch Voltage Check & Adjustments ......... .......... 19-7-7
Qble ,~
- Clamp
Tilt and Auxiliary Switches +
guide
x Markmg Tape
SM-587
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 19 Control Handle
A WARNING
Drive wheel must be off the floor
before any adjustments are made.
Raise rear of truck and block it on
both sides.
6. Check that the adjustments of both switch plung- 8. Securely tighten the switch mounting bracket
ers are operating as set in Step 2. If they are not, screws without distrubting adjustmenta.
repeat Step 2.
TRANSDUCER ADJUSTMENT
Step 2
l Measure accelerator voltage at wire #29 on terminal TE31 of traction control oscillator card and battery
negative.
#I 3 Battery Negative -,
A
TBl
lwl
Oscillator Card
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Control Handle GROUP 19
Lock
Nut
l TLUTI
key switch ON.
DO NOT STEP ON BRAKE PEDAL.
l Loosen Lock Nut holding transducer to mounting plate.
Sep 4
l Measure voltage between wires #29 and #13.
A CAUTION
To prevent damage to wiring: Loosen wires #29 & #13 by pulling them part way
thru cam slot.
Usinczthe bodv of the transducer, slowly rotate body clockwise and then counterclockwise by hand
(voltage will increase and decrease as the body is rotated). Do not rotate the body to the extent thal
wires are pulled out (or damaged).
Stop rotation when voltage registers between 3.50 and 3.75 volts. This is know as the neutral point OI
maximum accelerator voltage position. Note when in this position the wire harness will be on the toI
Transducer
Wire Harness
1
Transducer
Body
SM-587 Dee94
Copyrighted Material
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Do not sell or distribute
GROUP 19 Control Handle
itep 5
l With transducer at the neutral point, tighten Lock Nut securing transducer in position..
. Verify acceleratorvoltageis between 3.50 and 3.75 volts and, any handlemovement (in either direction)
results in reducing accelerator volts.
Lock
Nut
Step 6
l Move handle to maximum forward and maximum reverse direction positions. Verify accelerator volts
are less than 0.20 volts.
r
/
Forward Switch Reverse Switch
19-7-6 SM-587
Dee 94
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Control Handle GROUP 19
=ORWARD AND REVERSE SWITCH ADJUSTMENT
Step 7
l Disconnect connectors SO-8 and PL-8.
NOTE
Forward and reverse switch voltages should be measured between wire #6 and wire #8
(alternately) on terminals TB-5 and TB-6 (on traction control oscillator card) and battery
negative, see below.
Battery Negative
TB6
Wire #F T2
TB5_
Wire #6
.lsdII Capacitor
Step 8
l Step on brake pedal. Measure directional switches and accelerator voltages at wire #6, wire #8 and
wire #29 with respect to battery negative (wire #13).
Capacitor l-l-l-
TB6
7
Wire #8 \
TB5
Wire #6
/
TBI _/
Wire #29
Step 9
. Move control handle to neutral posi-
tion,seeoppositeillustration.Direc-
tional switch voltage at wire #6 and
wire #8 must be zero (0). If voltage
at one and/or both wires is battery
volts, turn the adjustment screw(s)
as required to open (deactivate) the
forward and/or reverse switches.
NOTE
Adjusting the screw
counterclockwise will
operate the switch
closer to neutral posi-
tion of the control
handle.
Step IO
l Move control handle extremely slowly to
operate the forward switch. When switch oper-
ates, hold handle in this position.
l Now, verify forward switch voltage is battery
volts (measure voltage at wire #6).
l Monitor and note specific accelerator voltage
corresponding to forward switch operating po-
sition. This accelerator voltage (wire #29) must
be between 3.40 and 3.60 volt. Forward
Switch
Step 11
l Move control handle extremely slowly to
operate the reverse switch. When switch oper-
ates, hold handle in this position.
l Now, verify forward switch voltage is battery
volts (measure voltage at wire #S).
l Monitor and note specific accelerator voltage
corresponding to reverse switch operation posi-
tion. This accelerator voltage (wire #29) must
be between 3.40 and 3.60 volts.
Reverse
Switch
SM-587 Dee 94
Copyrighted Material
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Do not sell or distribute
GROUP 19 Control Handle
Step 12
To adjust actuation (operating) positions of Forward and/or Reverse Switches:
l Rotate the adjustment screw(s), as required to obtain specific accelerator voltage of
3.40 to 3.60 volts corresponding to the actuation positions of both switches.
The voltage measure at the actuation moment of each switch must be 3.40 - 3.60 volts
(+O.OSvolts apart maximum).
Step 13
l Plug in connectors.
Section 8
Periodic Electrical Checks
Contents
Preparation ..................... ................................................................... 19-8-2
Inspections . .. ...... ............ .......................................... ................ .... ..... 19-8-4
Copyrighted Material
Intended for CLARK dealers only
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GROUP 19 Periodic Electrical Inspection
1. Move truck to service area.
. Park truck on a flat level surface.
. Extend pantograph.
. Fully lower pantograph.
. Tilt forks forward until fork tips touch the floor.
A CAUTION
Using a shorting device
without a resistorloadcould
cause damage to the control.
A WARNING
Discharging the capacitors
without using specified
resistor could cause serious
injury to yourself and
bystanders.
Electrical Inspections
IMPORTANT
IMPORTANT
Connector Plugs and Receptacles are perma-
Tape Markers are used to correctly position each
nently labeled with the proper PL (Plug) and SO
wire harness and electrical cable on the truck. When
(Socket/Receptacle) number for easy identification.
correctly installed, the tape marker will be hidden by
the mounting clamp (guide). Be sure to follow the
A CAUTION
instructions, where notedinthis manual, when install-
Match the plug number with the appropriate ing a wire harness or electrical cables. If you do not,
receptacle number before making a connec- ossible shorts and equipment damage may result.
tion. If you do not, electrical shorts and
possible damage to the equipment may re-
sult. i.e., Plug #PL-6 plugs into pin socket
SO-6. etc.
s must face in direction shown.
L-Tape Marker
(Stamping: DT06-6P)
Torque specifications (where noted) for mounting hardware, clamps, etc., must be adhered to or equipment
damage may result.
Special Instructions have been illustrated to show proper installation of multiple cable and wire connections.
If the instructions are not specifically followed, possible electrical shorts and control damage may result.
Assemble Front-to-Front
;semble Back-to-Back
TC-NEG. Cable
(Pump Motor A)
TC-NEG. Cable (BAT.NEG.)
Broken Wires -I
IMPORTANT
Improperly Torqued Fasteners Can Cause Damage
l Use an appropriate wrench and tighten all fasteners to the torque specified
in the following inspection procedures.
Typical
Inch Pound
Torque Wrench
Pointer
Typical
Foot Pound
Pivoted
Torque Wrench
Scale Handle
Pointer
19-8-6 SM-587
Copyrighted Material
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Do not sell or distribute
Periodic Electrical lnpsection GROUP 19
Assemble Front -
TC-NEG. Cable
(Steer Control Negative) Buss Bar
Wire 13C & 13D (Main Harness)
e 138 (Main Harness)
1
\ \ -TC-P Cable,
able (or)
(Pump Motors) /
. Wire Harness
L Torque to: 100 lb. in.
m
Clamp
5ii?IMPORTANT
A! CAUTION
Wire harness, clamps (guides)
and terminal connections must
be installed exactly as shown.
ressure
If they are not installed as
illustrated here, you may
experience shorts and
component damage.
26 20 20A 5
Solenoid Control Card
134568 IO II I2
I I I I I I I I I I I I\
13C 48 38 58 I8 28 45 55 65 35 IOC IOE IOF
NOTE
Connect PL-DP to Display Unit
prior to assembling to bracket.
Copyrighted Material
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Periodic Electrical Checks GROUP 19
z 6
hrkrng
-Clamp
Tape
or
Guide
l Inspect wire and harness clamps for security of damage and proper installation. Refer to following
mounting. Make sure the harness Marking Tape page for detailed drawings.
is in alignment with or covered by the clamp. .
Inspect wiring for damage (cuts, etc.). Repair or
This assures the harness is correctly positioned.
replace as required.
l Inspect the multi-function control handle for .
Report condition on the PM check sheet and
damage. The handle has two halves. Check to be
give to the designated authority.
sure thefasteners on the switch and heel sides of
the handle are secure.
/ .
Plug (or Socket) Housing
l Inspect handle switches for damage (Reach,
Tilt, ALIX.).Replace any that are damaged.
l Check the handle mounting bracket for security
of mounting. The bracket must be adjusted so
the handle is vertical and in line with the hydrau-
lic control valves. Make certain the mounting
bolts are tight.
l Check security of all mounting fasteners (bolts,
screws and C-rings). Replace any that are miss-
ing or damaged.
Seal should be pressed flush with housing.
l Inspect all connectors (plugs and sockets) for
IMPORTANT
Typical Panel Firmly push plug into socket until
xeptacle & PI latch clicks locking the two com-
Assembly ponents together.
Ass$mbly
Rubber Seal
-----
r IMPORTANT 1
I End Seals must be 1
1 firmlysaatedwithin 1
I theassembly hous- I
ing.
L ----- i
E~8rvq30@
Pin
Retainer Plate (light orange)
rypical Illustration
The electrical connectors on this truck are equipped the end seals are seated flush with the end of the
with rubber seals to protect them from water and connector housing.
condensation. There is a seal at each end (wire end)
l The retainer plates snap into place to secure the
of the connector. The plug is equipped with a seal and
pins and their sockets.
retainer plate, see above. There is a pin retainer plate
in the socket sub-assembly. Check the plates for damage and security of
mounting.
l Check seals for damage that would make them
unfitforfurther service(cuts, etc.). Make certain
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Do not sell or distribute
Periodic Electrical Checks GROUP 19
l Make certain connec-
tions are made as il-
Assemble Back -t lustrated or possible
electrical shorts and
component damage
IMPORTANT
Cables must be positioned so all tape markers
are aligned with or hidden under clamps or guides.
Cables mIlnt he rmltd ac chnwn
l Inspect power cable connections on the drive motor and the contactor panel for damage and security of
mounting. Replace damaged parts. Tighten connections to the torque specified.
IMPORTANT
Clamps must be
positioned so all
TAPE MARKERS
are aligned with
or hidden under
the clamps or
clamp guides.
Q../
/ Torque Motor Cable Fasteners
Cables must be routed as shown.
to: 150 Ib.in. (16.9 N-m)
19-B-l 3 Dee 94
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Periodic Electrical Checks GROUP 19
- Rttrs Rar I ,<I
bsemble Front-to-Front
/sJ.. _ Pae,
-% TC-NEG. Cable
b (Pump Motor A)
c TC-NEG. Cable (BAT.NEG.)
_ TC-NEG.
7ack-to-Back
SC-POS. F
_ L hire 13C & 13D (Main Harness)
Control Panel 0
r.
Assemble Front-to-Front
Assemble
A CAUTION
-% TC-NEG. Eable
(Pump Motor A) Cables, Wiring and Terminal
- TC-NEG. Cable (BAT.NEG.
Connections must beinstalled
as shown. If they are not, you
may experience electrical
hw- TC-NEG. Cable (Steer Control Neg.)
shorts and component
damage.
1r
Cables must be
routed as shown.
A WARNING
The battery contains corrosive
acid which can cause injury. If
acidcontactsyoureyesorskin,
flush immediately with water
and get medical assistance.
//
f
Do not smoke or allow open
flame near the battery.
Explosive gas is always
A& I
I Battery
Retainer -
Copyrighted Material
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Do not sell or distribute
El!!YRK
~;$ria\Handling
GROUP 19
Section 10
Oscillator Card Remove & Replace
/
J
Truck Preparation
l Turn key switch OFF.
l Disconnect truck battery.
l Remove console cover.
l Discharge capacitors.
A
A
Removeall Jewelry before
working on truck. Always wear Safety Glasses
so-9
PL-9
/I A
Switches
CAUTION
may be
II
damaged if the Switch UP (Lift) & Down (Lower)
Cam is not removed. Switches
Be very careful when
removing cam that you
do not damage the
switches.
r Mounting Screew
TBl - TB6
- Mounting SC&w
Top View
Zero Ohms
: Common
Battery
Negative
n
Wire
arness
lo T.B.
- 13
- 48
- 18
-26-
- 28
-2o-
SELECTOR nr nr - 45
Common
_ +
n1
- 55
._-
c
- -..-
- 65
B
_?A
Battery - 35
Negative -5-
- 10
l RH5 Light ON
TB7 - Wire #26 10 to 12 Volts - Battery Charged indicating the Solenoid Card is receiving
BDI Signal from the EV-T15 Oscillator Card.
0 Volts means - Battery is below 80% Discharge and must be taken out of
service and fully charged or replaced if defective.
NPR-345
Solenoid Control Card
Copyrighted Material
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Do not sell or distribute
GROUP 22 Trouble Shooting
l Remove Jumper Plug JP2 ... if the truck is equipped with 2nd Auxiliary function.
See illustration below.
NOTICE
l If you have a truck without side shift function and the Jumper Plug JP2 is removed,
you will experience the following conditions:
-The hydraulic system will fail to function .. . there will be no hydraulics at all.
-The RI35 Indicator Light (LED) will be ON.
l If you have a truck equipped with side shift function and the Jumper Plug JP2 is in place, the
following conditions will exist:
-The monitoring function of the card for side shift solenoid circuit will not work.
-However, the side shift circuit will be operable.
IMPORTANT
When replacing plug,
be certain it is installed
correctly as shown. -, \ NPR-345
Solenoid Control Card
against board.
Section 20
Axle,
Articulartion Adjustment
Contents
Illustration . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... . .... . .. . .. .. .. . . ... . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 20-l-2
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . .. . . .. . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l-3
Articulating Axle
Copyrighted Material
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Do not sell or distribute
GROUP 20 Axle
\ Floor Plate /
Section 2
Drive Unit
Contents
Lubrication ........................................................................................ 20-2-3
Removing the Top of the Gear Unit ................................................... 20-2-4
Dismantling the Housing Lid ............................................................. 20-24
Dismantling the Crown Gear and Wheel Shaft ................................... 20-2-5
Dismounting the Outer Race .............................................................. 20-2-5
Dismounting the Inner Race .............................................................. 20-2-5
Dismounting the Helical Spur Gear and the Conical Pinion Shaft.. ... ..20-2- 6
Mounting the Gear Unit - General Remarks ....................................... 20-2-7
Measuring the Assembly Dimension of the Conical Pinion Shaft ..... ..20-2- 8
Preassembly of the Conical Pinion Shaft ............................................ 20-2-8
Preassembly of the Wheel Shaft ......................................................... 20-2-g
Preassembly of the Wheel Shaft Bearing in the Housing ................... .20-2-g
Setting the Circumferential Backlash ............................................... 22-2-10
Checking the Tooth Pattern .............................................................. 22-2-10
Setting the Conical Pinion Shaft, Helical Gear, and Bearing Cle a. ....22-2-12
Mounting the Conical Pinion Shaft .................................................. 22-2- 12
Mounting the Wheel Shaft ............................................................... 22-2-14
Mounting the Housing Lid ............................................................... 22-2-16
Mounting the Top of the Gear Unit .................................................. 22-2- 17
Special Tools ................................................................................... 22-2-18
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C=RnlIP
_.I__.
3fl
I_
Drive Unit
A WARNING
Wear eye protection and protective clothing when drying with air pressure.
Reduce air pressure to 30 PSI (207 kPa). Debris removed with air pressure can
cause injury.
Typical
Foot Pound
Pivoted
Torque Wrench
Pointer
\ Seal
Drain Plug
Level Plus lbp3
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Drive Unit GROUP 20
3. Insert a g-mm diameter punch into the threaded hole of the wheel shaft and drive to dismantle the wheel
shaft.
4. The wheel bolts (120) can be removed by pressing them out when the wheel shaft is dismantled
5. Take the crown gear out of the gear unit.
Dismounting the outer race (122), shims (124-127), radial sealing ring (102).
1. Dismount the outer race (122 inside) by lightly tapping with a copper punch or the like. Make sum not to
damage the shims. Bind the outer race and the shims together with a wire or the like and place them with
the crown gear,
2. Pry out the sealing ring, dismount the outer race (122 outside) by lightly tapping with a copper punch or
the like, and place the outer race with the wheel shaft.
Dismantling the inner race.
1. The inner race should be dismantled only if the bearings am damaged and have to be replaced. If a new
wheel shaft or a new set of bevel gears is mounted, new bearings must be fitted.
2. To dismantle the inner race, cut open the bearing cage and extract the inner race via the small bearing collar
using the extractar.
Dismounting the helical spur gear (201) and the conical pinion shaft (104).
1. Unscrew the hex nut, dismount the helical spur gear using the extractor, and drive out the conical pinion
shaft (e.g., using a copper punch).
2. Remove the top inner race (112) and place it with the helical spur gear. Press the lower inner race (105)
with spacer bushing (111) off the conical pinion shaft using the special tool B (see page 18) and place
them with the conical pinion shaft.
3. Dismount the top outer race (112) by lightly tapping with a copper punch or the like. Make sure not to
damage the shims (114-l 17). Bind the outer race and the shims together with a wire or the like and place
them with the inner race or the helical spur gear.
4. Dismount the bottom outer race (105) by lightly tapping with a copper punch or the like. Again make sure
nottodamagethe shims (107-l lO).Bindtheouterraceandtheshims togetherandplacethemwiththeinner
race or the conical pinion shaft and the spacer bushing.
The thickness X of the shims (107-l 10) is calculated according to the following formula:
X=E-B-T
E = housing dimension
B = Assembly dimension of conical pinion shaft (marked)
T = Bearing width (105)
Pre-assembly of
1. Press the inner race (105) carefully with special tool C(see page 18) up to the limit stop.
IIE"
@.
inside
SM-587 Dee 94
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 20 Drive Unit
Setting the circumferentail backlash on the crown gear (104) and checking the tooth pattern
1. Press the inner race (122) onto the crown gear using the special tool H (see page 20).
2. Insert the crown gear (101) into the housing.
3. Push in the pre-assembled wheel shaft and use special tool J (see page 20) to pull together the crown
gear and the washer (128) until the bearing clearance is approximately zero.
4. For measuring the circumferential backlash at the crown gear, secure the conical pinion shaft against
turning, e.g., with a wooden wedge.
5. The circumferential backlash is corrected by adjusting with shims (124-127).
6. Admissible circumferentail backlash 0.1-O. 15 mm (0.004 - 0.006).
Checking the tooth pattern
NOTE
For checking the tooth pattern it is necessary to apply a thin coat of marking ink to 3-4 tooth
flanks of the crown gear.
1. Mesh the coated tooth flanks several times with the conical pinion. The pattern will show better if the
conical pinion is slightly braked while in mesh. Compare the pattern obtained with the Mounting
guideline below.
2. If a correction is necessary, its direction is indicated by the Mounting guideline.
3. Secure the hex nut (118) by staking. - ITY
wooden wedge
SM-587 Dee 94
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 20 Drive Unit
Setting the conical pinion shaft (KM), helical gear (201) and setting the bearing clearance
1. Position the shims (107- 110) according to instructions on page 8 and insert the outer race (105) into the
housing (101).
2. Insert the previously mounted conical pinion shaft.
3. Using the special tool F (see page 19), apply a light pre-stress to the conical pinion shaft via the housing
towards the stop.
Adjustment of bearing clearance.
1. The thickness of the top shims (114- 117) to be fitted can now be determined on the basis of the following
dimensions:
c= Distance between spacer bushing/conical pinion shaft and contact of outer race.
S= Distance between surface of outer race and surface of inner race.
NOTE
If the outer race is higher than the inner race (dimension as shown in detail Z), dimension X is determined
as follows:
Shim thickness X = C - S - 0.02
If the outer race is lower than the inner race, dimension X is determined as follows:
Shim thickness X = C + S - 0.02
2. Insert the shims and the top outerrace. Fit the inner race by tapping onto the pinion shaft using special tool
G(seepage19).Placethehelicalspurgear(201)ontotheconicalpinionshaftandscrewthehexnut(l18).
Hold the helical spur gear tight using the special tool (see illustration) and torque the nut to 60 + /- 5 Nom
(44+/- 3.7 ft-lb.). After checking the tooth pattern the shaft nut is locked by staking.
Checking the bearing clearance of the pinion shaft
1. Mark the measuring point on the helical spur gear with a grease pencil.
2. Press the conical pinion shaft downwards by hand, while turning it serveral times through approximately
180. Adjust the dial gauge to zero at the measuring point.
3. Pull the conical pinion shaft upwards via the helical spur gear, turning it as described above, and hold it
steady at the measuring point.
4. Read the bearing clearance off the dial gauge. Allowable clearance: O-0.05 mm (O-0.002).
NOTE
When taking this measurement it is important to turn the shaft several times so as to align
the rollers in the taper roller bearing.
detail ,. Z
Dee 94
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 20 Drive Unit
Mounting the wheel shaft (119), crown gear (104), and setting the bearing clearance.
1. Use special tool J (see page 20) to pull together the mounted wheel shaft and crown via washer (128):
Torque to 10 Nom (7.4 ft-lb.) = approximately 5000 N bearing pm-stress
2. When doing so, turn the wheel shaft several times tin both directions to enable the bearing rollers to align
themselves.
3. Measure dimension Y via the hole of special tool J (see page 20).
4. Shim thiclcness X = Y - washer thickness of auxiliary unit.
5. Unscrew special tool J (see page 20) and remove.
6. Insert shims in accordance with dimension X.
7. Apply Loctite 242 to screw (129) and pull together the previously mounted wheel shaft and crown gear
via the washer (128). Tightening torque MA = 110 Nom (81 ft-lb.) +/- 10%.
NOTE
A direct check of the bearing pre-stress as not set is hardly possible. When checking
according to the measu.ring method described above, there should be no measurable bearing
clearance. Nevertheless, it should still be possible to rotate the wheel shaft easily by hand.
NOTE
If the basic gear unit is stored as an assembly group, e.g., for standby purposes, it should be
suitably protected against corrosion and be packaged accordingly.
Conservation can be carried out, e.g., by filling the unit with oil and draining it afterwards.
SM-587 Dee 94
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 20 Drive Unit
SDecial Tool A
I 1 HFK 200 1 HFK 250/300 1 HFK 400/500 1
! A 1 180 I 210 I
B 167 178
C 152 165
0 46 65
E 1302 0.2 1692 0.2
F so,+s.z 4820.2
G 21 k3.2 42 20.2
1 H I 28 I 46 I
J I R90 R95
68 8
K 43
L 19 30
o( 7s I 7o
dent-h) 618 707 1 618 708 1 618 709 1
Special Tool B
HFK 200 HFK 250/300 HFK 400/500
Od 30-0.2 35.SQ.2 40.50.2
00 67.5 79.5 79.5
Jdcnt-Nr. 618 710 618 711 618 712
Special Tool C
HFK400/500
00
0d HFK
28.2200
23+O.2 f HFK 26'0.2
250/300 3oj;O.I 'F-F3
31.2 -2
L min. 95 170 17s
{dent-Nr. 618 713 618 7lL 618 715
Special Tool D
fl--L-?~
HFK 200 HFK 250/300 HFK 400/500
0D 46,5 51.5 63,5
L
Ident-Nr.
55
618.716
67.5
618.717
77s
618.718
Id _I&
W
Y
* rated dimension -<
II
-2 Actual dimension marked
on bushing
Special Tool E
Teil 1 Teil 2
,
Special Tool G
,
HFK 200 HFK250/300 HFK400/500
23-0.2 26+0.2 30.5'0.2 --.
0d
mm. L 35 35 35
Ident-Yr. 618.840 618.841 618.842
Special Tool H
~1
l NennmaQ
Special Tool I
f7.2O.:
Special Tool J
hex nut
M 12 DIN 934
headless screw
M 12 55 DIN 939
Dec94
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Drive Unit
GROUP 20
Special Tool K
0d 136 140
A 13.7+0,l 14,7+o;l
28
Ir
max. 270
DRIVE UNIT
-I--
303
407
408
304
402
Upper Half
Section 22
Traction Wheel & Tire
Contents
Preparation ....................................................................................... .22-l-3
Illustrtion, exploded view .................................................................. 22-l-2
Pressing Tire .................................................................................... .22-l-3
Tracti
Fastener
Tightening
Sequence
Tir
Wheel
Torque Fasteners
to:
124 - 139 Ib.ft.
(168 - 188 Nom)
Drive Unit
- -_
_ of truck using
- - hardwood (oak)
blocks.
Replacing Traction Wheel Tire
1. A sleeve slightly smaller in diameter than the
wheel with a depth larger than the wheel should Press Direction
be used when pressing on a new tire, see oppo-
site illustration.
2. Install wheel fasteners and torque them to 124 - ~~~;~~~,~q :g#;:;:
......:.:+.
::::::::.:+:.
:::::::::::::::
;:{:;:;:$;:s:.
....y.:+:
:~$$:~:~:
press ~
:jjjjjjjjj
~
Old Tire
Table
Section 2
Caster Wheel & Tire
Contents
Preparation ........................................................................................ 22-2-3
Illustrtion, exploded view .................................................................. 22-2-2
Pressing Tire ..................................................................................... 22-2-3
Bearing Adjustment Procedures ......................................................... 22-2-4
SM-587 22-2-l
Copyrighted Material Dee 94
Intended for CLARK dealers only
Do not sell or distribute
GROUP 22 Tires
Refertoadjustmentprocedures and
torque specifications outlined on
Page 4 in this section.
Nut 1
Chamfer
IMPORTANT
Be sure the chamfer side of
nut is installed toward wheel
bearing. Refer to opposite
illustration.
Adjustment
l Spin wheel when torquing nut to specifications.
Chamfer To Face Inward
This is to insure proper seating of the wheel
bearings.
l Using a torque wrench and the special tool
shown below, torque the bearing nut to 300 lb.in.
(33.9 N*m) while spinning the wheel.
l Loosen nut and then retorque to 25 lb. in. (2.82
Nom) while spinning the wheel.
The wheel should spin freely, yet not have
more than 0.006 end play after adjustment.
l Tighten nut (do not loosen nut) to the first
available locking tab of the lock washer. Bend
lockwasher tab into nut slot to secure adjust-
ment. Install hub cap.
Applications:
Used to torque 24H Nuts.
May be purchased from
most engine or auto parts
stores.
Section 1
Brake, Motor
Contents
Motor Brake Service.. ....................................................................... .23-l-2
Brake Adjustment.. ........................................................................... .23-l-5
Final Brake Adjustment Specifications ............................................. .23- 1-8
Caster Brake (Refer to) ..................................................................... 23-2- 1
Brake Bleeding Procedures (Refer to) ................................................ 23-3- 1
Brake Pedal Check and Adjustment (Refer to) ................................... 23-4- 1
Brake System
The brake system consists of a brake mounted on top of the drive motor and a brake mounted in the caster wheel
assembly. Both brakes are spring applied and hydraulically released by a brake pedal and two master cylinders.
The caster brake service procedures are covered in Section 2 of this manual. Brake Bleeding Procedure is
covered in Section 3 and Brake Pedal Check and Adjustment Procedure is covered in Section 4 of this manual.
Drive Motor
SM-587
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Brakes
GROUP 23
Brake Pressure
A! CAUTION
Park truck on a level surface
and chock wheels.
NOTE
only be necessary to do the
It will
if
following two steps thecomplete
brake assembly is to be removed
NOTE
On 24 Volt models it is necessary
to perform the following two steps
to allow brake drum removal.
23-1-2 SM-587
Dee94 Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Brakes GROUP 23
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 23 Brakes
l Apply Anti-Seize, Clark Part No. 1802307 to l Reconnect pressure switch wiring
motor shaft, bore and threads. Now install the l Replace hydraulic hose and retighten.
drum, key andnut. Torque to specification shown
above. l Release pedal and remove blocking.
Drive Motor
Dee 94 23-1-4
Copyrighted Material
SM-587
Intended for CLARK dealers only
Do not sell or distribute
Brakes GROUP 23
Brake Adjustment l Loosen and back-off jam nut (1) freeing brake
arm, see below.
Step 1
l Loosen nuts (2 & 3). Rotate them inward several
l Pull boot from cylinder exposing the cylinder turns. Now loosen nut (4) releasing spring pres-
piston and rod end, see below. sure.
Step 2
l Rotate actuating rod counterclockwise while l Now depress brake pedal several times to move
holding nuts (1,2, 3 & 4). Rotate rod outward piston outward until it is flush with housing
until piston is fully released (there must be some l Pedal will become very firm. Do not force pedal
gap between rod end and piston). Brake are must down. While holding light pressure on pedal,
be fleeto move in either direction. loosen bleeder to allow pedal to be depressed to
IMPORTANT the floor. Do not release brake pedal. Tighten
The brakearm must beallowed bleeder.
to float until adjustment is
made.
Typical Illustration
Typical Illustration
Step 4 l Next, tighten nut (2) against arm ... finger tight.
l Next, install the boot. l Using two wrenches, securely tighten both nuts
0 While holding arm in neutral (brake released), with&t moving brake are &t-of neutral.
tighten nut (1) against arm . .. finger tight.
Secure Adjustment
Tvnienl llhxtratinn
23-1-6 SM-587
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Brakes GROUP 23
Step 5
l Fkeload brake spring. Tighten nut (4) against the
spring washer, as shown, until spring length is
44.5 mm (l-3/4). Measurement should be taken
from the inside of spring washer to inside of
spring washer as shown below.
Typical Illustration
Step 6
l Using two wrenches, tighten jam nut (3) while
holding nut (4) to secure adjustment. Make
certain jam nut is tightened securely without
disturbing the spring preload adjustment.
Typical Illustration
SM-587
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 23 Brakes
Brake
Pressure Spring
Final
Adjustment Specification
Drive Motor
Typical Illustration
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
El!!RKM$&ri;\Handling GROUP 23
Section 2
Caster Brake
Contents
Truck Preparation . .. .. .. .. .. .. .. .. .. .. .. .. . ... .. .. .. .. .... . ... .. .. .. .. .. .. .. .. . .. .. .. . .. .. .. .. . 23-2-2
Service Procedure . .. .. .. .. .. .. .. .. .. .. .. .. . ... .. . . .... . . .. .. .. .. .. .. .. .. .. .. .. . . .. ... . .. .. .. .. . 23-2-2
Slave Cylinder Remove & Replace . .. .. ... . .... .. .. . . .. .. .. .. .. .. .. .. . ... ... . .. .. .. .. . 23-2-5
Brake Backing Plate Remove & Replace . .. . ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 23-2-5
Brake Arm and Brake Shoe Installation . .. .. .. .. .. . .. .. . ... . .. .. .. .. .. ...I.......... 23-2-6
Caster Wheel Brake Linkage Installation ,.......................................... 23-2-7
Caster Brake Adjustment . .. . ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. .. .. 23-2-8
Bleeding Brake System (Refer to) . .. .. .. .. .. .. .. .. .. .. .. .. . ... .. .. .. .. .. .. .. .. .. .. .. .. . 23-3-l
Brake Pedal Check and Adjustments (Refer to) . .. .. . ... .. .. .. .. .. .. .. .. . . .. .. .. . 23-4- 1
Brake System
The brake system consists of a brake mounted on top of the drive motor and a brake mounted in the caster
wheel assembly. Both brakes are spring applied and hydraulically released by a brake pedal and two master
cylinders. The motor brake service procedures are covered in Section 1 of this manual. Brake Bleeding
Procedure is covered in Section 3 and Brake Pedal Check and Adjustment Procedure is covered in Section
4 of this manual..
Caster Assembly
Typical Illustration
Brake Spring
Release spring application pressure and remove
spring.
Loosen and back off jam nut (1).
Slowly rotate nut (2) away from the spring until
thecasterwheelis free torotate. Remove nut and
spring.
Caster Assembly
ypical Illustration
Spring
@ ~ -y;
f$$s
I
Retainer
Ring
c
NOTE
Go to Step 7 if the Slave Cylinder
or Brake Backing Plate does not
require service.
SM-587
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Brakes GROUP 23
SLAVE CYLINDER
1 Tightening Sequence
BRAKE BACKING PLATE
Typical Illustration
Typical Illustration
Typical Illustration
Typical Illustration
Typical Illustration
NOTE
Check brake pedal up-height for
correct adjustment.Refer to section
4.
Typical
SM-587 23-2-9
Copyrighted Material Dee 94
Intended for CLARK dealers only
Do not sell or distribute
Cl!!lRK
Material Handling
Company GROUP 23
Section 3
Brake Bleeding Procedure
Contents
Bleeding the Brake ............... ............................ ........ .................. ....... 23-3-2
Brake System
Drive Motor
NOTE
&!.?a
:3
Keep Reservoir
* Master Cylinder(s) filled wi ith fluid.
Bleeder Valves
SlavXylinder
(Caster Brake)
Section 4
Brake Pedal Adjustment
Contents
Brake Pedal Check and Adjustments . . ... .. .. . ... . ... .... . . .. .. .. .. .. .. .. . .. . .. .. .. .. . 23-4-2
* Master Cylinder(s)
Typical Illustration
Brake System
Pedal Up-Height Adjustment
rBrake Pedal
Measure the distance between the floor plate
and the bottom edge of the brake pedal as shown
below.
If measurement is not as specified, then an
adjustment should be made at the brake master
cylinder(s). See opposite illustration.
Adjusting Pedal Up-Height
l Using two wrenches, hold piston rod(s) and
loosen jam nut(s). Rotate piston rod(s) until
correct adjustment is accomplished.
l Tighten jam nut after making adjustment.
IMPORTANT
Be absolutely certain that both cylinders are ad-
justed evenly. Check by lifting pedal full up and
individually check piston for even tension. If one is / Master Cylinder
loose, adjustment is not even. Correct adjustment as
required. Again, be certain to secure adjustment with
jam nut(s).
ADJUSTING
NOTE
Checkthat both brakesrelease with PEDAL UP-HEIGHT
pedal down. If not, further brake
pedal height adjustment may be
necessary.
Floor
Plate
* Master Cylinder(s)
Section 1
Hydraulic Pressure Checks
Lift, Steering, Auxiliary, Reach & Tilt
Side Shift (if so equipped)
NPR-345
Remove Cover
for access
to:
Press4 re
Check
Connections
Fork
Open Door
for access
to Auxiliary
Pump Relief
Valve
Test Port 1
l Auxiliary, Reach &Tilt, Steering and Side Shift
(if so equipped) pressure test port.
Test Port 2
l Refer to Group 30 for Lift Circuit Relief Valve
check and adjustment procedures.
IMPORTANT: Check system pressure with the
hydraulic fluid at operating temperature ...
110 to 130F.
NOTE
Relief valve(s) are factory preset
and shouldnotrequire adjustment.
However, if adjustment is required,
do not exceed specified setting.
Spring(s)
I
Auxiliary Pump
SM-587
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 26 Hydraulic Pressure Checks
Test Port 1
l Refer to Group 26 for Auxiliary, Reach & Til
Steering and Side Shift (if so equipped) pressur
check and adjustment procedure.
Port 2
Lift Circuit pressure test port.
IMPORTANT: Check system pressure with th
hydraulic fluid at operating temperature:
110 to 130 F.
NOTE
Relief valve(s) are factory preset
and should not require adjustment.
However, if adjustment is required,
do not exceed specified setting.
Adjustor -1
Section 1
Hydraulic Sump Tank
Filter and Strainer
Drain, Clean and Refill
NPR-345
A WARNING
Hydraulic fluid is toxic to skin,
eyes, and respiratory tract.
Good ventilation is normally
adequate.
A CAUTION
Cleanliness is of extreme
importance. Before dis-
connecting the hydraulic
components, clean exterior of
plumbing and solenoid valve
to prevent dirt and foreign
matter from entering hydraulic
system.
A WARNING
When usina air pressure to clean off truck:
Wear eye protection and protective clothing when drying with air pressure.
Reduce air pressure to 30 PSI (207 kPa). Debris removed with air pressure can
cause injury.
Removeall Jewelry
before working on
truck.
Always Wear
Safety
Glasses
A CAUTION
Protect drive motor and brake
assembly from any oil spill.
10 Gallon Capacity
SM587 29-l-5
Copyrighted Material Dee 94
Intended for CLARK dealers only
Do not sell or distribute
GROUP 29 Hydraulic System
IMPORTANT
Multi-Function
Control Handle
Refer to Group 01
for recommended
Hydraulic Fluid(s).
Section 2
Hydraulic Schematic
NPR-345
w Typical Illustration
29-2-l Aug 93
SM-587 Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Hydraulic Schematic
----_-__1 P
-v-e
1 i _
I 2gfi$s
A
I
( valve
I
~----------~--
i
I_ _s_-____
-4
Aux Control
I- L
T
2 1
Al IS
vl Lift
3
Sl
ReachIIin
Selector Valve
Reach Cylinders I I
r-i------iLz----F_l____;
mli2Y!~
b---a
I
-------
I Lift inder
i!l
:
:
L Flay ?!. imiter
I valves
:
I-
Section 4
Hydraulic Pump Overhaul
Contents
Disassembly ..................................................................................... .29-4-3
Parts Inspection ................................................................................ .29-4-3
Reassembly ...................................................................................... .29-4-5
SM-587
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 29 Hydaulic Pump
Outlet
-Seal (5)
Dee94 29-4-2
Copyrighted Material SM-587
Intended for CLARK dealers only
Do not sell or distribute
Hydraulic Pump GROUP 29
DISASSEMBLY l An alternate method of removing the rear cover
is to pry simultaneously with two large screw-
Preparation for Disassembly drivers in the relieved areas between body and
cover.
Overhaul pump only in a clean, dust-free location,
using clean tools and equipment. Dirt or grit will
damage the highly machined surfaces and will result
A CAUTION
in leakage or premature failure of the pump. At no timeshould screwdrivers
be inserted further into pump
body more than the depth of
Pump Disassembly the relieved areas. Any burr
NOTE must be removed from the
Allreferencenumbersrefertoitems body (14) and/or cover (3) after
thisoperationtoassureagood
illustrated in the illustrations on
seal between body and cover.
the opposite page.
4. Holding shaft end down, remove rear cover (3).
1. Clean outside of pump in a S toddard type clean-
Dowel pins (7) may remain either with the body
ing solvent and dry thoroughly.
or with the rear cover.
2. On models with splined drive shaft, proceed to
NOTE
Step 3. On models with keyed drive shaft,
Cover seal (5) and thrust plate (6)
remove drive key (11) from drive shaft. Using a
may or may not remain with rear
file or stone, remove any burrs from shaft end or
cover. Should they remain with
key way.
the body, remove seal and lift out
NOTE thrust plate before proceeding.
During disassembly, take special
note of the wear patterns on the 5. Lift out driven gear (13), drive gear (12), and
wear plate (8), thrust plate (6) and wear plate (8).
body (14). The large port in the 6. Invert pump body with shaft seal up. Remove
rearcover (34) always corresponds shaft seal (10) by prying it out with a large
to the inlet side of the pump. The screwdriver.
inlet side can be further identified
by the gear contact pattern in the .A CAUTION
body (gear) bore. The wear plate Care should be taken not to
(8) will have a somewhat heavier damage (gouge) the shaft seal
wear pattern on the inlet side. The bore, because this will result
thrust plate (6) will also have a in shaft seal leakage.
pattern than can be established for
reassembly. Also note that the long Parts Inspection
journal of the driven gear (13) is
toward the front of the pump. 1. Wash all parts and dry thoroughly with a clean
lint free cloth.
3. Separate rear cover (3) Ii-om body (14) by sup-
2. Inspect wear plate (8) and thrust plate (6). Re-
portingpump,shaftendup,onmountingflanges
place if scoring or uneven wear is observed.
andpressing on drive shaft end in arbor press, or
tap drive shaft with a plastic mallet. Use one NOTE
hand tosupport rear cover from underneath, Somewhat heavier wear pattern is normal on the
since cover and internal parts will drop sud- lowpressure (inlet) side of the plates (6 & 8). How-
denly when dowels are disengaged. ever, there should be no heavy scoring in this area.
Seal (5)
SM-587
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Hydraulic Pump GROUP 29
3. Remove pressure loading seal (15) and seal (9) 2. Invert body so that gear boresare up. Install wear
from wear plate. The seals may be two-piece or plate (8) in bottom of bore, making sure that
one-piece design. In either case, discard old seal pressure loading seals (9 & 15) are positioned
or seals. All replacement seals are two-piece properly in seal grooves and installed against
design and should be installed into groove. See bottom of bore surface. Ensure outside of w
circled view in exploded parts illustration on seal is exposed to the discharge pressure. (Or
opposite page. The seal should extend a mini- legs of W seal pointing toward the suction
mum of 0.005 (0.127 mm) beyond surface of PO@.
wearplate. Do not push seals below wear plate
3. Lubricate the bushings in body (14) and wear
surface at any point.
plate (8) with SAE 10 engine oil.
4. Inspect bushings in body and cover. Replace
4. Apply Lubriplate or equivalent to outer surface
cover or body if bushings are heavily scored or
of drive shaft in installation sleeve. (Sleeve I.D.
burned.
should be slightly larger than the O.D. of the
5. Inspect gear journals and faces. Replace if faces shaft.)
or journals are scored or worn.
5. Lubricate rear gear faces and journals with S AE
6. Inspect body for wear and scoring. If gear con- 10 engine oil and install thrust plate (6) in its
tact wear on low pressure side (inlet) exceeds original position, bronze face toward the gears.
0.005 (0.127 mm) depth, replace body. If the
6. Apply a small amount of grease to rear cover
body is usable lightly remove/wipe burr with
seal (5) and install seal into groove.
suitable de-burring tool.
7. Lubricate bushings in rear cover (3) with SAE
Pump Reassembly 10 engine oil.
Cleanliness is of extreme importance. Prevent dirt 8. Position pump with shaft end down. Match
or foreign matter from entering hydraulic system. scribe marks on cover and body and install
cover.
1. Place body (14) on flat plate with shaft seal bore
up. Install new shaft seal (10). Press seal into 9. Install cap screws (1) and washers (2) finger
bore until it is to approximate depth shown tight. Torque bolts to: 34 - 38 lb.ft.
below. (The outside diameter of the sleeve should 10. On models equipped with keyed drive shaft,
be slightly smaller the outside diameter of the install drive key (11).
shaft seal.)
11. Check that drive shaft turns with adjustable
l Pack the area between the double lip of the seal wrench without evidence of mechanical bind.
with Lubriplate or equivalent grease.
*Sleeve wall thickness should be
approximately 0.25 mm (0.010).
rShaft Seal
-ing
.ess I-Mounting Face Bear ..-J--j\
-J
\
/&_JGearlShaft
-+
.. . ..V.C_ Installation
*Sleeve
-_Ekl.52 mm (l/l 6)
Figure 1 Figure 2 Figure 3
Section 1
Hydraulic Control Valves
and
Solenoid Control Valves
Remove & Replace
Contents
Truck Preparation . .. .. .. .. .. .. .. ... . .. .. .. .. .. .. .. .. .. . ... .. .... .. . . .. .. .. .. .. .. .. . .. . .. .. .. .. . 30-l-2
Control Linkage . . . ., . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . .. .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30- l-5
Removal of Hydraulic Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30- l-6
Lift, Auxiliary, Reach & Tilt Control Valves . .. .. .. .. .. .. .. .. . ... . . .. .. .. .. .. . ... . 30-l-8
Flow Regulator.. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. . .. .. .. .. .. .. .30- l-9
Auxiliary and Lowering Solenoid Valves ... .. . ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 30-l- 10
Reassembly Suggestions . .. .. .. .. .. .. ... . .. .... .. ... . .. ... . .. .. .. .. .. .. .. .. . . ... . .. .. .. . .. 30-l-13
Hydraulic Tube Installation . .. .. .. .. .. .. .... .. ... . .... .... .. .. .. .. .. .. .. .. . . .. .. 30-l-13 & 14
7
Lift
I I Aux I
Solenoid Valve
Typical Illustration
\...
,,
j
.\
A WARNING
:
:,
,j
When usina air pressure to clean off truck:
Wear eye protection and protective clothing
@
when drying with air pressure. Reduce air
pressure to 30 PSI (207 kPa). Debris removed Typical Illustration
v
Hydraulic fluid is toxic to skin, eyes, and
respiratory tract. Good ventilation is normally
Q:: :
adequate. I /i
.:.. . ..
,.>;.-
Always wear F?+.,
ih.
L ;;:.F ,,+Y
;......Y
Safety Glasses
-.c
2. Turn key switch off.
l
Remove key.
. &connect truck battery.
l-
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Hydraulic Valve GROUP 30
. Remove console cover from truck. Refer to
opposite illustration.
Typical Illustration
A CAUTION
Using a shorting device
without a ~esisfor/oadcould
cause damage to the control.
A WARNING
Discharging the capacitors \ unplugged. )
without using specified
resistor could cause serious
injury to yourself and Typical Illustration
bystanders.
/d CAUTION
Cleanliness isof extremeimportance. Beforedisconnecting hydrauliccomponents,
clean exterior of plumbing, valves and compartment to prevent dirt and foreign
matter from entering hydraulic system. Immediately cap fittings as lines are
removed to prevent fluid leakage and contamination.
Lowering Solenoid Valve
ux Solenoid Val
Twical illustration
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Hydraulic Valve GROUP 30
Step 1
A CAUTION
Switches may be
damaged if the Switch
Cam is not removed.
Be very careful when
removing cam that you
do not damage the
switches.
i
Step IA .:j::
.::I.,
r Mounting Pin
&&Control Linkage
Control Linkage
- Bulkhead Fittings
Retu
Disconnect Return Line from lift valve. Disconnect Tube #l from Aux Valve and Bulkhead Fitting.
Disconnect Return Line from Aux. Sollenoid Valve. Disconnect Tube #2 from Aux Valve and Bulkhead Fitting.
Dismnect Tube #I from the Lowering Solenoid Valve and Flow Regulator.
Disconnect Tube #2 from the Aux Solenoid Valve and the Lift Valve.
Disconnect Tube #1 and #2 from P.S. Control and Aux. Solenoid Valve.
Step 8
\I a\ve \JT
Step IO
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Hydraulic Valve GROUP 30
Step 11
)
*
Flow Regulator
I.Jc
L
r--------7
Typical Illustration
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 30 Hydraulic Valve
Step 12
- ---
Typical Illustration
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Hydraulic Valve GROUP 30
Step 13
Nuts
1 Lowering Solenoid
Aux Solenoid
Valve e
Typical illustration
Step 14
Typical Illustration
SM-587 Dee 94
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 30 Hydraulic Valve
3. Using a pen or marker,
mark a line on the nut
STEP 1 Assembly Instructions
and extend onto the
adapter (or connector) as
shown.
rl
II c
for
Fittings equipped with
1
4. Holdconnector withone -! O-Ring Face Sea/s
wrench and tighten the
cap with a second
wrench.
l Rotatenutjustoneflatas
shown.
STEP 2 Tighten
One (1) Flat
from finger tight
(bottomed out)
position
using
I I second wrench.
Initial
osition
-
IMPORTANT
Hold connector with one wrench while tighten-
ing the nut with a second wrench, see above.
Section 2
Auxiliary, Reach & Tilt Control Valve
Contents
Valve Cut-A-Way with Specifications .............................................. .30-2-2
Disassembly ...................................................................................... 30-2-3
Cleaning, Inspection and Reassembly ................................................ 30-2-4
AUX VALVE - SIDE VIEW Plug Torque to: 8 - 10 Lb. Ft. (10.8 - 13.6 N-m)
7 Breather
(Must be open at all times.) r
-Bushing
/ LSpacer Ls2asher
!- Body I_ O-Ring
Typical Illustration
A CAUTION
Be extremely careful when
removing spool and O-rings
from valve body. Do not
scratch, nick or m ar the spool
or the body bore. To do so will
make the valve unfit for further
service.
NOTE
Do not remove spring retainer ring
unless the spring is broken and
needs to be replaced
SM587 30-2-3
Copyrighted Material Dee94
Intended for CLARK dealers only
Do not sell or distribute
GROUP 30 Hydraulic Valve
Cleaning and Inspection
l Wash all parts in a Stoddard type cleaning
solvent and place them on a clean surface for
inspection. Inspect the cap breather to be sure it
is not obstructed with dirt, paint or debris. Be
certain all foreign matter has been removed
from the spool and valve body. Air dry parts
A WARNING
AIR PRESSURE
Wear eye protection and
protective clothing when
cleaning or drying with air
pressure. Reduceair pressure
to 30 PSI (207 kPa). Debris
removed with air pressure can
cause injury.
l Lubricate all parts with clean hydraulic fluid to (10.8 - 13.6 N*m)
facilitate reassembly andprovide initial lubrica-
tion.
Port Plug
l Install a new O-ring on the port plug and screw
the plug into the appropriate port - finger tight.
l Torquetheplug to: 8- lOlb.ft. (10.8 - 13.6Nem)
Typical Illustration
Typical illustration
Typical Illustration
/ LSpacer
~s~asher
- Cap Torque to: 20 - 25 Lb. Ft. (27.1 - 33.9 Nem)
Typical Illustration
Typical Illustration
L
Multi-Function
Control Handle
Section 3
Lift Control Valve
Contents
Specifications ............................................................................ .30-3-2 & 3
Pilot Operated Relief Valve Assembly with Schematic ..................... .30-3-5
Cut-A-Way View of Valve ................................................................ 30-3-6
Lift Control Valve ...................................................................... 30-3-7 & 8
Valve Disassembly ............................................................................ 30-3-g
Valve Reassembly .......................................................................... .30-3-10
A WARNING
When usina air oressure to clean off truck:
Wear eye protection and protective clothing
when drying with air pressure. Reduce air
pressure to 30 PSI (207 kPa). Debris removed
with air pressure can cause injury
Hydraulic fluid is toxic to skin, eyes, and
respiratory tract. Good ventilation is normally
adequate.
Always wear
Safety Glasses
/@ GROUP 30
Q
e
A CAUTION
Using a shorting device
without a ~esisforloadcouid
cause damage to the control.
A WARNING
Discharging the capacitors
without using specified
resistor could cause serious
injury to yourself and
bystanders.
TorqueDrive Screw
to: 20 -
- 35 lb.ft. (41- 47 N*m) 11
NOTE
f? : Liquid Lock Threads1
Spool and Body are a
matched set and cannot
4
s,,,,,
Torque to: 2 - 3 Ib.ft. (3 - 4 N*m)
bepurchasedseparately. T
SM587
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 30 Hydraulic Valve
I O-Ring O-Ring 1
Return Spring
Spring T I
l Remove O-ring from hex plug. Discard O-ring. Lubricate new O-ring withclean hydraulic fluid.
Install O-ring onto hex plug. Take care not to cut
Inspection or over-stretch the O-ring.
l Clean all parts in a Stoddard type cleaning Install plug (finger tight) into valve body over
solvent and allow to air dry. poppet and spring.
l Inspect poppet for scratches or nicks. If found, Torque hex plug to 30 - 35 lb.ft. (41 - 47 N*m).
replace poppet with a new one.
(Washer) m
30-3-8 SM587
Dee94 Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Hydraulic Valve GROUP 30
Cleaning and Inspection
Valve Disassembly
Wash all parts in a Stoddard type cleaning
Ceanliness is of extreme importance. Before dis- solvent. Be certain all foreign matter has been
connecting hydraulic components, clean exterior removed from the spool and valve body. Air dry
of plumbing, valves and compartment to prevent parts.
dirt and foreign matter from entering hydraulic
system. Immediately cap fittings as lines are re- Discard all seals, spool seals and springs.
moved to prevent fluid leakage and contamina- Reassemble only with new seals and springs.
tion. Inspect the surface of the spool and body bore
End Cap Removal for cuts, scratches, nick etc. Examine the spool.
Look for loose chrome plating, cracks or other
l Remove both mounting screws securing end damage caused by foreign material in the hy-
cap to valve body using a Phillips screwdriver. draulic system. Use a light to inspect the spool
l Insert a rod with an O.D. only slightly smaller bore in the valve body. Nicks on the spool can
than the hole in the end of the valve spool. Too be removed with a crocus cloth. Any surface
small a diameter rod will cause damage to the having cuts or scratches makes the part unsuit-
spool cross hole bore. able for further service and the valve should be
replaced. The spool and body are a matched set
l Retain spool with rod and using a standard type
and cannot be replaced as individual parts.
screwdriver, remove screw (A).
NOTE
This may require heavier than
normal forces since the screw has
been installed using loctite.
A CAUTION
Be extremely careful when removing spool and O-
rings from the valve body. Do not scratch, nick or
mar thespool or the body bore. To doso,will make
the valve unfit for further service.
l Using a brass tool similar to that shown, care-
fully remove O-rings from valve body bore.
Discard these seals.
A WARNING
AIR PRESSURE
Wear eye protection and
protective clothing when
cleaning or drying with air
pressure. Reduce air pressure
to 30 PSI (207 kPa). Debris
removed with air pressure can
cause injury.
Section 4
Lowering Solenoid Valve
Contents
Specifications, Wamings and Caution . .. .. .. .. .. .. .. .. ... . .. .. .. .. .. .. .. . ... .. .. .. .. . 30-4-2
Hydraulic Schematic . .... . ... . ... . ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. ... ... .. .. 30-4-3
Disassembly .. . .. .. .. .. ... . .. .. .. . . .. ... . .. . ... .. .. .. .. .. .. .. .. .. .. . .. . .. .. .. .. .. .. .. .. .. .. .. .. .. . 30-4-4
Reassembly . .. .. .. .. .. .. .. .. .. ... . ... .. . .. .. .. .. . ... . ... .. .. .. .. . ... .. .. .. .. .. .. .. .. .. .. ... .. . .. .. 30-4-5
Installation Notations (refer to Section 1 for Removal Instructions) . ...30-4-5
A WARNING
Hydraulic fluid is toxic to skin,
eyes, and respiratory tract.
Good ventilation is normally
adequate.
A CAUTION
Cleanliness is of extreme
importance. Before dis-
connecting the hydraulic
components, clean exterior of
plumbing and solenoid valve
to prevent dirt and foreign
matterfromentering hydraulic
system.
A WARNING
When using air pressure to clean off truck:
Wear eye protection and protective clothing when drying with air pressure.
Reduce air pressure to 30 PSI (207 kPa). Debris removed with air pressure can
cause injury.
Removeall Jewelry
before working on
truck.
Always Wear
Safety
Glasses
Torque: 35 Ib.ft.
---
1 I
I II
1 io
II
li
II
2
-J
-+ p-1
----- 4
II
1 I
I ----
L__,__ $
0 1
Rated Flow: 114 L/MIN (30 G.P.M.)
Rated Pressure: 24132 kPa (3500 PH.)
Minimum Pull-in Voltage: 85% of nominal @ 20685 kPa (3000 PSI).
Typical Illustration
Manual Override
ACAUTION Retainer Control
Thevalvestemisveryfragile. Beverycareful Nut Torque: 5 Ib.ft.
when handling the valve that you do not L (6.8 Nom) max.
dent or bend the stem.
Torque: 35 Ib.ft.
-----
(47.4 NVTI)9.
BodyT-
Vave
Lead Wires-,,
1
(I) O-Ring
Back-Up Ring
(3) L__//-(21 O-Ring
ACAUTION
Valve is not serviceable. Do
not take apart.
A CAUTION
Cleanliness is of extreme
importance. Before dis-
connecting the hydraulic
components, clean exterior of
plumbing and solenoid valve
to prevent dirt and foreign
matter from entering hydraulic
system.
Wire Leads
DISASSEMBLY
l Remove nut and coil from solenoid valve stem.
l Remove solenoid valve from valve body.
l Remove fittings from valve body. l Wipe all parts dry with a clean lint-free cloth.
Allow components to airdry beforereassembly.
Cleaning & Inspecting Solenoid l Replace al seals with new ones.
l Wash all parts but the coils in a Stoddard type
l Inspect wire leads and plugs for further service-
cleaning solvent.
ability. Replace defective parts.
Dee94 30-4-4
Copyrighted Material SM587
Intended for CLARK dealers only
Do not sell or distribute
Solenoid Valve GROUP 30
A CAUTION Typical Illustration
Be certain to tighten coil retainer nut to 5lb. ft. (6.8 Nom) maximum. If you over-
tighten the nut damage to the valve stem will result.
18
HARNESS CLAMP/GUIDE
must be installed as shown or the harness will not fit resulting in possible
shorts and component failure.
REASSEMBLY
INSTALLATION
Lubricate all parts in clean hydraulic fluid prior
to installation. Reassemble only with new seals.
Install large O-ring (1) into its groove being IMPORTANT
Inspect hoses, hydraulic connections and their seals
verycarefulthatyoudonotnickorcuttheO-ring
for damage. Replace defective parts.
making if unfit for service as it will leak.
Prior to attaching hose ends and connections to the
Install O-ring (2) and backup ring (3) as shown
fittings on the solenoid valve, clean and lubricate
on opposite page. Again, be very careful you do
them with new hydraulic fluid.
not nick or cut the O-rings or leakage will occur.
Remove caps just prior to installation.
Install solenoid valve into body bore. Be certain
solenoid valve is tightened securely to the body.
Torque to 36 ft lb (47,4 N*m).
Install coil onto valve stem. Position the coil to When Mounting Solenoid Valve:
allow easy connection of the electrical plugs as l Align valve body slot with mounting bolt on
shown in above illustration. truck. Locate valve over bolt and install retainer
Install coil retainer nut and torque to 5 ft lb (6-8 nut finger tight. Refer to Section 1.
Nom)
Install hydraulic fittings install finger tight.
IMPORTANT
Allelectricalplugsandtheirreceptaclesarematched
labeled for easy connection. Check to be sure each
plug and receptacle match before attempting to
make connections.
l Check wire harness clamps for security of
mounting. Be certain the harness is in good
condition and that it is routed properly.
l Replenish hydraulic system. Refer to instruc-
tions in Section 1.
Section 5
Auxiliary Solenoid Valve
(Reach and Tilt Control)
Contents
Specifications, Warnings and Caution ......................................... .. ..... 30-5-2
Hydraulic Schematic , . . . , . . , . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. .. . . .. . . . . . . . . . . . . .. . . 30-5-3
Disassembly . . . . . . . . . . . . . . . . . . . . . ,. . . ..,.........,................................................ 30-5-4
Reassembly ... ...... .................................................. .... .... ................ .... 30-5-5
Installation Notations (refer to Section 1 for Removal Instructions) .... 30-5-5
A WARNING
Hydraulic fluid is toxic to skin,
eyes, and respiratory tract.
Good ventilation is normally
adequate.
A CAUTION
Cleanliness is of extreme
importance. Before dis-
connecting the hydraulic
components, clean exterior of
plumbing and solenoid valve
to prevent dirt and foreign
matter from entering hydraulic
system.
A WARNING
When usina air Dressure
to clean off truck:
A CAUTION
Cap all ports to prevent dirt and foreign debris from entering assembly.
Always Wear
--
--
Hydraulic Schematic
Rated Flow: 114 L/MIN (30 G.P.M.)
Rated Pressure: 20685 kPa (3000 P.S.I.)
Minimum Pull-in Voltage: 85% of nominal @ 20685 kPa (3000 p-s-i.).
-ypical Illustration
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 30 Solenoid Valve
O-Ring(s)
/-
-ypical Illustration
Disassembly
l Unplug Coil S3 from wire harness.
res 10K & IOL
* Remove nut and coil from solenoid valve.
l Remove solenoid valve from valve body.
l Remove fittings from valve body.
Cleaning & Inspection
Wash all parts except coils in a Stoddard type
cleaning solvent. Wipe coils with a clean cloth.
Wipe all parts dry with a clean lint-free cloth.
Allow components to airdry before reassembly.
Replace all seals with new ones.
Inspect wire leads and plugs for further service-
ability. Replace defective parts .Use Service l
Parts Kit(s). I
Body @I
Inspect wire leads and plugs for further
l- -----
servicability. If damaged, replace the coil.
L 1rypical Illustration
Cleanliness is of extreme
importance.Before
disconnecting the hydraulic
components, clean exterior of Wires 10K & 1
plumbing and solenoid valve
to prevent dirt and fqreign
matter from entering hydraulic
system.
l Lubricate all parts in clean hydraulic fluid prior When Mounting Solenoid Valve:
to installation. Use only new seals.
l Align valve body slots with mounting bolts on
l Install large O-ring into its groove being very truck.Locatevalveoverboltsandinstallretainer
careful that you do not nick or cut the O-ring nuts finger tight. Refer to Section.
making if unfit for service as it will leak.
When Connecting Hydraulic Plumbing:
l Install three O-rings and six backup rings as
l Be certain valve fittings and hose ends are clean
shown on opposite page. Again, be very careful
and in proper alignment and then install each
you do not nick or cut the O-rings or leakage will
one finger tight until1 all connections have been
OCCUT,
made..
l Install solenoid valve into body bore. Be certain
l Tighten valve body mounting nuts securely.
solenoid valve is torqued correctly to the body.
Now go back and securely tighten each hydrau-
l Next, install coil over solenoid valve. lic connection.
l Installcoilretainernut and tighten to5 lb.ft. (6.8
A CAUTION
N*m).
Be certain coil is positioned so
l Lubricate fittings with clean hydraulic fluid and wire leads may be connected
install them finger tight to the valve body. to the harness leads without
causing damage to wiring.
INSTALLATION l Connect coil plugs to their receptacles in the
IMPORTANT wire harness.
Inspect hoses, hydraulic IMPORTANT
connections and their seals
All electrical plugs and their
for damage. Replace defective
receptacles are matched labeled
parts.
for easy connection. Check to be
sure each plug and receptacle
Prior to attaching hose ends
match before attempting to make
and connections to the fittings
connections.
on the solenoid valve, Clean
and lubricate them with new l Check wire harness clamps for security of
hydraulic fluid.
mounting. Be certain the harness is in good
Remove caps just prior to condition and that it is routed properly.
installation.
SM587 30-5-5 Dee 94
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 30 Solenoid Valve
Wires 1 OK & 1 OL
Multi-Function
Control Handle
Use
. ..-_I
I22
MS68
Clark Part No.885385
\
Typical lllustratior jpical Illustration 1 Hydraulic Fluid
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Material Handling
C19RK Company GROUP 30
Section 6
Reach & Tilt Selector Valve
Contents
Truck Preparation ............... .. .................................... .................... ..... 30-6-2
Discharge Capacitors ... .............. .................................. .. .................. .. 30-6-3
Hydraulic Plumbing Diagram ........................................................... . 30-6-6
Specifications and Hydraulic Schematic ............. ...........I........ ........... 30-6-6
Location and Mounting Illustration ... ................ ...............I...... ........... 30-6-9
Removal, Disassembly & Reassembly . .......... .................................... 30-6-9
A CAUTION
Using a shorting device
without a resisforloadcould
cause damage to the control.
A WARNING
Discharging the capacitors
without using specified
resistor could cause serious
injury to yourself and
bystanders.
A WARNING
Hydraulic fluid is toxic to skin,
eyes, and respiratory tract.
Good ventilation is normally
adequate.
A CAUTION
Cleanliness is of extreme
importance. Before dis-
connecting the hydraulic
components, clean exterior of
plumbing and solenoid valve
to prevent dirt and foreign
matterfromentering hydraulic
system.
A WARNING
When usina air Dressure to clean off truck:
Wear eye protection and protective clothing when drying with air pressure.
Reduce air pressure to 30 PSI (207 kPa). Debris removed with air pressure can
cause injury.
Removeall Jewelry
before working on
truck.
Always Wear
Safety
Glasses
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Selector Valve GROUP 30
Selector Valve
(Reach & Tilt)
Valve Mounting Fastener Pantograph
IMPORTANT
ROUTE HOSING AS SHO
Grease
Fitting
WARNING
Place a 4x4 support between front and
rear members of pantograph (as shown).
This is to prevent retraction of the
pantograph when disconnected from the
upright.
#6SAEO-RingPort(ConnectstoAuxContmlValve
Hydraulic Circuit
Typical Illustration
u* = Counterbalance Valves
s5 = Solenoid Valve
S6 = Solenoid Valve
s5 (Vl) C2 Port = Back Tilt or Side Shift Right control circuit
S6 (172) C4 Port = Forward Tilt or Side Shift Left control circuit
s5 (Vl) Cl Port = Reach (Pantograph) control circuit
S6 (172) C3 Port = Retract (Pantograph) control circuit
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Selector Valve GROUP 30
9&10-
8
A Selector Valve
B Pantograph Frame
C Reach Arms
D Carriage Frame
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 30 Selector Valve
REACH 81TILT SELECTOR VALVE 7. Removevalve from the pantograph. Place com-
ponents on a clean work bench.
A WARNING DISASSEMBLY
Be sure pantograph is blocked
l Remove coils and solenoid valves S5 & S6 from
as illustrated on page 5.
valve body.
A CAUTION
Residual pressure will be
pressent when disconnecting
lines. Use caution when
disconnecting fittings.
Solenoid Valves
es
rypical Illustration
A CAUTION
Cleanlinessisof extremeimportance. Before
(NON-ADJUSTABLE) dis-connecting the hydraulic components,
If thevalve has been tampered with 9c 1eanexteriorof plumbing and solenoidvalve
itmustbereplaced with anew one. to prevent dirt and foreign matter fr
entering hydraulic system.
REASSEMBLY INSTALLATION
Nui
A Solenoid Valve
B Pantograph Frame
C Reach Arms
D Carriage Frame
Typical lllustratior
3. Remove cap, hose tag and then install connec- 9. Install and tighten clamp bolts #M.
tion #l 1 to valve finger tight.
4. Remove cap, hose tag and install #12 connec-
tion finger tight.
4. Install connections #5 and #8. Then install con-
nections #6,7,8,9 & 10 to the reach cylinders
finger tight.
5. Now, securely tighten each hydraulic connec-
tion to the valve body and the reach cylinders.
IMPORTANT
Be sure the hoses are routed
correctly before attempting to
connect them to the valve. Refer to
page 5 for correct routing.
Section 7
Side Shifter Solenoid Control Valve
(Optional Equipment)
Contents
Truck Make Ready ........................................................................... .30-7-2
Removal ............................................................................................ 30-7-4
Specifications and Hydraulic Schematic.. ................................... .30-7-5 & 6
Disassembly and Reassembly ........................................................... .X&7-7
SM587 Dee 94
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 30 Solenoid Valve
1. Move truck to service area.
l Park truck on a flat level surface.
l Extend pantograph.
l Fully lower pantograph.
l Tilt (if so equipped) forks forward until fork tips
touch the floor.
Typical Illustration
Typical Illustration
S8
.
~--~--_-_-_---_rxrr~~~
Top view
[ Solenoid j
I I
_-_-_-I
j
r Valve t
c4 #4 S AE O-Ring Port
C5 #I4SAJZO-Ring Port C6
NOTE
Refer to Hydraulic Schematic on
the next page.
Fmnu Back
Hydraulic Schematic
0*
Vl _-._
...........
4 Hydra-
.........
...........
c2
0**
c4
...............
..........
Hydraulic Circuit
tv2 C6
J
______-___r-_l---I- _I_ . . .._-_.....
rypical Illustration
30-7-6
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Solenoid Valve GROUP 30
jlpical Illustration
Disassembly
l Remove nut and coil from each solenoid valve. Torque nuts Receptacle Leads
8 - IO lb. ft.
l Remove both solenoid valves from valve body.
------
Cleaning & Inspection
(11 - 14 Nom)
r
f-l1
Wipe coil(s) clean using aclean shop rag. Inspect wire r...........< .. .. .. .. .. .. .. .. . .. .. 11..
Reassembly
l Lubricate seals, valves and body in clean hy-
draulic fluid.
l- ---- -l
l Install seals and backup rings as shown above. - Retainer Nut
Becarefil that you do not nick or cut seals upon r
installation. Body--l
l Install cartridge valve into valve body and torque
-ypical Illustration
to 8 - 10 lb. ft. (11 - 14 N*m).
30-7-7
Copyrighted Material
Dee94
Intended for CLARK dealers only
Do not sell or distribute
GROUP 30 Solenoid Valve
Installation
Mounting Fasteners
IMPORTANT
All Wiring, Plugs and
Side
Receptacles arelabeledfor
easy identification. You
must install cables and
wiring exactlly as shown
or you will experience
shorts and component
failure.
II
Mounting Bracket
Side
Shift
Cylinder
Greast
Fitting
I
Grease
Fitting
Typical Illustration
Section 2
Tilt Cylinder Overhaul
Contents
Models Equipped
with
1
Side Shift
SM-587
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 32 Tilt Cylinder
Air Hose
A WARNING
When using air pressure to clean off truck:
Wear eye protection and protective clothing when drying with air pressure. Reduce
air pressure to30 PSI (207 kPa). Debris removed with air pressure can cause injury.
A WARNING
Hydraulic fluid is toxic to skin, eyes, and respiratory tract. Good ventilation is
normally adequate.
A CAUTION
Cleanlinessisof extreme importance. Before disconnecting hydrauliccomponents,
clean exterior of plumbing and solenoid valve to prevent dirt and foreign matter
from entering hydraulic system. Typical Illustration
Dee 94 32-2-2
Copyrighted Material SM-587
Intended for CLARK dealers only
Do not sell or distribute
Tilt Cylinder GROUP 32
Preparation Cleaning & Inspection 1
Suggestions
l The exterior surface of a cylinder should be
thoroughly washed before disassembly.
l A soft fiber brush should be used to remove
debris and foreign objects from grooves and
threaded areas, etc.
Nut
Rod En d
NOTE
PressBushings flush with rod end.
SM-587 32-2-3
Copyrighted Material Dee94
Intended for CLARK dealers only
Do not sell or distribute
GROUP 32 Tilt Cylinder
Disassembly (Refer to illustration above.) are free of cylinder housing. Remove gland.
Wash exterior of the tilt cylinder in a Stoddard type Gland Assembly
cleaning solvent before disassembly. Use a brush to
1. Remove wiper ring.
remove grease and grime from the cylinder tube,
anchor and rod ends. Remove rod end and jam nut. 2. Remove seal from inner groove. Be careful that
you do not nick or scratch inner sutiace if gland
1. Placecylinder in avise equipped with softjaws.
assembly.
Do not over-tighten - distort barrel
3. Remove outer O-ring and backup ring from the
2. Push piston rod all the way into cylinder.
gland assembly.
3. Using a narrow blade screwdriver, remove the
4. Discard seals, wiper and backup rings.
split type retainer ring.
Piston Rod & Piston
4. Remove washer.
1. Insert a 12 to 15 inch holding rod into the hole
5. Remove white backup ring.
provided just below threaded area of piston rod,
6. Remove O-ring. see arrow (4) above. Now install a l-l/S socket
7. Using a bronze drift, gently tap gland assembly onto the piston rod nut.
into cylinder housing clear of the shear ring. 2. Remove nut from piston rod while holding
8. Using screwdriver, carefully lift end of shear retainer rod.
ring from its groove. Becareful you do not nick 3. Pull piston free of piston rod.
or scratch the piston rod.
4. Remove O-ring from piston rod and discard.
9. With a pair of pliers, carefully pull shear ring 5
Remove sealing ring (Glyde Ring@) and the
from cylinder tube. Again, be carejXyou do not
energizer from piston. Use care not to nick or
nickor scratch the piston rod. Discard the shear
scratch piston surfaces.
ring.
6. DiscardO-ring, sealing ring (Glyde Ring@) and
10. Pull outward on piston rod until rod and gland
energizer. Always install new seals.
Back-Up Ring
O-Ring-, 1 r Split Retainer Ring
-Nut
lRod
Typical Illustration
5. Lubricate and install a new O-ring in the grove 12. Lubricate a new backup ring and place it over the
next to the backup ring. Note position of backup O-ring just installed.
and o-ring per above diagram.
13. Install the washer over the gland and next to the
6. Place a plastic parts bag over the threaded end of backup ring previously installed.
the rod (to protect seals) and carefully slide the
14. Install a new split retainer ring into its groove in
gland over the rod and into the cylinder housing.
the gland assembly. Be sure it is completely
7. Push gland as far as it will go into the housing. seated in its groove.
8. Insert the open end of a new shear ring into the 15. Install jam nut and rod end to the same location
cylinder housing while pushing on the ring with it was when removed from the piston rod.
your fingers. Push ring inward as far as you can.
16. Cap cylinder ports until such time as the cylinder
9. Now, using a bronze punch, gently tap ring the is installed in the truck.
rest of the way into the tube and groove. Be sure
the shear ring is fully seated in its groove.
10. Next, pull piston rod out as far as it will come.
This will position the gland so the retainer ring
groove is located above the cylinder housing.
11. Lubricate a new O-ring and place it over the
gland and into the housing on top of the gland.
Multi-Function
Control Handle
Section 3
Reach Cylinder Overhaul
Contents
Safety ................................................................................................
32-3-2
Preparation Cleaning and Inspection Suggestions .............................. .32-3-3
Disassembly ...................................................................................... 32-3-4
Cleaning & Inspection ...................................................................... .32-3-5
Reassembly ................................................................................ 32-3-5 & 6
Sump Tank Fluid Level .................................................................... .32-3-7
)_
0
JQ
0
,==z\
I, II
II II
II II
II II
Ii Ii r
A WARNING
When usina air Dressure to clean off truck:
Wear eye protection and protectiveclothing when drying with air pressure. Reduce
air pressure to 30 PSI (207 kPa). Debris removed with air pressure can cause injury.
A WARNING
Hydraulic fluid is toxic to skin, eyes, and respiratory tract. Good ventilation is
normally adequate.
A CAUTION
Cleanlinessisofextremeimportance. Beforedisconnecting hydrauliccomponents,
clean exterior of plumbing and solenoid valve to prevent dirt and foreign matter
from entering hydraulic system. Cap all ports (after overhaul) until assembly is
ready for installation.
-
l A Stoddard type cleaning solvent should be used
to wash the cylinder. Soft Fiber Brush
Nut
Rod En d
a, :::.
[ii
.::
Y:..
,:,,,:C.~.../ ..,;
0 v.:..:.;,:,:..
:....
f,
,.:::z
ILSdf-Alionino
Energizer,
.::
ii;
F Anchor End
Piston Seals1
1
6. Using screwdriver, carefully lift end of shear 2. Remove nut from piston rod and remove hold-
ring from its groove. Be carefulyou do not nick ing rod.
or scratch the piston rod or cylinderbore 3. Pull piston free of rod.
7. With a pair of pliers, carefully pull shear ring 4. Remove O-ring from rod.
from cylinder tube. Again, becarefil you do not
nick or scratch the piston rod or cylinderbore. 5. Remove seal ring (Glyde Ring@) and the ener-
Discard the shear ring. gizer from piston.
8. Pull outward on piston rod until rod and gland 6. Discard O-ring, sealing ring (Glyde Ring@) and
are free of cylinder housing. Remove gland. energizer. Always install new seals.
Reassembly
Piston Rod & Piston 10. Start piston into cylinder tube while gently
pushing and rotating piston rod until piston and
1. Lubricate all parts with clean hydraulic fluid.
seal have passed the shear ring groove in the
2. Lubricate and install the square energizer ring cylinder housing. Becarefulyou do not damage
into the groove in the piston. Refer to illustration seal.
on previous page.
11. Push the piston rod all the way into the cylinder
3. Lubricate and install the GlydeB over the ener- Housing until it bottoms.
gizer. Be careful not to nick or cut the seals
Gland Assembly
making them unjit for service.
1. Lubricate new seals, wiper ring and gland as-
4. Place a plastic parts bag over the threaded area
sembly with clean hydraulic fluid.
of the piston rod (to protect seal). Slide a new O-
ring over the bag and into the groove in the rod. 2. Install the inner seal, with the sealing lip faced
inward, into the gland groove. Be careful not to
5. Remove bag and install piston onto rod. Care-
cut or nick the sealing lip upon installation.
fully slide piston over the O-ring and up against
rod shoulder. 3. Install a new wiper ring into the gland.
6. Install nut onto rod finger tight against the 4. Lubricate and install a new backup ring into the
piston. outer groove on the gland..
7. Install the 12 to 15 inch rod into the hole pro- 5. Lubricate and install a new O-ring in the grove
vided just below threaded area of piston rod. next to the backup ring as shown in illustration
on opposite page..
8. Using a torque wrench, torque nut to:
6. Place a plastic parts bag over the threaded end of
115 to 132 lb.ft. (156 - 179 N*m).
the rod (to protect seals) and carefully slide the
9. Now, lubricate piston and piston rod with clean gland over the rod and into the cylinder housing.
hydraulic fluid.
Wiper
7. Push gland into the thousing until it is clear of 11. Lubricate and install the washer over the gland
shear ring groove. next to the housing.
8. Insert the open end of a new shear ring into the 14. Install a new snap ring into its groove in the
cylinder housing while pushing on the ring with gland assembly. Be sure it is completely seated
your fingers. Push ring inward as far as you can. in its groove.
9. Now, using a bronze punch, gently tap ring the 15. Install jam nut and rod end in the same location
rest of the way into the groove. Be sure the shear it was when removed from the piston rod.
ring is fully seated in its groove. 16. Cap cylinder ports until such time as the cylinder
10. Next, pull piston rod out as far as it will come. is installed in the truck.
This will position the gland so the retainer ring
groove is located above the cylinder housing.
Multi-Function
Control Handle
Section 1
Upright & Pantograph
Remove & Replace
Roller Shim Adjustments
Contents
Pantograph ....................................... ............ ........................ ............ . 34-l-2
Upright ....................................... .................. .................................... . 34-l-7
Cables, Hose & Chain Sheaves ............. .............................. .. .......... . 34-1-18
Pantograph Carriage Rollers ............................................................ 34-l-23
Upright Rollers ................................. .................................. .............34- l-29
Overhead Guard
Upright
PANTOGRAPH REMOVAL
Preparation
1. Move truck to service area.
NOTE
Iftheupright is to be removed, a
5ton chain hoist equipped with
safety hooks is required. Upright
weights are provided in
Specifications, Group 40 of this
manual.
Remove jewelery
before working
on truck
Dee 94 34-1-2
Copyrighted Material
SM-587
t Upright
6. Remove two bolts (1) from cable retainers (2). 11. Remove cotter pins (6).
7. Remove front and rear retainers. 12. Remove chain anchor pins (7) securing the lift
chains to the carriage chain anchors.
8. Disconnect electrical plug (3).
9. Remove both harness clamp bolts (4). NOTE
10. Disconnect hydraulic hoses from tube connec- Lift Chains may be disconnected
tions (5) using two wrenches. One wrench to at the Primary Cylinder Piston
hold the tube connection(s) while loosening the Head (see next page) or from the
hose connection(s). There will be some hydrau- carriage as shown here.
lit fluid leakage upon disconnecting fittings.
Typical Illustration
NOTE
Carriage chains may be dis-
connected at the primary cylinder.
I
.
.
;
i
. Hooks
. 13
.
.
..
..
.
.
F Raise both inner and
intermediate rails until the
. inner rail channels are
clear of the carriage
rollers.
13. Using a 5ton chain hoist, attach hoist to the .4. Raise both inner and intermediate rails until the
inner and intermediate rail assemblies, see illus- inner rail channels clear the carriage rollers.
trations above. Be sure hoist is equipped with
safety hook(s).
SM-587 34-l -5
Copyrighted Material Dee 94
Intended for CLARK dealers only
Do not sell or distribute
GROUP 34 Upright
15. Move truck away fi-om pantograph just far NOTE
enough to allow the intermediate and inner rails If the upright or rail lift cylinders
to clear the pantograph. are to be removed, refer to the
16. Completely lower the intermediate and inner following pages.
rail assemblies.
The free lift (center) cylinder may
17. Disconnect chain hoist and move truck away be removed without removing the
from pantograph. upright.
INRails
Hardwood (0ak)Blocking
Preparation
NOTE
If the pantograph has not been
removed, refer to pages 2 thru 6 for
removal instructions. Pantograph
must be removed from upright
before attempting to remove
upright.
Remove jewelery
before working
on true
L
Cleanliness is of extreme
importance. Before disconnecting
hydraulic components, exterior
surfaces to prevent dirt and foreign
mater from entering the hydraulic
system.
Typical Illustration
4. Remove Console Cover, see above. Remove fasteners securing cover to truck. Remove cover. Open rear
door.
5. Remove Center Pad, see below. Loosen bolts located beneath the pad at the lower edge. Lift pad upward
and remove from truck.
Hook(s)
Center
Pad
3i0tf S Etsoo
L.H. Side Center Hanger
Typical Illustration
beneath frame on
both sides of truck
-- just behind the
Butriggers.
9. Elevate and support each side of truck with suitable hardwood (Oak) blocking,
see above.
A WARNING
Make certain upright lift cylinders are fully lowered before
disconnecting hydraulic lines.
10. Disconnect the bulkhead fittings, see illustration below and on the following
pages.
IMPORTANT
Cap all Hydraulic Fittings upon
removal of tubing.
Cbnnections \
!Pl Y\i \\
.I Bulkhead Fitting
T Fitting Connecti
11. Disconnect hydraulic tube from lift valve and T fitting (at the bulkhead
fitting), see above.
12. Disconnect hydraulic tube with 7 fitting from lowering solenoid valve and
bulkhead fitting, see below.
I
Dee 94
SM-587 Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 34 Upright
Hydraulic y
Connections \ \
Rail Cylinder
SM-587 Dee 94
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 34 Upright
Outrigger(s)
d
Inner Rail Assembly
t Floor
A CAUTION
Be careful not to damage
hoses.
Rail Cylinders
Pulling the inner and intermediate rail assem-
blies part way out of the top of the outer rail
assembly will allow removal of the secondary
cylinders. The rail cylinders must beremoved to
adjust or replace the lower rail rollers.
Rollers & Shims
Access to the rollers and their shims is accom-
plished by pulling the rail assemblies part way
outthebottomoftheouterrail assembly after the
rail cylinders have been removed.
!3. Loosen and then remove hydraulic fittings at the 24. Remove snap ring located at the base of eacl
base of the L.H. and R.H. Rail Lift Cylinders. cylinder, see below.
Discard old O-ring seals. Use new seals at time
of installation.
Outrigger
7
L-
Rail Assembly ;semblv Oak Blockinae
t Floor
Typical Illustration
25. Remove the external snap ring from the top of each piston rod.
26. Remove washer from each rod.
27. Support the cylinders, and move the rails outward far enough to
allow removal of the cylinders.
NOTE
Each cylinder is equipped with a weldment near the
top end of the barrel assembly. This weldment fits
over an alignment pin that is part of the upright.
Move cylinder off pin and out of upright.
A WARNING
Rail cylinders weigh between QQQ and ooo
pounds each. Exercise care when removing a
cylinder from the upright.
Rail
Cylinder
SM-587 Dee 94
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 34 Upright
Cable, Hose & Chain Sheaves
Remove snap rings (6) and sheaves (5).
Remove screws (4) securing mounting plates to
block (16) and remove assembly from block.
Remove pin (15) and block (16) from cylinder
rod.
Loosen and remove nuts (l), bolts (3), and spac-
ers (2). 16
5
Disassemble assembly. Replace any damaged
6
components.
Installation is the reverse of removal.
7
Free Lift Cylinder Cylinder 8
l Remove cotter pins (7), jam nuts (1 l), nuts (lo),
centering bushings (9).
l Remove chain anchors and lift chains (items 8 &
13).
l Remove snap ring (14). Lift cylinder off center-
ingpin (12) andout of upright. Installation is the
reverse of removal.
NOTE
Free Lift Cylinder may beremoved
with upright attached to truck.
A WARNING
Free Lift Cylinder weights
between ooo and ooo pounds.
Excercise care when removing
cylinder from upright.
t Floor
Nut (1) -
+- Screw (4)
Block (11
Sheave (5)
Chain Sheave
SM-587 34-1-21
Copyrighted Material Dee 94
Intended for CLARK dealers only
Do not sell or distribute
Upright
GROUP 34
Carpenter Square
34-1-22 SM-587
Dee 94 Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Upright GROUP 34
Pantograph Assembly
t Floor
Inner Rail
Step 1
Span Rail i
to find
narrowest
point.
Step2
Insert
Dee 94 34-l-28
Copyrighted Material
SM-587
Intended for CLARK dealers only
Do not sell or distribute
Upright GROUP 34
The triple stage upright, as the name implies, As the free lift cylinder fully extends, the rail lift
has three sets of upright rails. The rails are identified cylinders and lift chains elevate the intermediate and
as: inner rails to maximum fork height.
. Outer Rails The upright is equipped with 8 rollers. This diagram
. shows the position of therollers within the triple stage
Intermediate Rails
upright.
. Inner Rails
Therearefourrollers that workbetweentheouterrails
When the free lift (center) cylinder is fully extended, and the intermediate rails.
the pantograph carriage elevates through what is
Four more rollers work between the intermediate rails
called free lift portion of upright travel. Just beyond
and inner rails.
themaximumfi-eeliftposition, therollerson top ofthe
carriage are visible as they extend out the top of the The pantograph has six rollers that work within the
inner rails. inner rail. The top two are retained by Allen screws.
34-l-30
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 34
Triple Stage Upright
mmmmm
m
m
c 3
IMPORTANT
With age and wear, clearance between upright rails can increase and cause excessive
looseness between rails and rollers. Upright rollers become worn, rail surfaces wear, and
stress relieving due to handling of heavy loads over a period of time may cause slight
dimensional changes between upright rails. The white arrows show clearance between rails
and rollers. The dotted lines indicate roller operating channels.
A roller clearance inspection should be performed if, during an operational check of the
upright, you note excessive looseness or binding between rail sets, or if scoring is evident
on the rails.
Properroller clearance should be maintained because the system is designed to nest the rails
snugly while providing smooth extensions.
usec-&Imp
to force roll-
ers to one
side. Torque
on C-Clamp
shouldnotex-
teed 20 Ib.ft.
Shim
Check Roller
\
ii..:.:.:.:.:.:.):.:.:.:.:.: .,.,.,.,.,.,.,.,.,.(,.,.
::::::a:::::::~:::::::~.~:~.~:~:~:~:~:~:~~:~:~
:.:.:i...A.... . . ...... . ,. ,. ,.
I
Point of roller contact.
Inner Rail
t Floor
A WARNING
ROLLERS SHOULD BE ADJUSTED
LINE TO LINE WITH
0.020 MINIMUM CLEARANCE
PINCH POINTS
Adjustmentreference chart when usingfeelergauges.
Useextremecarewhenworking
on the upright to avoid placing IFeeler 1 Gauge will I Shimmed 1 Shim
hands or fingers into potential Step; Gauge I pass / not uass I Correctlv
pinch points. Unexpected I
movement of upright 1 l.020 I PASS I check with al
components can cause serious
injury
1.050 I not nass I Yes I 0
2 ;.050 ; PASS check with a
I I
I.080 I not pass I No, add I 1
I 1 PASS 1 check with al
Roller Clearance Inspection 3 soso I I
1.120 I notpass I No, add
Before checking roller clearance, place the intermedi-
ate rail approximated 6 inches outof the outer rail and
the inner rail approximately 6 to 12 inches out of the
intermediate rail as illustrated on opposite page. If the
upright is mounted and you are elevating the rails
hydraulically, the inner rail will automatically assume
its correct position. Note the procedure for checking
clearance is basically the same whether the upright has
been removed or is mounted on the truck.
There are two methods covered, one is using a pry bar
to position rails and rollers and the other is using a C-
clamp.
If the upright is mounted to the truck, the use of an
approved safety platform or step ladder is recom-
mended when making inspections and checking clear-
ances at the upper levels.
If the upright has been removed and placed flat on the
floor, proper blocking of hard wood (oak) or steel
supports must be used to keep the upright horizontal
with thejloor. This is especially important when fully
extending the intermediate and inner rails.
IMPORTANT
There is to be some clearance but it
should not be less than 0.020 or
more than 0.050.
$T C-Clamp
Bottom Roller
View
Check
r Inner Rail
Intermediate Rail
t Floor
SM-587 Dee 94
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
Upright
GROUP 34
I
Shim Check
procedure as before.
l Record the number of shims to lx used on the
miter 2nd intmnwdi~t~ mfl inner railc nnnnci+a
w_.__ .+.._ ^..._-A.UI.I _.._. a . . . .
----v -rr ..LC
the rollers checked.
Top View
Shim Check
reeler tiauge
Point of roller contacT
I I I I
I I
SM-587 34-l -37 Dee 94
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 34 Upright
Fe&x Gauge
Point of rot ler contact.
1 Pry Bar
2 I .050 1 PASS
f .080 f not pass
I checl
1 No, add
al
1 1
I I I
3 1.080 I PASS 1 check with a I
Check
j ,
Intermediate Rail
i
Typical Illustration
Left
@
Left
@
1
II
SM-587 Dee94
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
El!!!!Rl5
lVl;~;~-i~Handling
GROUP 34
Section 2
Pantograph & Fork Carriage Assembly
Contents
Safetyand Preparation . .. . . .. ... . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. .. .. .. .. .. .. .. .. .. .. .. .. .. 34-2-2
Remove Forks .. . .. .. . . .. .. ... . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... . .. .. 34-2-4
Servicing Carriage . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . .. .. .. .. .. .. .. . ... .. .. .. .. .. 34-2-6
Servicing Pantograph Arm Rollers . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 34-2-9
+ Upright kUpright
oClra..h r Inner Arm
Outer Arm
The Pantograph Assembly may be serviced while installed in the upright with two exceptions:
The carriaee rollers and the inner and outer arm bushinps must be serviced
with the
pantograph removed from the upright.
Refer to GROUP 34, Section 1 in this manual for adjustment and service procedures.
A WARNING
When using air pressure to clean off truck.
A WARNING
Hydraulic fluid is toxic to skin, eyes and respiratory tract. Good ventilation is
normally adequate.
0q?gJ@&
A WARNING
Remove all Jewelry before working on truck.
A WARNING
Always wear Safety Glasses when working on truck.
Preparation
. Move truck to service area.
. Park truck on a flat level surface.
. Extend and lower pantograph.
. Turn key switch OFF.
All Models
Bolt
Torque-l
Specification
2. EIevate and Block Pantograph. 17 - 190 Nom
. (125 - 140 Ib.ft.)
Turn key switch ON and elevate pantograph
approximately 3 to 4 feet.
Fork Chriage
. Place oak blocking (hardwood) between panto-
graph carriage and fround. Lower pantograph
until carriage rests on 4x4 blocking as shown
here. I II it
. Tilt forks forward.
. Turn key switch OFF and remove key.
. Disconnect truck battery.
as shown.
A WARNING
Support forks as
fork bar is removed
so they cannot fall.
Fork Guide
34-2-4
Copyrighted Material SM-587
Intended for CLARK dealers only
Do not sell or distribute
Pantograph GROUP 34
Side Shift Models Only - continued -
A WARNING
brass drift). When bar (B) is free of carriage,
remove forks.
Support forks as fork bar is l. Examine bushings in fork guides (C) for damage. If
removed so they cannot fall.
bushings are unfit for further service, install new
bushings.
l Check fork bar (B) for burrs or excessive wear.
SERVICING
FORK CARRIAGE
Bushings
SERVICING
FORK CARRIAGE
?
d. Remove Roll pin (5) from Tilt Cylinder
Rod End Mounting Shaft (6).
3. Using a brass drift, drive shaft (6) out of
each bell crank (3A) freeing cylinder
rod end from both bell cranks.
34-2-7 Dee 94
SM-587 Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 34 Pantograph
_.
0
Bushinas
NOTE
The bell crank with tilt roller (or
block) may be removed as a sub-
assembly. Removing shaft (3) will
allowbothbellcrank(3A)&roller
(4A) to be removed as a sub-
\Shaft (3)
assembly.
Solenoid Valve
b Liftingztraps
Safety Hook
Pivot Bearing
L Shield
Nut (*)
Install with chamfer towards nut lock. Torque to: 27 - 41 lN.m (20-30 Ib.ft.
IMPORTANT
Prepack bearing cup & cone assemblies prior to installation
Dee 94 34-2-l 2
Copyrighted Material
SM-587
Section 3
Rail Lift Cylinder Overhaul
Contents
Disassembly ...................................................................................... 34-3-3
Inspection ............................................................. ............................. 34-3-4
Reassembly ................................... ...... ...... .. .... .................... .............. 34-3-5
Rail Lift
Cylinder --)
\
Alignment
Pin
A WARNING
When usina air pressure to clean off truck:
Wear eye protection and protective clothing when drying with air pressure. Reduce
air pressure to 30 PSI (207 kPa). Debris removed with air pressure can cause injury.
A WARNING
Hydraulic fluid is toxic to skin, eyes, and respiratory tract. Good ventilation is
normally adequate.
A CAUTION
Cleanliness isof extremeimportan ce. Beforedisconnecting hydrauliccomponents,
clean exterior of plumbing and solenoid valve to prevent dirt and foreign matter
from entering hydraulic system.
Seal ,
l A soft fiber brush should be used to remove
G3
debris and foreign objects from grooves and
threaded areas, etc.
l A Stoddard type cleaning solvent should be used 0 Ian Spring
8
Plunger m)
GI
Back-Up: 1
Install
i Back-Up & O-Rings
asshown.
Barrel
r Plunger
7 I r.
Washer
Spring
SnaD Ring7 ---Barrel
Piston Rod
LRing
Mounting
Groove
L Split Piston
Washer Bleeder L u-cup
Section 4
Free Lift Cylinder Overhaul
Contents
Disassembly ...................................................................................... 34-3-3
Inspection .......................................................................................... 34-3-4
Reassembly ...................................................................................... .34-3-5
A WARNING
When usina air pressure to clean off truck:
Wear eye protection and protectiveclothing when drying with air pressure. Reduce
air pressure to 30 PSI (207 kPa). Debris removed with air pressure can cause injury.
A WARNING
Hydraulic fluid is toxic to skin, eyes, and respiratory tract. Good ventilation is
normally adequate.
A CAUTION
Cleanlinessisofextremeimportance. Beforedisconnecting hydrauliccomponents,
clean exterior of plumbing and solenoid valve to prevent dirt and foreign matter
from entering hydraulic system.
Washer :
I-
Section 5
Lift Fork Inspection
Contents
Inspection Procedure ........................................................................ .34-5-2
Fork Wear Caliper .......................................................................... ...34-S-2
For Inspection Illustrations .......................................................... 34-5-3 & 4
Lift Forks
Shank
NOTE Once the top (outside) jaws are set to the thick-
Fork Wear Calipers (Clark Part No. 1803641) ness of the shank, the calipers are then ready to
havetwomeasuringpointsorjaws(Figure 1,opposite check the blade of the fork.
page), they are:
l Check Fork Blade against Shank Thickness
l The outside or top jaws are used to set the in the area shown in Figure 2.
calipers.
Carefully fit the caliper over the fork blade. Ifthe
l The inside or lower jaws have been fixed at a inside or lower iaws of the calipers pass over the
point on the caliper legs that will always mea- flanks of the fork blade at any point between the
sure 10% less than the reading recorded by the end of the taper and the heel of the fork, the forks
top jaws (Figure 3, opposite page). should be replaced.
Incorrect Readings
Incorrect readings may be mistakenly made by accidentally altering the setting of the calipers when
laying them down or when checking the blade. If is good practice to recheck caliper setting on the shank
each time before checking a fork blade.
Accuracy in caliper measurement depends on the sense of touch. To get a delicate touch of
the caliper on the fork, the caliper should be held lightly and not with a grab grip. With a
little practice the required skills can be easily acquired.
Fork Wear
The most common cause of fork wear is when the fork is allowed to drag the floor due to misadjusted
chains,chainstretch,tirewear,etc.Carriagechainsshould beadjustedso theforkis 1/2offthefloorasmeasured
at the heel of the fork. The area that fork wear usually appears is illustrated in Figure 4.
t f
Area of Fork Blade to
- be measured for wear.
Figure 2
Figure 3
Cross Section
Figure 4
Fork Blade
r 3% of B Maximum Difference
... __..._._.-..._..__._________
...._ ....~......._._
.......__.
.. -
/ +ForkTps
Carpenter
Inspect Forks for Twists and Bends Square
l Place a 2 thick metal block, at least 4 wide by
24 long on the blade of the fork with the 4
surface against the blade.
l Put a 24 carpenters square on the top of the
block and against the shank.
l Check the fork 20 above the blade to make sure
it is not bent more than 1 inch maximum.
Dee94 34-5-4
Copyrighted Material
SM-587
Section 6
Upright Chain Inspection; Adjustment & Replacement
Contents
Periodic Inspections .. . ... ... .. .. .. .. .. .. .. ... .. .. ... .. .. .. ... ... .. .. .. .. .. .. .. .. .. .. . .. ... .. . . 34-6-2
Chain Length Adjustments . .. .. .. .. .. .. .. .. ... .. .. ... . ... .. .. .. .. .. .. .. .. .. .. . ... .. .. . . .. . 34-6-3
Triple-Stage Upright (TSU) Chain Length Adjustments . .. .. .. .. .. .. . ... .. .. 34-6-4
Chain Lubrication .. . ... . .. .. .. .. .. .. .. .. .. .. .. .. .. . ... . ... .. .. .... .. .. .. .. .. .. .. .. . . .. .. ... . .. . 34-6-6
Chain Removal and Replacement . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. . . 34-6-6
General Guidelines . .. .. .. .. .. .. .. .. .. .. .... .... .. . ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . ... . 34-6-6
Lift Chains . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . ... .. .. .. .. .. .. .. .. .. .. .. .. .. ... . .. .. .. .. .. .. .. .. .. .. . 34-6-6
Primary Cylinder/Carriage Chains (T.SUs) . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 34-6-7
Other Chain Service Notes . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 34-6-7
Chain Anchor W
Typical Illustration
k5X of H
Worn contours and worn sulfates on the outside links
G3
Fatigue cracks generally run from the pin hole toward
or pin heads should not exceed 5% of new link height. the edge of the link plate approximately 90 from the
line of pull.
Turning or Protruding Pins Fatigue cracks almost always start at the link plate
pin hole (point of highest stress) and are
Highlyloadedchainopemtedwithinadequatelubncation
perpendicular to the chain pitch line. They are often
can generate abnormal frictional forces between pin
microscopic in their early stage. Unlike a pure
and link plates. In extreme instances, the torque could
tensile failure, there is no noticeable yielding
surpass the press fit force between the pins and the
(stretch) of the material.
outside plates, resulting in pin rotation. When chain is
Tight Joints
All joints in leaf chain should flex heely. Tight joints resist
Arc-like cracks in plates are a sign of stress corrosion. flexure and increase internal friction, thus increasing chain
tension required to lift a given load. Increased tension
More than one crack can often appear on a link accelerates wear and fatigue problems.
plate. In addition to rusting, this condition can be
caused by exposure to an acidic or caustic medium
or atmosphere.
An upright
Aor
WARNING
carriage can move
For this same reason, never attempt to electroplate
a leaf chain or its components. The plating process unexpectedly:
liberates hydrogen, and hydrogen embrittlement
cracks will appear. These are similar in appearance l Do not walk or stand under raised forks.
to stress corrosion cracks.
If a plated chain is required, consult Clark. Plated l Keep clear of load and carriage when
chains are assembled from modified, individually making any check or adjustment.
plated components which may reduce the chain
rating. l Keep your arms and fingers away from
moving parts of the upright.
l Corrosion Fatigue - Corrosion fatigue cracks are
very similar (in many cases identical) to normal l Block the carriage or upright when
fatigue cracks in appearance. They generally begin working with the components in a raised
at the pin hole and move perpendicular (90) to the position.
chain pitch line.
l Do not reach through open areas of the
Corrosion fatigue is not the same as stress corrosion. upright.
Corrosion fatigue is the combined action of an
aggressive environment and a cyclic stress (not a l Never attempt to move or align the rails
static stress alone, as in stress corrosion). by hand. Use a prybar.
IMPORTANT
For all chain adjustments:
IMPORTANT
The carriage stop must not be
allowed to contact the upright
stop under any circumstance
during normal operations.
Whatever method is used, the oil must penetrate the chain Chain Mountings - Double check to be sure all chain
joint to prevent wear. Applying oil to external surfaces will fastening devices are secured and all adjustments have
prevent rust, but oil must flow into the live bearing surfaces been made to assure uniform loading of multiple chain
for maximum wear life. applications. Check chain anchors and pins for wear,
breakage and misalignment. Damaged anchors and pins
To prepare the chain for oiling, the leaf chain plates should be should be replaced.
brushed with a stiff brush or wire brush to clear the space
between the plates so that oil may penetrate the live bearing Sheaves - Sheaves with badly worn flanges and outside
area. diameter should be replaced. This wear may be due to
chain misalignment or frozen bearings.
Oil may be applied with a narrow paint brush or directly
poured on. Chain should be well flooded to be sure the oil
penetrates the joint.
In locations difficult to reach, it may be necessary to use a Lift Chains (Standard and TSUs)
good quality oil under pressure such as an aerosol can or
pump pressure spray. To remove and replace the lift cylinder and/or carriage chain
set on standard and triple-stage uprights (TSU):
Chain Removal and Replacement
1. Attach a hoist strap on the carriage of the standard
A WARNING
upright or inner rail of the TSU.
The procedures for removing and replacing chain set 2. Lift the carriage or inner rail slightly to create slack in
involve hoisting and blocking components. the chains. Block the carriage or inner rail up for safety.
Do not walk or stand under raised forks.
Keep your arms and fingers away from moving 3. Remove the chain anchor pins on the outer rail and pull
parts of the upright. the chains off of the sheaves on the inner or intermediate
Do not reach through open areas of the upright. rails.
4. Remove the chain anchor pins from the carriage on the
Failure to follow these warnings can result in serious standard upright or the inner rail on the TSU. On the
injury. See Lifting, Jacking and blocking for safe TSU, the inner rails must be lowered to the floor to
blocking procedures. access the chain anchor pins.
Section 1
Load Wheels
Contents
Remove & Replace.. ......................................................................... .13- 1-2
Inspection .......................................................................................... 13-1-2
Installation and Lubrication ............................................................... 13-1-2
Articulating Axle 2
. 2. Rotate bearing by hand. Note any rough spots l Elevate outrigger and remove blocking. Lower
while rotating bearing. outrigger until load wheels are flat on the floor.
IMPORTANT
Extruded edge of bearing must face outward.
2. Fill groove between bearings with grease.
3. Locate wheels in outrigger with extruded side
(seal side) of bearing facing outward.
Specif icatio ns
N -345
Narrow Aisle Electric Stand-Up Rider Reach Trucks
Violet 7
Gray 8
White 9
Note
Data listed on the following pages is based on:
N-PR-17 3500 lbs (1600 kg) @ 24-inch (600 mm)
NPR-20 4000 lbs (1800 kg) @ 24-inch (600 mm)
198 MPH Upright, with or without sideshift as noted.
42.0 Forks
Hvdraulic Performance and Pressure Checks published herein is
with Clark MS-68 Hydraulic Fluid @ Operatering Temperature
of 120 F.
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 40 Specifications, Truck
r
Fork Stwead 1 2 3 4 I 5
33 Wide Pantograph 330.6n-m 577nx-n 682mm 787mm
13 22.73 26.86 31
37 Wide Pantograph 330.6mm 574.6mn-r 677.6nx-n 784mm 889mm
13 22.62 26.68 30.87 35
33 Wide Pantograph 482.6mm 582.6mm 677.6mn-1
with Sideshift Forks 19 22.94 26.68
37: Wide Pantograph 559mn-l 703mm
with Sideshift Forks 22 27.68
101.6mm (4.00) y 9 Or
Top View
NOTE
All dimensions are in inches unless otherwise specified.
NPR- 17 Data is based on 3500 lb. load, 42.0 forks, 198 MFH Upright with no sideshift.
NPR-20 Data is based on 4000 lb. load, 42.0 forks, 198 MFH Upright with no sideshift.
A B C D E
5232mm 4318nx-n 1814kg 2260mm 2209mm
206 170 40001bs 89 87
5943mIn 5029mn-l 1814kg 2260mm 2209mm 1372mm 814kg 449kg
234 198 4OOOlbs 89 87 54 17951bs 18001bs
6248nxn 5334nxn 1814kg 2413mm 2362mm 1524mm 853kg 449kg
246 210 40OOlbs 95 93 60 18801bs 18OOlbs
701Omm 6096mm 1814kg 2718m.m 2667mm 1828nx-n 982kg 449kg
276 240 4OOOlbs 107 105 72 21651bs 18OOlbs
t
7468mm 6553mm 1588kg 2870mm 2819mm 1981mm 1069kg 449kg
294 258 35001bs 113 111 78 23571bs 18OOlbs
t
7772mm 6858mm 1361kg 3022mm 297 lmm 2134nx-n 1108kg 449kg
306 270 30001bs 119 117 84 24431bs 18001bs
E Rail length
1219.18mm (48.00)
Load Backrest Extension
Pantoiraph
Extended I
........
I
:...... .
+
Pantograph B/C
Retracted
-e
I
Roller(s)
. ..---
...~~
..x ;,y,.,::::~:.,:.:
:::.!.. x.: ..... -2
==-I+
I,..
.. .,
,.,.,.,.,....
~,.,,..,,...,.,.,.,.,...
E
.I . . . . . . . .
..A A.
1
t
50.8mm (2.00) f
38.4mm (1.51 I) J
Center of roller to bottom
of inner rail.
40-l -5 Dee 94
SM-587 Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GROUP 40 Specifications - Truck
Overall Dimensions
Ground Clearance minimum with 4 Dia. Load Wheels: 1.OO
Ground Clearance minimum with 5 Dia. Load Wheels: 1.75
Ground Clearance minimum with 10.5 Dia. Load Wheels: 1.75
Length to fork face (13.38 & 13.88 Battery Compartment Width):- 47.9
Length to fork tip (16.13 Battery Compartment Width): 50.1
Turning Radius:
Outside:(13.38 & 13.88 Battery Compartment Width): 66.5
Inside: (13.38 & 13.88 Battery Compartment Width): 36.9
Outside:(16.13 Battery Compartment Width): 68.7
Inside:(16.13 Battery Compartment Width): 36.9
Width: 53.0
Battery Compartment Size Maximum Battery Size Min. Weight
N-PR-17 38.75 W x 13.38 L x 32.0 H 38.69 W, 13.00 L, 31.5 H 1400 pounds
NPR-17 & 20 38.75 W x 13.88 L x 32.0 H 38.69 W, 13.50 L, 31.5 H 1590pounds
NPR-17 38.75 W x 16.13 L x 32.0 H 38.69 W, 15.75 L, 31.5 H 1885 pounds
(Maximum size including cover if required)
Battery
T-e - Lead-Acid Canacity (6hr. rate) Maximum: KWH (6hr. rate) Maximum
SM-587 40-lMaterial
-7 Dee 94
Copyrighted
Intended for CLARK dealers only
Do not sell or distribute
GROUP 40 Specifications - Truck
Service/Parking Brake(s)
Spring Applied and Hydraulically Released. Brakes must be capable ofholding truck, with
a full rated capacity load on a 15% grade minimum.
.:.:,:,::::::
Brake PedEiI i rPedal Uo_Heiaht
112.5 mm (4-7/16)
41 Master Cylinder(s)
One cylinder connects to the Motor Brake.
I
170 - 190 Nom
(125~1401bfft)
IMPORTANT
Apply1802397
(Anti-Seize) to Install bolts using
motor shaft, bore and Loctite 242 on threads.
20 -25 Nom
(177 - 221 Ibf. in.)
Brake OFF
BrakeON
L
BrakeOFF _____-_
Brake ON
\ Cover must be
in place at all times
to provide required
Typical illustration
Caster Brake
Tighten Sequence
Brake Assembly (Caster Brake Mounting Bolts)
Mounting SDecification 1
Meter set on Rx10,OOOScale, measure from Negative battery connector to truck frame.
SM-587 -11
40-l Material
Copyrighted Dec94
Intended for CLARK dealers only
Do not sell or distribute
GROUP 40 Specifications - Truck
I Auxiliary Control
I
Spool
I
___.- ---____
[System Reservoir Capacity (Gallons) 7.7 -1
Hydraulic Fluid MS68
Section 2
Service Weights
Contents
Service Weights in Pounds . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . ... .. .. .. .. . ... .. .. .. .. .. 40-2-2
SM-587 40-2-l
Copyrighted Material Dee 94
Intended for CLARK dealers only
Do not sell or distribute
GROUP 40 Specifications
N/A _______ DATA NOT AVAILABLE, CONFIGURATION HAS NOT BEEN TESTED
Pantograph Assembly
I Location of:
Pantograph Serial Number
(You must refer to this number when
ordering parts for the Pantograph).
r
Section 3
Lubricants and Shop Supplies
Easy Referene Listing
Lubricants ......................... ................ ...... .. .... .... .................................. ................ .. 3
GASKET PRODUCTS
- continued -
CLEANING PRODUCTS
- continued -
CLEANERING PRODUCTS
LUBRICANTS
continued -
Lubricants
Part Number Description
1802153 - 1 Qt. Motor Oil lOW30
Clark all-season lOW30 motor oil is unexcelled for keeping Clark engines clean. It
protects against formation of sludge, varnish and harmful deposits which cause
sluggish performance. Clark premium lOW30 motor oil is made from high-quality
solvents and refined neutral stocks and is especially suited for gasoline engines which
include emission-control systems. Specially formulated additives prevent rust and
provide effective detergent action. This superior oil product meets API service
classifications SE, SD, SC, SB, CC, CB, CA andmilitary specification MILL-46152
and exceeds hUL-L-2104B.
1802152 - 1 Qt. Motor Oil Extra-Duty 30W
Clark extra-duty 30W motor oil was developed for the lubrication of gasoline, diesel,
Ll?G, and natural-gas engines for which MIL-L-2140B products are recommended.
This oil also meets or exceeds API service class CD, CC, CB, CA, and SB. Clark 30W
oil may be used in stationary, automotive, fzum, and marine-engine service use. It is
especially effective wherever the use of heavy-duty motor oil is recommended.
Suitable for oil-bath aircleaners, chain drives, hydraulic systems, and general lubrica-
tion service.
Dee 94 40-3-4
Copyrighted Material SM-587
Intended for CLARK dealers only
Do not sell or distribute
GROUP 40
Lubricants
Part Number Description
2776236 - 1 Gal Transmission Fluid Specifically recommended for Transmission Models:
916027 - 1 Qt H2OO,H210andH211
HR500 and HR600
TA-12 and TA-18
This product provides proper frictional characteristics, superior wear protection
for gears, excellent water tolerance to avoid excessive foaming and rusting within the
system, good filterability, and low temperature fluidity. These fluids meet CMHC
MS-276A and the requirements for the following:
John Deere Quatt-ol Q-41 Catepiller TO-2
Allison C-3 International Harvester Hy-Tran B-6
SM-587 40-3-7
Copyrighted Material Dee 94
Intended for CLARK dealers only
Do not sell or distribute
GROUP 40
Part Number Description
886399 Chain and Cable Lubricant
Chain and Cable Lubricant provides constant lubrication by penetrating chain links,
andreducesfrictiondragsonsuddenoverloads.It alsopreventsdrippingonsloworidle
chains.
Sealants
Part Number Description
886398 Battery Saver
Battery Saver preserves battery power by retarding acid action, preventing corrosion,
and sealing vibration cracks.
Part Number Description
886784 Spray - Kote
Spray-Kote renews, insulates, and protects. It seals electrical wires and keeps them
pliable while preventing rust and corrosion. Resists extreme heat or cold and requires
no pre-cleaning before use.
Part Number Description
1801146 MS 180 Freon Degreaser
Non-flammable and non-conductive, MS 180 Freon Degreaser is ideal for SCR
controls and panels, harness plugs for electrical wiring, and SCR terminal strips.
Part Number Description
1801145 Conquer-3
Conquer-3 is a water dispersive and corrosion preventive that protects against
oxidation. It displaces water and moisture, even from wet insulation, and leaves a
protective film. Excellent for protecting SCR control panels
Part Number Description
1801480 GE Silicone
Protects SCRs by weatherproofing and sealing while resisting chemicals, oils, and
solvents.
Part Number Description
1803280 Electric Tune-Up Grease
Protects electric connections and wiring from salt, dirt, and corrosion. Extends the life
of the bulb sockets. Prevents voltage leaks around any electrical connection. Also
prevents spark plugs from fusing to boots. Use in extremely dusty, dirty, or corrosive
applications.
Gasket Materials
Part Number Description
1802303 Gasketmaker
Flexible, non-corrosive gasketing material for use on rigid machined flanges with less
than .OlO (.25 mm) gap. Use where anaerobic (cures in the absence of air) gaskets
are specified. Seals transmission cases, transaxle castings, waterpumps, andotherrigid
covers and plates.
Part Number Description
1802308 Gasket Remover
Quickly removes baked-on gaskets and all types of gasket adhesives. Prepares metal
parts for new gaskets and assembly. For all metal parts.
Part Number Description
1803252 Ultra Blue@
High performance, oil resistant RTV silicone. Low odor, low volatility. Eight times
more flexible than cork/composite gaskets and three times more oil resistant than other
silicones. Forms in-place gaskets on valve covers, oil pans, intake manifold and seals,
timing covers, water pumps, and thermostat housings. Use as a gasket dressing to
upgrade conventional metal and pre-cut gaskets.
Part Number Description
1803253 Hi-Temp RTV Silicone
For very high temperature applications. Replaces cut gaskets. Makes reliable formed-
in-place gaskets that resist cracking, shrinking, and migrating caused by thermal
cycling. The temperature range is - 75 F to 650 F. Form in-place gaskets on valve
covers, oil pans, intake manifolds and seals, timing covers, water pumps, and
thermostat housings. Use to coat pre-cut gaskets to increase reliability.
Part Number Description
1803254 Form-A-Gasketa No. 2
Slow drying, non-hardening sealant designed for sealing cut gaskets and stamped parts.
Allows for easy disassembly if required. Use where sealing is more important than
adhesion. Temperature range is - 8.5F to 4ooOF. For valve-cover gaskets and oil-pan
gaskets.
Adhesives
Part Number Description
1802304 Bearing Mount
Anaerobic adhesive helps restore the fit between replacement bearings in worn
housings or worn shafts. Fills clearance to .OOS (.015 mm) and will disassemble.
Mounts and retains ball bearings in housings or on shafts, roller bearings, plain
bearings, and bushings.
Part Number Description
1802309 SuperbonderR
Revolutionary thick no-run formula developed specifically for making fast heavy duty
repairs. For metal, plastic, rubber, leather, paper, wood or cork. Use to repair broken
or loose trim, dash panels, seat cushions.
Part Number Description
1803259 Fast Cure Epoxy 45
Easy to use pre-measured epoxy mixer cups. Ideal for bonding glass, plastics, rubber,
and metal. Bonds in 5 15 minutes. Useon loose trim, broken grilles, casting cracks, and
holes.
Part Number Description
1803260 Spray Adhesive
Dries clear with superior bonding strength. For permanent or repositionable applica-
tions. Resists water, humidity, and heat. Used for attaching cloth, carpeting, sound
insulation, and floor coverings.
Part Number Description
1803261 Steel And Aluminum Epoxy
Grey epoxy adhesives for metals, concrete, and many plastics. When cured, can be
drilled, sanded, threaded, or filed. Resistant to fuels and solvents. Fills gaps and bonds
trim. Use on casting cracks and holes, auto trim, and ornaments.
Part Number Description
1803262 Loctite Weld - An Alternative To Welding
A 15minute, 2-part adhesive and tiller system that eliminates the need for welding or
brazing. Once cured, it can be drilled, sanded, filed, or painted. Use on aluminum, steel,
brass, bronze, casings, stampings, etc. Over 3000 psi shear strength.
SM-587 40-3-l
Copyrighted 1
Material Dee 94
Intended for CLARK dealers only
Do not sell or distribute
GROUP 40
Part Number Description
1803263 Loctite Weld Stix
SimilartoLoctite Weldonly inpre-measuredribbons. Sets in 5 minutes andcures fully
in 1 hour. Fills gaps to 2 (50 mm) and is ideal for under water applications. Use on
aluminum, steel, iron, wood, glass, masonry, ceramic, gas tanks, oil pans, and most
plastics.
Cleaners
Part Number Description
886397 Penetrating Oil
An easy-to-use penetrating oil that cuts rust, paint, and grease and is effective on hot
surfaces. Saves time, labor, and broken parts; contains Moly.
Part Number Description
1800330 Degreaser
This easy-to-use degreaser is water soluble, safe for paint, and does not rust.
Part Number Description
1802522 Brake Cleaner
This brake cleaner provides fast, complete cleaning, removing oil, dirt, and grease,
leaving no film. It is non-flammable and can be used on brake parts, and electrical and
ignition accessories. An effective, thorough, safe, and economical parts cleaner.
Part Number Description
1803264 - 4 oz.; Natural BlueTMCleaner/Degreaser
1803265 - 24 oz.; General purpose, biodegradable, cleaner for removing grease, grime, oil, and mildew,
1803266 - gal. food or other stains from any washable or metal surface. Non-toxic, non-corrosive,
U.S.D.A.-authorized, contains no butyl. Dilutes with water. Great for pressure washers
and steam cleaners. Also cleans engine parts, floors, porcelain and more.
Part Number Description
1803267 Locquic@ Primer N
Degreases oily parts and speeds the curing ofanaerobic products such as threadlockers,
pipesealant,bearingmount, andgasketmaker.Recommendedforcoldweatheruseand
quick repairs. Use with anaerobic products to speed assembly in all applications.
Part Number Description
1803268 Brake dz Parts Cleaner
Quickly dissolves and removes oil, grease, brake fluid, and oxidized oils. Dries fast
without leaving a residue and is non-corrosive.