SM-587

NPR 17/20

CLRRK

Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute

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

25 Brake Bleeding Procedure 23-3-l Pictorial Indexes are provided on
the following four pages.
26 Brake Pedal Adjustment 23-4- 1
26-l-l Index ............................ ....Page 6/7
27 Hydraulic Pressure Checks
28 Hydraulic Sump Tank, Filter and
Strainer(s), Service 29-l-l
29 Hydraulic Schematic 29-2- 1

30 Hydraulic Pump Overhaul 29-4- 1

SM-587 Copyrighted
Table of Material
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INDEX Pictorial Index

Pictorial Index #1
NPR-345

/ 23

Dee 94 Index-2 SM-587
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Pictorial Index INDEX

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

SM-587 Copyrighted Material
Index-3 Dee 94
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INDEX Pictorial Index

Pictorial Index :#2
NPR-345

Dee 94 Index-4 SM-587
Copyrighted Material
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Do not sell or distribute

Pictorial Index INDEX

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

SM-587 Copyrighted Material
Index-5 Dee 94
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INDEX
m Group No-Section No.-Page No. Ttem Grout No-Section No.-PaPe No.
Axle Motors
Articulation Adjustment 20-l-l General 16-2-1
Battery Traction 16-3-1
Remove & Replace 12-1-1 Auxiliary/Steer Pump 16-7-1
Service 12-1-1 Pantograph & Fork Carriage
Brakes Remove & Replace 34-2- 1
Motor 23-l-l Roller Shim Adjustments 34-2- 1
Caster 23-2- 1 Lift Fork Inspection 34-5 1
Bleeding 23-3-l Periodic Electrical Checks 19-8-1
Pedal Adjustment 23-4- 1 Cable & Wire Routing 19-8-1
Master Cylinder 23-4- 1 Planned Maintenance Procedures PM- 1 thru 29
Caster Service Checks PM-17 Caster Special Socket Adapter PM-24
Control Panel Pressure Checks
Contactors 17-1-1 Steering 26-l-l
Oscillator Card, Lift Circuit 26-l-l
Remove & Replace 19-10-l Auxiliary Reach & Tilt 26-l-l
Cylinders Pump Overhaul 29-4- 1
Tilt Cylinder Overhaul 32-2- 1 Sequence of Operation
Reach Cylinder Overhaul 32-3- 1 Electrical 19-2-1
Rail Lift Cylinder Overhaul 34-3-l Solid State Control
Free Lift Cylinder Overhaul 34-4- 1 Status Codes (EV-T15) 19-3-1
Diagrams Oscillator Card Settings/Tests 19-4-1
Electrical 19-6-1 Steering Adjustments
Hydraulic 29-2- 1 (EV-TSPS) 19-5-1
Drive Unit Switches
Overhaul 20-2- 1 Directional, Lift & Lower 19-7-1
Lift Chains Multi-Function Control Handle 13-l- 1
Inspection 34-6-2 Transducer Adjustment 19-7-1
Lubrication 34-6-6
Remove & Replace 34-6-6

Lubrication
Charts & Specifications 01-1-l

Dee 94 Index - 6 SM-587
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INDEX
Upright & Pantograph
Lift Chains 34 - Manual Insert
Remove & Replace 34-l-l
Roller Shim Adjustments 34-l-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

SM-587 Copyrighted Material
index- 7 Dee 94
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proper precautions are not taken. A! CAUTION This message is used as a reminder of safety practices which can result in personal injury if proper precautions are not taken. Contact your Clark dealer for replacements. tools. NOTICE This message is used when special information. If the above is not followed. Cautions The following is a list of “CAUTIONS” connected with the operation andmaintenance of trucks equipped with Solid State Control Panels. Protect electrical wiring and components from weld spatter with a shield. equipment. signs and messages. 3. instructions or identification is required relating to procedures. If warning decals are damaged they must be replaced. A DANGER This message is used when an extreme hazard exists. Damage to the truck or serious injury to you or other persons may result if these messages are not followed. A WARNING This message is used when a hazard exists which can result in serious personal if injury or death. pressures. 4. Be sure you know and understand the meaning of these instructions. A WELDING ON TRUCKS 1. 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. 2 Disconnect truck battery. Safety Signs and Safety Messages SAFETY SIGNS and MESSAGESareplaced in this manual and also on the truck to provide instructions and to identify specific areas where potential hazards exist and special precautions must be taken. Ventilate battery or remove battery from truck. Make sure the truck has no grounds. capacities and other special data. damage can result to wiring and electrical components on a solid state control truck. SM-587 Copyrighted Material i Dee 94 Intended for CLARK dealers only Do not sell or distribute .

A CHECK POLARITY Battery Polarity must be correct or the truck will not operate. Appropriate servicemethodsandproperrepairproce. anyone departing from the instructions individual doing the work. The detergent should be rinsed off and the controls must be thoroughly air dried before putting truck into service. Drive and work safely and follow the safety signs and their messages displayed in the work area. Blowing dirt off with an air hose (that is restricted to 30 psi [207 kPa]) periodically will. eliminate any serious cleaningproblems. Solid State Controls should be cleaned at regularintervals. should preclude the need for using a degreaser.180 Freon TF Degreaser and Cleaner. effective techniques. Periodic 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. materials. Use Clark #I1801146 Degreaser. and parts may jeopardize and repair work with tested. reliable operation of tions and provide advice or precautions as to each. Read and understand the procedures for safe opera- as well as in the skill of the individual doing the work. Improper or careless techniques cause accidents. tools and parts for servicing industrial trucks. or the equivalent to MS. However. This Service Manual provided in this manual through procedures used or provides general directions for accomplishing service choice of tools. niques. Dee 94 ii SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .CAUTIONS A DO NOT STEAM CLEAN Do not steam clean a solid state controlled truck as excessive moisture will interfere with proper operation of the solid state components. tion and maintenance outlined in this manual. reliable truck operation. A USE TRUCK BATTERY ONLY Do not use a motor generator unit such as “ready power” or a battery charger to move and/or check this truck as serious damage may occur IMPORTANT SAFETY NOTICE Read and understand all Safety Precautions and Warnings before performing repairs on lift trucks. such as those mentioned above. tech. Should the need arise for a more thorough cleaning. take chances with incorrect or damaged equipment. This manual cannot possibly anticipate all such varia- dures are essential to the safe. his or her personal safety and/or the safety of the Following them will help assure successful repair and vehicle user. for the most part. industrial trucks as well as the personal safety of the Accordingly. on the truck and in this manual. if a degreaser is used we recommend the following: Only approved solvents should be used to clean Solid State Control Components. Don’t There are numerous variations in procedures.

and rear surfaces of the tires to provide further sive gases. “Handling Storage Batteries”. restraint from inadvertent vehicle movement. Refer to Do not smoke while working on a vehicle. Set the parking brake. SM-587 Copyrighted Material III Dee 94 Intended for CLARK dealers only Do not sell or distribute . watches. clothing before working on a vehicle. the instructions outlined in Group 19. “Dis- charging Capacitors”. dure requires you to be under the vehicle. Putpowerkey switchintheOFFposition. Cautions GENERAL PRECAUTIONS Thefollowing list contains general precautions that should be followed when working on a lift truck. . equate overhead clearance and on a flat. Follow the instructions outlined in Group 12 “Handling Storage Batteries” and those instructions received with your battery and charger. Follow the Safety Instructions outlinedin Group Remove rings.unless otherwise required by the procedure.. Service Electric Truck Batteries in a well-venti. clear of pedestrians and with ad. Always wear safety glasses for eye protection. level Use safety stands or blocks whenever a proce- surface. Place chocks to the front lated area to avoid the danger of lighting explo.. The battery contains corrosive acid which can cause injury. to avoid Always Discharge the Capacitors prior to work- serious injury. ing on or around electrical components. A! CAUTION Avoid contact with Battery Acid. loose jewelry and open 12.

Adjustment Procedures. adjust. before start- technicians. Lubrication Guides. It general instructions required to explain the activity. inspection. cleaning. NOTICE The descriptions and specifications included in this manual were in effect at the time of printing. maintenance and repair of providing specific steps only when necessary and the Clark industrial lift trucks noted on the cover. before beginning to work. pressures. correct maintenance and care of component or subsystem. reassembly.. measurements. Specifications. tional steps of standard procedure for removal. Preventive mainte- content listings are placed at the beginning of each nance instructions are provided for reference in set- Section in the manual.. including any special instructions. procedures are outlined (as required) for each Regular. Refer to the index. The manual includes: . nance.. recommended lubricants the vehicle. ABOUT PLANNED MAINTENANCE 01-40 Service specifications. The information is organized by use of the The technician is cautioned and expected Basic Group Numbering System used in the to. installa- are trained and authorized to do lift truck mainte. 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. The importance of proper maintenance through The Pictorial Index lists components or systems planned service. ting-up and conducting a recommended periodic Planned Maintenance (PM) program. as needed. The Planned Maintenance Procedures ments. adjustments.Foreword This Service Publication provides information Procedures have been made easier to use by covering normal service. Contact your authorized CLARK dealer for information on possible updates or revisions. tion. Master Parts Book and the Customer Parts Manuals. assembly. Dee94 iv SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .M. including any special instructions. has been specifically prepared to help owners and component. 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. etc. It is designed to provide essential information Tobe better prepared to do the necessaryservice about the correct and safe service maintenance and work. The Table of Contents list the pages in this manual. or process being worked on.. 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. service personnel maintain these trucks in efficient The technician is expected to include obvious addi- and safe operating condition.. Additional not be emphasized too strongly. torques. illustrations and other items may change at any time. take time to completely read the entire proce- repair of the truck by trained mechanics or service dure. *Take time to completely read (entire) procedures. P. disas- This manual is intended for use by persons who sembly. or subsystems. inspection and qualified repairs can- by Basic Group Number of Major Parts. Clark reserves the right to discontinue models at any time. ing any work. etc. Specifications. Planned Maintenance Procedures including precautions and safe maintenance recommendations. or make improvements and changes in specifications or design without notice and without incurring obligation. and service weights.

This tion forms. the PM interval may have to be reduced. brake checks which are part of the PM will uncover the need for adjustments and/or repairs which may be required periodically. with the interval being determined by operating conditions. dealer for more information on l If an oneration is extremelv dirtv and strenuous. they will assist you in determining when water levels. 3. If the PM is faithfully followed. Foreword An effective PM program should incorporate Inspection Forms two basic phases: ~ To insure that the daily inspection and PM are prop- 1. instruments to schedule a vehicle for major repairs. An insnection net-formed bv the driver or main. For instance. Increase vehicle productivity. The Planned Maintenance routine is based on of unscheduled down time. NOTE Refer to the Operator’s Manual.acheckoffluidsand eachvehicle. To reduce costly unscheduled downtime. Consequently and warning devices. Increase personal safety of drivers and other personnel. for additional Records will tell you how often PM information on the operation.. major adjustment and component replace- ment will be discovered and such work can be scheduled eliminating unnecessary downtime and cost. Reduce maintenance costs. 50 to 250 operating hours .. 2. SM-587 Copyrighted Material V Dee 94 Intended for CLARK dealers only Do not sell or distribute . care should be done. we recommended the use of inspec- tenance man at the beginning of each shift. l If an oneration is clean and not strenuous. and maintenance of your truck. located on the truck. theserepairscanbedonewithoutthedisruptiveeffect 2. erly performed. a PM Contact your authorized Clark interval can be extended. The objectives of PM are: 1. maintenance and repair of these t?-UCkS.. lights (if so equipped). Such forms not only provide a guide for is a quick visual check for obvious damage and the inspections and maintenance requirements for leaksandafunctionaltest. needs for repair.. 4.

. Requires Shop Repair .. shouldbe 2. SM-587 Copyrighted Material PM-l Dee 94 Intended for CLARK dealers only Do not sell or distribute . Code l (s) indicates the need for urgent repair or replace $ = O...(. As the P. l (r) indicates there is a potential problem that couldresult in damage to acomponent or system and requires attention..M. Walk Around Visual Inspection. Each catagory is preceded with a summary of the inspections.:.:. CHECK SHEET 1.:..:.. Operational Tests.:. The nature of problems found during aP..:...v...:.K.) that should be taken care of in the near future.:.:.:.M.:... .. Visual Inspection A special coding system on the P.M. Planned Maintenance Procedures The Planned Maintenance Procedures Outlinedon the following pages are organized in five basic catagories. X = Adjust (Not P..:.M. is performed.:.M.. Whenever a system or comnonent is faultv or unsafe. l (x) indicates the component or system is in need of a minor adjustment or service (not part of the normal P. tests.... . etc. Checks and Minor Adjustments..‘. ~~~~~~~~ s = ‘.:.:..:.. Lubrication.K. noted in the “comments” portion of the check sheet. that should be per- formed in each catagory.:.:.:. l (4) indicates the particular truck component or system has been checked.(. 3.. ment of a component or system and the truck 1 O. it must be noted on the check sheet andreported to the 4. checks. a mark should be made in the appropriate box of the compo- nent being checked.:.:.:.(.:. Check sheet allowstmckcondition tobereportedwithaminimum number of words. P.) I should be shut down as possible property dam. Cleaning..M.‘.. .:. 5.. designated authority at the conclusion of the P.: . They are: 1... Potential r = Repair or Replace age or personel injury may result.. ....M.

l Inspect the spring loaded terminals in the truck battery receptacle and check the battery plug terminals. l Check that “ground chain link” is touching the floor. decals and truck data plate. check sheet.M. Pull back on the battery disconnect lever located at the right front Truck corner of the console. l Overhead Guard for security of mounting (loose or missing fasteners) and damage. l Visible fluid leaks. l Tire Wear and/or lodged foreign objects in tire tread and/or badly darnaged side walls. Burned or pitted terminals should be noted on the P. Insuect Batterv Plugi BzTruck Receutacle Battery Plug 7 l Disconnect battery from truck. l Load Back Rest for security of mounting and damage. Visual Inspection 1. floor mat. l Safety Screen and/or Glass for security of mounting and damage. pads.Planned Maintenance Procedures l Visible frame damage. l Visible signs of wear and/or damage to upright. tsconnect Batterv and check Spring Loaded Terminals Dee 94 PM-2 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . l Presence and condition of covers.

Make cer- tain retainers are locked in position at each end of the battery compartment. Check safety screen and/or glass for security of mounting and damage. pads and floor mat. Make a quick overall inspection for oil leaks. SM-587 CopyrightedPM-3 Material Dee 94 Intended for CLARK dealers only Do not sell or distribute . Check for Obvious Oil Leaks and peneral condition of Frame & Overhead Guard . at this time. If oil leaks are found. Be sure warning and instructional de- cals are readable. Check overhead guard for damage and security of mounting. . Planned Maintenance Procedures 2. Inspect name plates. Check for Obvious Leakage aged. 4. Be sure the legs of the overhead guard are mounted securely and are not dam. . warning decals and truck date plate for damage and to be sure none are missing. or later in the P. 5. fuc the minor leaks and report on the check sheet any leaks which will require major repair. Check battery retainers for damage. Batterv Retainers . cracked or bent.. Check condition of covers. 3.M.

FT.139 LB. Retorque drive wheel fasteners afterthefirst2OOhoursofopera- tion. breaks. Fasteners must be tightened using a diagonal sequence as shown below (let- tered A through G). Wheel Wheel & Tire & Tire Fastener Tightening Sequence D F B A G @ C E TORQUE FASTENERS TO: 124 . caster and drive wheels. If they are loose. Remove objects that are embedded in the tire.188 N*M) Dee 94 PM-4 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . “chunking” or bond failure between the tires and wheels. Check for obvious damage to tires on the load. torque them to specifications. Be sure drive wheel fasteners are secure and none are missing. Look for excessive tire wear. (168 .Planned Maintenance Procedures 6. cuts. Inmect Wheels & Tire . Make sure grease fittings are not damaged and none are missing.

Control should spring l Connect battery. Check battery connection. l Check acceleration. Check the Multi-Function Control for Freedom of movement. The control must operate freely without binding and spring return to neutral. operation. l Check control plugging. Planned Maintenance Procedures Check Mullti-Function control for freedom of l Check brakes. Then move it into the full left and full right positions. Check horn. Check Controls functions checking for free- dom of movemenet. l Check speed limit switch operation. SM-587 CopyrightedPM-5 Material Dee 94 Intended for CLARK dealers only Do not sell or distribute . l Check steering. Move control to the full forward and rearward positions. Operational Tests Move control through all a. l Check hour meter. l Inspect multi-function control handle for free- dom of operation. NOTE Battery connector should be disconnectedandkey switch turned OFF before making these checks. Check upright operation. Check key switch and dash display.

l Wrench Symbol: If this light comes on. This indicates that the digital readout is okay. The status code may indicate an easily correctable “operator fault” or it may indicate that the truck should be serviced. c. and can be corrected by the operator as explained in Group 19. Turn the key switch to the OFF position. Check horn to be sure it operates. \ l Battery Symbol: When the battery syrnbol light comes on.Planned Maintenance Procedures b. either the battery symbol or the wrench Digital Readout symbol light should come ON. -06 and -08 are usually operator fault codes.M. The hourglass symbol light Battery ‘Symbo should come on. the digital readout shows the percent- age of usable remaining battery charge. If the readout registers 19 or less. Check the hour meter. l Fault Codes: Codes -01 through -03. The hours registered on the truck should appear on the digital readout for about four seconds. the readout will flash. a status code will appear on the digital readout. Turn key switch ON. Section 3. Check the Diamostic Disdav & Kev Switch l Digital readout should display “8888” for about one second after you turn the key switch ON. I Wrenchkymb d. then. Record this hour meter reading on the PM check sheet. A momentary display of status code -99 indicates that the truck hours exceed the preprogramed maintenance reminder hours and the functions must be reset after completing the P. Dee 94 PM-6 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .

do not operate the truck. Check Brake After checking that you have a clear travel path ahead. The pump motor should turn on and the carriage Tilt Control should begin to elevate.. The control should (Optional) not bind when moving it any position. Report condition to designated au- thOIitJC SM-587 Copyrighted Material PM-7 Dee 94 Intended for CLARK dealers only Do not sell or distribute . Pantograph should reach and retract smoothly without hesitation. Elevate the upright to maximum fork height. Fork Side Shift operation should be smooth without binding. Release the control. Watch the upright to make sure Multi-Function Control Handle it operatessmoothly between the “Switch Buttons” free lift and rail lift stages. ReachControl gently pull back on the Multi-Function Control. rollers and damage to hose and lift chains. Slowly lift foot from brake pedal. reach and side shift (if applicable) for proper operation andrange. Aftermaking sureyouhaveoverheadclearance. Lower the upright to full down position.. move the truck forward at a slow speed. watch for mechanical binding of rails. Hold in one button at a time and check tilt. Note any excessive “slop” or “noise” in the upright that may indicate roller damage or roller reshimming is required. Drive motor should cut off before the brakes apply. watch for mechanical binding of rails. It should return to neutral without binding and the !SideShift Control pump motor should turn off. . rollers and damage to hoses and lift chains. the motor should cut off before the brakes apply. Check List. Planned Maintenance Procedures e. As the upright raises. Check Hvdraulic Function% . Forks should tilt evenly and smoothly. Record any malfunction and/or damage on the P. Move truck in reverse at a slow rate of speed. As the upright lowers.M. Slowly lift foot from pedal. Ifoperation is notsatisfactory .

Planned Maintenance Procedures

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.

j. Check Controlled Plwwing (BrakiwI
. Operate truck at a slow speed in a forward
direction of travel. Reverse direction of travel.
The truck should slow down to a smooth con-
trolled stop, and accelerate normally in the op-
posite direction.
If plugging is as specified, then repeat the proce- l Now, after checking to see that you have a clear
dure at high speed. The truck should come to a path behind, drive the truck in reverse. Check
smooth controlled stop in approximately 20- acceleration from stand still condition through
feet (6.1Omm) with Multi-Function Control in top travel speed. Acceleration shouldbe smooth.
maximum travel position.
l Report condition on PM Check List.
. Repeat the procedure at high speed with the
1. Check Srxed Limit Switch Oneration
Multi-Function Control moved in reverse direc-
tion half way. l After checking for overhead clearance, elevate
upright until the intermediate rail operates the
If plugging (braking) is not as specified, refer to
speed limit switch attached to the outer rail
the adjustment instructions in Group 19 of this
assembly.
manual. Report condition to designated author-
ity. l Drive truck forward in a straight line of travel
with the control held in top speed position.
k. Check Acceleration
. Now, after checking to see that you have a clear
path ahead, drive the truck in a straight line at a
high rate of speed in a forward direction of
travel. Listen for unusual drive train noise. Stop
truck.
. Check acceleration from a stand still condition
to top travel speed. Acceleration should be
smooth without hesitation.

Dee 94 PM-8 SM-587
Copyrighted Material
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Do not sell or distribute

Planned Maintenance Procedures

CLEANING

l Battery Compartment. l Caster Wheel and Brake.
l Lower Compartment. l Hydraulic Compartment.
l Drive Motor and Steer Motor. l Pump Motor.
l Brake Components. l Control Compartment.
l Axle Mounting. l Upright and Pantograph.

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.

SM-587 CopyrightedPM-9
Material Dee 94
Intended for CLARK dealers only
Do not sell or distribute

Planned Maintenance Procedures

a. Remove Batterv A WARNING
l Disconnect battery from truck receptacle. The battery contains corrosive acid which=
can cause injury. If acid contacts your eyes’
l Remove battery retainers and inspect them for
or skin, flush immediately with water and gel:
damage.
medical assistance.
l Remove battery from truck. Refer to Croup 12
Do not smoke or allow open
for removal and safety instructions.
flame near the battery.
l Clean off deposits of corrosion on the battery. Explosive gas is always
present around batteries.
l Check battery cables for fraying and damage. A
frayed or damaged cable can cause a short.
Report condition on P.M. Check List.

Cap Vents Must Be Open At All Times
Damaged Cable
l Check battery vents for obstruction. The cap
vents must be open at all times. If any are found
to be plugged, they may be washed in a solution
of baking soda and water.
b. Access Internal Comr>onentq
l Remove fasteners securing front console cover
to truck.
Slip boot off cover lip and tuck bottom of boot
into cover hole.
Carefully lift cover a little forward and upward
until the cover is free of the control.
Remove console cover from truck.
l Remove fasteners securing the side cover to the
truck.
Lift cover off truck.
l Remove fasteners securing floor plate to truck.
Lift floor plate upward and over the brake pedal.
l Open Access Door. Loosen door fasteners until
the door is free to open exposing internal com-
ponents.

Dee 94 PM-l 0 SM-587
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute

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/oad”could
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.
SM-587 Copyrighted Material
PM-l 1 Dee94
Intended for CLARK dealers only
Do not sell or distribute

Planned Maintenance Procedures

. Check condition of the steering slip shaft and the
universal joints. Clean area around the grease
fittings. Check their condition and be sure none
are missing.
. Checkcomponents for security of mounting and
general condition.

is* Air Clean Drive Unit
. Blow off the drive unit.Be sure all dirt and dust
is removed around the level and drain plugs.
Drive Motor and Steer Motor
. If the motors are equipped with brush covers,
remove the covers.
. Remove the brushes and inspect them for wear.
Refer to the Brush Inspection Chart in Group 16.
. Inspect commutator bars for “bridging” dust or
copper material while slowly rotating the brake
drum. 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.
. Reinstall brushes and brush covers (if appli-
cable).
. Recordcommutatorcondition and brush lengths
on the P.M. Check List.

Make certain that all dust is removed from both the outside and inside of the motor.

Dee 94 PM-l 2 SM-587
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute

Planned Maintenance Procedures

Brake Line Retainers (Bracket and Fastener)

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.

SM-587 Copyrighted Material
PM-1 3 Dee 94
Intended for CLARK dealers only
Do not sell or distribute

Planned Maintenance Procedures

Axle Mounting Block
(with Bushing)

Axle -to- Frame Retainment 601

h. Axle Mounting
. Be sure the axle to frame retainment
bolts are in place and tightened se-
curely.
......
.>>F.. . . . . .. .. . . . . . . . . . . .. . . ..~.~......
:~:~:::::jj,::~.~.~.~.::::~.~~.~:~:~

. Each axle mounting block is equipp- :::::::::::::::::::::::::::i:::.:;:~:~:~:~
iiiliii:i:i:i:i:i:i:i:i:i:ijii:i:,i:i: V Grease Fitting
::::::::i:i:i:i:i:l:~:~:~:~:~:::~:~:~~:~
...........:.
.......................................................................................
ed with one bushing and a flush type ..:.:.~,.:.:.:.:.:.:.:.:.:.:.:.:
................................,.. ...._. ,...
.......................,.,.,.(.,.,.,.(.,.(.,.,.,~,.,.,.
.......................:.:.:,:,: ....,...... ..,...
grease fitting. The grease fitting is ...,...,
.............,.,.,.....,.,.,.,...,.,...,.,.,
. . . . . . . . . . . . . . . . . . . . . . . . . . .. ....,.
...
.,...,
.....:.:
,.... .....,.,.,.(.,.,.,.,.(.,.,.........,.
..,.,.,.,.,.,.,.,.,.,...........
.,.,.,.,.,.,.,.(.,.,.,.....,...
.,.,.,.,.,.,.,.,.,.......,...
accessible through an opening in the f::::::::~:~:::::::::::~:~:~:~~:$~:~:~:
,...:... ...........
.:.:.:.:.~j::::jjjj::j)j:.:.:.:.:
.....................................................................................................,...,.
,....
.... Truck Frame .,.,.,.. ..,.. ,.......
,.,....
top side of the axle weldment or “dog- :::::::::::::::::
:::::::::::::::::
:::::::::::::::::
house” located just beneath the opera- :jj j:i:jj::
:::::::::::::::::
i;;;;>:;i;;;;;;;;
.y>;:::::,:::
tors compartment floor. Clean the area .:~l.,\di:;j
.....
aroundthefitting andwipe the fittings
clean. Be certain they are in good
condition.

Dee 94 PM-14 SM-587
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute

Planned Maintenance Procedures

j- Air Clean Caster Wheel & Brake
. Blow off the caster wheel assembly.
. Checkforobviousdamageandsecurityofmount-
ing.
. Check caster wheel for loose wheel bearings.
. Air clean the cover located on the back side of
the caster wheel and check it for damage.
. Remove the cover and air clean the caster brake Fasteners <u,_/
cylinder, spring and linkage.
. Inspect brake cylinder and lines for leakage.
. Check the brake spring, linkage and cylinder for
damage and security of mounting.
k. Check Brake Sm-iw Len&h
l Measure the distance between the inside of one
washer to the inside of the opposite washer (as
shown here). If spring length is not as specified,
an adjustment must be made.
l Using wrench, turn nut (1) against washer until
2-l/4” (57.2mm) can be measured between in-
side of one washer to the inside of opposite
washer.
l After obtaining correct spring adjustment, use a
second wrench and tighten jam nut (2) against
nut (1) without disturbing spring adjustment.

Be sure to Lubricate linkage. Refer to Croup 01.

SM-587 Copyrighted Material
PM-1 5 Dee 94
Intended for CLARK dealers only
Do not sell or distribute

Planned Maintenance Procedures

AdiustinP for LininP Wear
When to ReDlace Brake Lininps Lining Wear Check

As brake linings wear, the brake arm will move Brake
inward toward the caster “weldment”. When the arm
is within 3/16 of an inch from this weldment, move
arm 1-spline away from weldment.
Refer to Group 23, Section 2 for
CheckandAdjustmentPs.

IMPORTANT: This adjustment may be made a
maximum of four (4) times. When the brake arm
reaches the 3/16” measurement a fifth time, install
new brake linings.
Brake Pedal Up-Height should be checked after
installing new brake linings.
Refer to Group 23, Section 4 to the
CheckandAdjustmentProcedures.
-

Now install the cover onto the caster assembly
being certain the fasteners are tightened se-
curely. Never place truck into service with the
cover missing. It should be installed at all times.
Check the brake line for damage and security of
mounting.
Check to be sure lock ring is not missing or
damaged. I-

.-

b_
Make certain retainer plate is properly located
against the brake line fitting. \

Make certain the retainer plate is tightly secured
to the axle frame. -

Fa

Dee 94 PM-l 6 SM-587
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute

ft. (40. then adjust the pivot (trnnnion) bearings as outlined here. Lock Nut Be sure the lock nut is installed with the chamfer side (UP) away from bearing. Lock the nut in place with washer locking tab. Mounting Spindle SM-587 Copyrighted Material PM-l 7 Dee 94 Intended for CLARK dealers only Do not sell or distribute . Check Caster (Stabilizer) Installation for loose Trunnion Bearinas. Once this has beenaccomplished. retorque nut to 30 _ Grease Shield lb.ft.M. rotatecaster assembly at least two (2) full revolutions. Thrust Washer & l Next.ft. Reneat nrocedure until toraue is stabi- lized at 30 Ib. M. If the bearings appear to be loose.7 Nom). NOTE Check. adjust and lubricate Thrust Bearing axle trunnion bearings every “P. Now. (40. bearing Cone IMPORTANT Bearing Cup The above procedure must be repeated until bearing preload is stabilized (you Axle can no longer turn the nutlat the 30 Ib. Lock Washer %323 l Using a torque wrench. torque nut to 30 lb.ft.“. M. they should be inspected for damage and proper adjustment( Refer to Group 01 for lubrica- tion specifications. Frame torque. IMPORTANT . Planned Maintenance Procedures . Adjustment l Unlock bearing lock nut. Refer to Lubrication in Group 01.7 N*m). tighten the lock nut (do not back off nut) to the next available locking tab. l Try to move the caster assembly up and down and check for side to side movement.) If bearings appear to be fit for further service. +.

Air clean the complete compartment. l Record commutator condition and brush lengths on the P.Planned Maintenance Procedures Hvdraulic Comnartmen$ l Blow off the valves. remove the cover. and steering sensor. sump tank and hydraulic lines. l Inspect commutator bars for “bridging” dust (copper material) while slowly rotating armature. l Blow off the filter. Air clean the commutator after removing bridges. l Visually inspect hydraulic hoses and clamps for damage. pump and motor. gently remove the bridging dust using a sharp pointed tool such as a scribe or ground off hacksaw blade. l Reinstall brushes and brush cover (if applicable). l Clean area around the fluid level indicator. Dee 94 PM-l 8 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . l Be sure area around the sump breather fill cap is clean. l Remove the brushes and inspect them for wear. Note any damage on the P. If bridging exists.M. Tighten loose clamps and/or fittings. Check List. Make certain that all dust is removed from both the outside and inside of the motor. Check List. horn. Refer to the Brush Inspection Chart in Group 16.M. Valve & Lines Puma Motor l If the motor is equipped with a brush cover. leakage and security of mounting.

capacitors and th steer control box. . Planned Maintenance Procedures Contactors A WARNING When clean with compressed air: Wear eye protection and. protective clothing when cleaning or drying with air pressure Reduce air pressure to 30 PSI (207 kPa). . Air clean the Multi-Function Control Handle switches. Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Switches Electrical Controls ComDartment. switches and harm ness. wiring. Blow off the control cards. Jeer . Blow off the contactor panel. contactor tips wiring and cables. Completely air clean the compartment floor. . transducer. Debris removed with air pressure can cause injury.

Planned Maintenance Procedures Umight . . Clamp 5. Connector 4. lift cylinders and carriage. Air clean the packing glands on all cylinders. Check List. valves and piping. . nicks. 1. 1 l Note condition on P. Blow off the piston rods. . . Tighten loose connections. .M. nicks.M. Check the chain anchor pins (7). Check List. . Check List.M. Examine the hydraulic plumbing and connec- tions (5). Blow off the safety screen (or glass). Check rods and glands for obvious damage. . . Cotter Pin 7. Check screen/shield for security of mounting. Be sure the cotter pins (6) are in place and not damaged. andconnectors (3) for security of mount- ing and damage. Checkcondition of hydraulic plumbing and connections. Chain Anchor Pin - Dee 94 PM-20 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Checkcondition of hydraulic plumbing and connections. Check rods and glands for obvious damage. If the cylinders am leaking or rods are damaged note condition on the P. Air clean the pantograph. Tighten connec- tions if loose. Fastener 2. Air clean the cylinders and piston rods. Check theharness hold-down clamps (4). If the cylinders are leaking or rods are damaged note condition on the P. upright chains. brack- ets (2). Fitting 6. marring. marring. scratches that might damage the cylinder packings. . Tighten connec- tions if loose. . Bracket 3. scratches that might damage the cylinder packings. * Check lift chains for damage.

Planned Maintenance Procedures l Inspect condition of fork retainment pins. Retainment Pin tion. l Check the fork mounting bar to be sure it is properly located. Be certain the snap ring and retainment pins are in place and in good condi. f4. Snap Ring Fork RetainmentPin + Fork SM-587 Copyrighted Material PM-21 Dee 94 Intended for CLARK dealers only Do not sell or distribute .

Dee 94 PM-22 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . located at the l AllLiftChainsmustbeadjustedtoproperlength back of the Outer Rail Assembly are used to and equal tension as outlined on the following adjust Inner Rail Lift Chains attached to chain pages. The Inner Rail Lift Chains are routed over l Adjustment Chain Anchors (Al. located at the Sheaves (C) attached to the Intermediate Rail back of the Free Lift Cylinder are used to adjust Assembly. one set for carriage free lift and (see above). These chains attach to Intermediate Rail elevates thus the lift chains chain anchors at the base of the lift carriage. As the Rail Lift Cylinders extend the the carriage lift chains. one set for inner rail lift. The routed over Sheaves (C) elevate the Inner Rail carriage chain anchors are not adjustable. l Adiustment Chain Anchors (B).. Assembly.Planned Maintenance Procedures Checks 81Minor Adjustments IMPORTANT Anchor Cotter Pin Heads must be to the inside of Upright Lift Chains Triple-stage uprights use two chain sets (refer to anchors at the base of the Inner Rail Assembly illustration above).

uart number 886399. and bushing in roller chain). The best nance of lift chains is lubrication. Applying Lubricate immediately after the chain is dry. life without periodic lubrication. This helps prevent chain “twist” and excessive chain stress that eventually results in chain damage. will be increased by periodic lubrication. less than if the chain is permitted to operate dry with metal-to-metal contact between pins and plates (pin Keep tight joint in chains to a minium number.M. linkplates to crack. operation conditions and the environment. The lubricant will pen. Heavy motor oil is At every P. Chain Lubrication The frequency of lubrication will change with the The most important consideration in field mainte. Chain Anchors must be free to pivot Chain Anchor in their mounting holes at all times. “paste”of oil and dirt. Hard-working. Help give smooth. lubricated chains will gather dirt. for lubrication of chains. quiet chain action. clean the chains also a very good lubricant. Use Clark Chain and Cable Lubricant. Keeping a layer of oil on all chain surfaces will: In dirty operating conditions. To do so will result in chain carnage. plates in leaf chain give more paths for the lubricant __ . (50-250 hours or heavily-loaded chains cannot give acceptable wear four weeks maximum actual truck operating time). etrate into the chain joint to prevent wear. The friction in the chain. but the cleaning is not recommended because some clean- lubricant must flow into the bearing surfaces for ing solutions contain chemicals which can cause maximum chain life. In dirty operating conditions. As with all bearing Trucks that are parked outdoors or in very severe surfaces. layer of oil on all chain surfaces. Steam lubricant to external surfaces willpreventrust. lubrication time is during each P. but joint wear will still be much Reduce the chance of pin turning.M. SM-587 Copyrighted Material PM-23 Dee 94 Intended for CLARK dealers only Do not sell or distribute . Even under these conditions. Planned Maintenance Procedures A CAUTION Never tighten Chain Anchor against weldment. in a Stoddard type cleaning solvent to remove dirt. the joint-wearing surfaces need a layer of oil service may need lubrication more often to keep a between mating parts to prevent wear. Joints get a Prevent or reduce the rate of corrosion. chain life Keep joint wear (chain wear) to a minimum. or four week intervals. leaf chain can be more Lower the chain tension by reducing internal easily lubricated than roller and rollerless chain. Maintain Freedom of Movement Weldment All Chain Anchors must be free allowing their Spherical Bushings to Spherical Bushing self align in the machined surface of their anchor weldments. to reach the pin.

adjust the chains as instructed on this page. Torque Jam Nut to: 100 . and not twisted. l If they do. Rotate chain adjustor nut on each chain anchor the inner rails protrude l/8 inch above the inter.. Rail l/g-inch above the Intermediate Rail. chain tension .. Rail Chains do not require adjustment. Finger tighten jam nuts against chain adjustor page. check for equal longest span.148 Ib. check to see if 2. make a minor adjustment to the chain that has If the above checks are as specified. the Inner the least tension. nuts. After completing adjustment. the same number of turns to position the Inner mediate rails (both sides). Chain tension should be the same. + Spherical Bushing + Chain Adjustor Nut + Jam Nut 4-b Torque Specifications Using two wrenches. Chain Tension should be the same for each chain. . If not. they should be the same. check to be sure chains are straight fied. (A third wrench on the chain anchor is helpful) . l With the upright fully lowered. Loosen jam nut on each chain anchor. You can “feel” chain tension by pushing on each chain by hand. Check the carriage chains as outlined on the following 4.) Dee94 PM-24 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .200 N*m (74 . Make sure the chains are not twisted and torque jam nuts as instructed in illustration be- If any one of the above checks are not as speci- low. check tension of both chains on the 3. Again.ft.Planned Maintenance Procedures Lift Chain Adjustment Step 2: Adjustment Procedure Step 1: Adjustment Check 1. a torque wrench on the Jam Nut and a second wrench to hold the Chain Adjustor Nut..

third wrench on the chain anchor is helpful) . Chain tension should plished. check tension of both 3. Once the l/2-inch clearance has been accom- chains on the longest span.. make a minor adjust- ment to the chain that has the least tension. Finger tighten jam nuts against chain adjustor next page. a torque wrench on the Jam Nut and a second wrench Lift Chains connect to to hold the Chain Adjustor Nut. If not. adjust the chains as instructed on this page straight and not twisted. nuts . tion insert below. u w Chain Anchor + Spherical Bushing o + Chain Adjustor Nut 8 0 + Jam Nut 4-k Toraue Soecifications f&a [ Using two wrenches.ft.. Planned Maintenance Procedures Carriage Chains Step 4: Adjustment Procedure Step 3: Adjustment Check 1. and then continue to Step 6 on the next page. see illustra- the floor. Rotate chain adjustor nut on each chain anchor graph fully retracted. (A Pantograph Carriage. check for equal chain tension .) SM-587 Copyrighted Material PM-25 Dee 94 Intended for CLARK dealers only Do not sell or distribute .148 Ib. Loosen jam nut on each chain anchor. they be the same. 2. should be the same. Check both forks. Torque Jam Nut to: 100 .. 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.. see insert below. check to be sure chains are fied. Ifclearance is as specified. l If the above checks are as specified. check to see if there is l/2. l With the upright fully lowered and the panto. follow the carriage instructions outlined in Step 5 on the 4. 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. Again.200 Nom (74 .

to . (A third wrench on the chain anchor is helpful) . a torque wrench on the Jam Nut and a second wrench to hold the Chain Adjustor Nut.. There Again. Elevate upright to maximum fork height. l/O Chain Anchor + Spherical Bushing + Chain Adjustor Nut + Jam Nut 4-k Toraue Specifications Using two wrenches. adjust chain anchors as outlined in next column . weldment on the Pantograph Carriage. torque jam nuts as previously described. For loca. Adjust no more “stop” weldment on the Inner Rail and the “stop” than necessary to provide this clearance. Now. If the carriage stop contacts the rail stop. Torque Jam Nut to: 100 ...148 Ib.) Dee 94 PM-26 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . between these stops..inch Check to see if there is clearance between the clearance between these stops. tion of these stops. check to be sure chains are straight and must be some clearance ..200 Nom (74 . Rotate chain adjustor nut on each chain anchor the same number of turns until there is l/8. approximately 15 mm not twisted.. Carriage stops must not make contact when upright is elevated to maximum fork height. see illustration below. A CAUTION Make sure there is adequate Step 6: Adjustment Procedure overhead clearance. (S9 inch) . Loosen jam nut on each chain anchor.ft.Upright Stop IMPORTANT The carriage stop must not be allowed to contact Step 5: Adjustment Check the upright rail stop under any circumstances during normal operation.Planned Maintenance Procedures Carriage Stop .

use nrotectivelubrication fluid. Brake Insuection wrong one. A l Meter should register 20. see below. not$t. or if it is routed incorrectly. Planned Maintenance Procedures 1. Check for Grounds be removed immediately and replaced with new. manufactured to an exact specification. l EV-T15’ A. Be certain the replacement cable is the l Meter should register 20. l Check for oxidation (white/blue) and discolora- nal crimp. Wire Terminals 13 (or 13B) and 26 l Relay Terminals (for optional equipment only) 2. Clark Part Number 1803827. endisproperly crimped anditsconnectionprop- l Meter should register 20. Make absolutely certain the cable battery connector terminal.M. it will power terminal and truck frame. This reflects high resistance joint Broken Wires Badly Damaged Casing Cables having small cuts may be repaired with electrical tape. 3. l Check for frayed/broken cable strands at termi. Refer to next page. size and has the proper when measured between truck frame and any connector. to coat terminals of followirw 111119s. If either a when measured between any EV-TSPS control harness or cable is routed improperly. when measured between any EV-T15 control Every cable and wiring harness on this track is power terminal and truck frame. l Cables having damage as shown above should 4. l Every P.Y and 2 Plugs (OSC or Traction Control Card) l EV-TSPS ‘PL4 Plug l DashDisplay Plug . Wire Spades 10 & 1OC and 12 & 12B l HornTerminals . Check Contactor Tips for the following: l Cleanliness l Wear l Metal transfer between stationary and movable tips.B. PL . check for brake lining wear and adjust.000 ohms or greater erly torqued during installation. if necessary.000 ohmsor greater exact same length. SM-587 Copyrighted Material PM-27 Dee 94 Intended for CLARK dealers only Do not sell or distribute . tion of cable edge on terminal barrel end.DP Plug l Key SwitchTerminals . Electrical shorts and damaged compo- nents may result if the replacement part is the 5. Check Harness/Cable/Fuse Connections for securitv of mounting and condition of terminals.000 ohms or greater shorter cable or harness willnotfit.

Make certain nuts are tight without disturb- ing the spring “preload” adjustment. . Nuts are used only at time of new lining Refer to Group 23. l Hand tighten nut (1) against brake arm without rotating the rod. . .Planned Maintenance Procedures Notice: AS Brake Linings Wear: l Brake Arm & Rod move inward. _ . INSTALL NEW BRAKE LININGS when the brake arm moves to within l/8- inch of the boot. 9 Pressure Spring Length increases. l Rotate Nut (2) inward against the brake arm and continue to tighten (T/T& moves the actuating rod outward compressing the spring. tighten nut (1) while hold- ing nut (2) to secure adjust- ment. . . specified spring length is obtained.) nut until . as shown. l Using two wrenches. Brake Cylinder A-+- Dee 94 PM-28 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . To Adjust for Lining Wear: l loosen nut (I).

Hose Sheaves and fluids. Section 1 Chart(s) in for all reauired lubrication Doin@ J N. Planned Maintenance Procedures Every 1.000 Operating Hours Check and Adiust the Followina: l Forward & Reverses Switches Multi-Function l Lift & Lower Switches l Transducer NOTE RefertoGroup 19. <.Section Forward Switch Reverse Switch 7ofthismanualforspecific procedures. Transducer &I Lubrication 0 Upright & Pantograph Refer to Lubrication Grow 01. Hydraulic Filter . Lift Chains Control Handle Gears & Spring Breather. Steer Shaft & U-Joints Sump Tank & Strainer - Brake Reservoir -1 Caster Pivot Bearings Motor Brake Linkage A Drive Unit Pivot Bearing I Load Wheel Drive Unit Crankcase Drive Unit Wheel Bearings Caster Axle Bearings Caster Brake Linkage Axle Pivot Block SM -587 Copyrighted Material PM-29 Dee 94 Intended for CLARK dealers only Do not sell or distribute .

-ia.Handling GROUP01 Section 1 Lubrication Chart & Illustrations NPR-345 Lube Chart& Specifications SM-587 01-1-l Copyrighted Material Dee 94 Intended for CLARK dealers only Do not sell or distribute .CLARKM$z.

3 to 5% moly additives. MS-107B General Purpose Grease containing anti-wear. ::::::::::::::::::::::: Applications ‘. or equivalent Dee 94 01-l-2 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . L5 Drive Unit Crankcase: Drain when oil is at MOCO loo0 AMOCO 1000 operating temperature. cans test with 50 mg total weight loss maximum per Hydraulic Fluid Clark Spec.. MS-68 A straw colored hydraulic fluid composed of a Royce 717 blend of highly refined hydrofined mineral oils Cold Storage ::+. per Clark Specification MS- NLGI #2 Grade ‘Ir 107. and rusting and to afford greater lu- Ef?I bricityandimprovedviscosity-temperaturechar- Hydraulic Fluid acteristics. as specified by L8 DOT 3 Federal MotorVehicle Safety StandardNo. m:: or equivalent and additives to impart resistance to oxidation. 886399 Chain & Cable Lubricant B Clark Part No. Grade DOT 3. MS-107C A multi-purpose grease of refined mineral oil L4 blended with a lithium soap thickener or equal NLGI #2 Grade General Purpose Grease containing anti-wearanti-rustandanti-oxidants Clark Spec. 885382 the requirements of ASTM D-2882 pump wear l-caseof 6 one gal. Clark Spec.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.. anti-rust and anti-oxidants L3 with EP additive with EP additives.:.:::::::::::. Fluid must meet M&F-1711 1. 116. MS-107D with EP and Moly additives with EP and.~ MIL-F-17111 corrosion. 885385 Use only high quality hydraulic fluid with Zinc of 24 one qt. L9 Acheson Gredag 2230 A specially formulated (tacky) grease with ex- Special Grease Dow Coming Assy Paste Texaco Texclad 2 cellent adherence capabilities. @ or equivalent L6 Clark Part No. A smooth high quality grease of refined mineral Cold Storage oilbase with a lithium soap thickener or equal w Temp Grease Applications compounded with corrosion and oxidation in- ML-G-23827A hibitors and containing 1 to 3% moly (molybde- num disulfide) NLGI #2. Brake Fluid.:. cans l-case or equivalent Anti-Wear additive which meets L7 Clark Part No.

LL = Lubricate each time a Load Wheel is replaced or squeaking occurs.M.Lubrication Chart GROUP 01 Lube Key Chart Caster Brake Linkage: Lubricate with engine oil at every PM Brake Inspection. only on new trucks. Note Lubricate length of rails at point of “roller Contact” first P. SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Pack each time the Caster Wheel is replaced.

(250 operating hours maximum) Corrosion Protection Mechanical Paste Lubricant Using Clark Part No. Dnnection. All Screw-On Tme Wire Terminals l All Card retainer screws. l Motor Ground Wire (both ends).Cold Storage & Standard Applications Every P. Note: ReaD- plybeforemakingthe c Dee 94 01-l-4 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . l Strobe Light Connections (if so equipped).GROUP 01 Lubrication . 2802205 apply to the follow- ing Power Cable and Screw-On type wire connec- tions: r A. l Reverse Alarm (if so equipped). Note: Reau- lybeforemakinrrthe l All Motor Cable Connections. c.I Ground Wire - Apply to wire con- nections any time they are discon.M. see below. l All Control Panel Cable Connections.pply to electrical CC 2nnections any time ley are discon- All Power Cable ConnectionS ected. Pump Motor nected.

Apply to electrical IMPORTANT connections any time Avoid direct spraying on contactor tips. 1803827spray the following: General Note l Contactor Panel. Motor l Reverse Alarm terminals (if applicable). Them0 stat located on contactorpanel.Cold Storage & Standard Applications GROUP 01 Every P. l Any and all switches used on the option(s). plvbeforemakinethe connection. l Wire Terminal Screws includinp the follow- & Control Card (1) and Control Card (2). Part Numbers: l Steer Control (EV-TSPS). (250 operating hours maximum) Corrosion Protection Mechanical Lubricant Using Clark Part No.M. l Forward Pointing Head Lights (terminals). A CAUTION Do not spray motor brushes and commutator. they are discon- nected. Switch cover must be removedfor access to screw terminals. Steer Interlock Switch on contactor panel. Electrical Options (Spray all connections). Speed Limit Switch mounted on outer rail tie bar. 1803827& 2802295. l Heater Thermostat (Cold Storage). Cover all motor openings prior to spraying.Lubrication . Brake Switch terminals. for l Drive Control (EV-T15). l Strobe Light (terminals) Aux. Note: Reau- l Power Cable Connections. SM-587 Copyrighted Material 01-l-5 Dee 94 Intended for CLARK dealers only Do not sell or distribute . l Push-On Connectors should be snravedt l Horn terminals l Key Switch terminals. l PL and DP plug connections.

GROUP 01 Lubrication . See ‘Threaded Areas” l Dowel Pin Retainers on panto- graph.M. See above. l Caster brake adjustment linkages. See below. l Motor brake adjustment linkages. (250 operating hours maximum) Apply Anti-Corrosion Spray Clark Part No. springs and bleeder screw (do not spray directly into the bleeder screw). springs and bleeder screw (donot spray directly into the bleeder screw).Cold Storage COLD STORAGE LUBRICATION Every P. There are nine (9) pins total. 2794748 to the following: l Reach and Tilt Cylinder Rod Ends (spray threaded area only). Dee 94 01-l-6 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .

or equivalent product.Lubrication .100 to +250”F. and rusting and to afford greater lubricity and I improved viscosity-temperature characteristics. Refer to Lubrication Chart on Page 3 for remainder of instructions and time intervals. r - 3 B .Cold Storage GROUP 01 COLD STORAGE LUBRICATION Hydraulic Sump Tank Specifications: Use Hydratic Fluid which meets ML-F. Temperature range: . SM-587 Copyrighted Material 01-l-7 Dee 94 Intended for CLARK dealers only Do not sell or distribute . corrosion. A straw colored hydraulic fluid composed of a blend of highly refined hydrofined mineral oils and \ additives to impart resistance to oxidation.17 111. \ - -T- Grease Fittings Sr>ecifications: Use an extreme low temperature aircraft quality grease meeting ML-G-23827A. (Royce 7 17 or equivalent) .

......................._......................_...... .i .. ..............y SERVICE ................___ _ :::. 12-1-7 Battery Records ............................. 12-1-6 Battery Installation .&.... 12-1-8 (............‘.............. 12-1-3 & 4 Battery Removal & Installation .......................... / BATTERY ......._.<“\ ~..~.......-............................... .............. GROUP 12 SECTION 1 Battery Contents Battery Service Area .........................................._......’ -..................................... D Remove all jewelery before working on the truck Copyrighted Material Dee 94 Intended for CLARK dealers only Do not sell or distribute ....Y’ ‘L..... nnrr I’....... 12-1-3 & 4 Handling Storage Batteries ....... “-...... 12-1-5 Battery Maintenance ................................................................ Y\ ‘.....................................

1147748 l l A WARNING Electric truck batteries are heavy and awkward to handle. Electric truck batteries are also costly. Dee 94 12-l -2 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Polarity must be correct to prevent damage. IF ACID CONTACTS YOUR EYES OR SKIN. On charge. are explosive. they give off hydrogen and oxygen which. consult BATTERY MANUFACTURER. in certain concentrations. so before you remove. Care- fully read and follow recommendations and instructions. FLUSH IMMEDIATELY WITH WATER AND GET MEDICAL ASSISTANCE. Disconnect battery before handling electrical components. for more recommenda- tions and instructions on handling and charging batteries. or install a truck battery.GROUP 12 BAllERY A WARNING SULFURIC ACID THE BATTERY CONTAINS CORROSIVEACID WHICH CAN CAUSE INJURY. service.

FLUSH IMMEDIATELY WITH WATER AND GET MEDICAL ASSISTANCE. Persons maintaining storage batteries must wearpro- tective clothing such as: l Face and head shields l Long shirt sleeves. sparks.__. especially when they are being charged. Fire extinguishers should be properly maintained and located in designated areas. A WARNING . The fol- lowing should be adhered to. l Check to see that there is fire protection. l No smoking shall be allowed in the charging area. IF ACID CONTACTS YOUR EYES OR SKIN. l Be certain the area has proper ventilation to ventilate fumes from gassing batteries. l Open flame.BAmERY GROUP 12 BATTERY HANDLING Fire Extinguishe -. or electric arcs shall never be allowed in the battery charging area.SULFURIC ACID THE BAlTERY CONTAINS CORROSIVE ACID WHICH CAN CAUSE INJURY. l Be sure this area has provisions to flush and neutralize acid spillage.+ Wash Stand Change or service batteries only in an area designated A&.. ------4 for this purpose. l Gaunlet gloves. SM-587 Copyrighted12-1-3 Material Dee 94 Intended for CLARK dealers only Do not sell or distribute . l Battery electrolyte shall never be checked with an open flame. A DANGER Explosive gas is always present around batteries.

Dee 94 12-1-4 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Typical lllustratior Plyw~ - l If the battery does not have a cover of its own. Make sure the lifting hooks are the correct size tofit the lifting eyes of the battery. When this is not possible.GROUP 12 BATTERY Be sure the battery service area is equipped with Overhead Hoist . be sure the battery is covered as shown below. 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. 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. The shorted cir- cuits could ignite battery fumes and cause the battery to explode. Metal objects contacting battery termi- nals will cause short circuits. the distance between the lifting hooks (of the spreader bar) must be adjusted to the same dimension as between the battery lijiting eyes. To prevent side forcesfrom damaging the bat- tery. l Be sure the hoist is equipped with a chain sulated Spreader Bar container to accumulate excess lifting chain. Safetv Hook / material handling equipment designed for the pur- pose of removing and replacing batteries.

Remove battery retainer plate. etc. Be sure battery is covered prior to attaching lifting device. Battery Disconnected . heavy cardboard. Once the battery is out of the truck./. a lifting device equipped with an insulated spreader bar Transporting and safety hook(s) can be used to transport Battery battery.BATTERY GROUP 12 Battery Removal Key Switch Off Brake Applied 1. 5. L ---I= - lad :A = - ---_ -ze -_ SM-587 Copyrighted Material 12-l -5 Dee 94 Intended for CLARK dealers only Do not sell or distribute . Platform cover battery with a non-conducting material (plywood. Push Battery onto l If the battery to be handled is uncovered. 2. A recommended method of handling the Retainer battery is to use a platform equipped with rollers similar to the one shown in opposite illustration.) prior to re- moval from truck.. Insulated Spreader Bar Uncovered Batteries: Cover With FVywood or Heavy Cardboard . Removing Battery 4. Turn key switch OFJ? and disconnect battery.. The battery must be pushed out of the compart. The safety hooks of the insulated spreader bar should be attached to the lifting eyes provided in the battery casing. 3. Move truck to the designated battery service area. NOTE Do not wash battery in truck. Chain/ 4 Container l An overhead hoist (of sufficient lifting capacity.. Remove Battery ment.. I refer to “Weights” in Group 40) should be used to lift battery.

l When mixing electrolyte. l When Cleaning Batteries: The vents must be tightly in place. Battery Charging Follow theinstructions suppliedby theBattery Charger Vendor. It is advisable to have this solution Battery top should be clean and free of cracks or breaks. Pouring water into acid will cause a dangerous chemical action. adhered to. Care must be taken to assure that vent caps are func- tioning. The battery cover must be removed/opened to dissipate heat and explosive gas. Battery terminals must be clean and solidly mounted.GROUP 12 BATTERY Battery Vents l When ChargingBatteries:Theventcapsmust be kept in place to avoid electrolyte spray. Damaged batteries should be repair or replaced.never pour water into acid. 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. around the battery service area at all times. The battery top can also be washed with a baking soda solution and rinsed with clear water. Dee 94 12-l -6 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . clear cold water. The cap vents must be open to allow the battery to breath. thoroughly rinse with Consult your battery vendor. l Check to be sure all vent caps are tight before washing the battery. Battery Cleaning The easiest and most satisfactory method of cleaning a battery is to wash it with a low pressure cold water spray. always pour acid into water . l After washing 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.

50 inches (982.7 x 400.) prior to installation.e.(537. l Install battery retainer.69 x 13.. l Remove non-conductive material from battery. A WARNING .7 x 330.O x 800.00x 31... clean the walls and floor of the compartment. For the NPR 17 a minimum battery size of 38.P.75 x 3 1.. Allow to air dry.. Reduce air pressure to 30 PSI (207 kPa).50 inches (982. Debris removed with air pressure can cause injury. an air hose. Install Battery If the battery is uncovered. SM-587 Copyrighted12-1-7 Material Dee 94 Intended for CLARK dealers only Do not sell or distribute . plywood. Batteries too small can shift and cause damage to thetruckor injury to the operator or bystanders. etc. l Push battery into battery compartment. (635.Okg)isrequired.l mm) and aminimumweightof 14OOlbs.. cover the battery with a non-conducting material (i. 1Fl “::. Rinse with clear water. sawa & Water Solution REPLACEMENT BAlTERlES Cautionshould beexercised to use a battery properly sized to the dimensions of the battery compartment.l mm) and aminimumweightof 1185lbs. l Connect battery to truck..2x 800.69 x 15. For the NPR 22 a minimum battery size of 38.BATTERY GROUP 12 Clean Battery Compartment Clean Battery Compartment l Using baking soda and water solution. Air Hose - Wear eye protection and protectiveclothing when drying with air pressure. l Blow off the compartment walls and floor with . heavy card- board.5kg)isrequired.

Do not over fill. . Follow the instructions provided by your ment and possible trouble areas. tions or posts. l Specific Gravity and Temperature readings. Dee 94 12-1-8 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .015). . Section 4 equipment.Record tion. Only use batteries that comply withfactory spec@ica- Each battery cell should be checked and re. Only qualified l Variation between each cell tested. Short circuits will cause battery l Charging Time. a cracked case. reference and comparison. If below 1. check to see if the battery is fully . use a lifting device readings are greater. Do not add acid to a battery. charge. There are approximately 2 volts for each cell in the commonly used lead-acid type battery. while it is performing work. Do not under charge a battery. this indicates there are defective cells. charged. corded before and after charging. supplier(s) of the battery and battery charging For further information. Keep an accuraterecordof the damage and could ignite battery fumes. should not be greater than 15 points (. if required. these records will help you and battery maintenance procedures and their expertise. designed for this purpose . in this manual. the actual time the battery is in use before . of the battery. Over recorded indicating the condition of a battery flushing causes loss of electrolyte. The varia. Maintain accurate battery records. power to operate an Electric Industrial Truck. explod- actual time the battery is on charge. After each ing the battery.250. refer to Croup 19. Add water. the battery OF YOUR BAITERY should be recharged and tested. . before when taking readings.. vent caps and excessive corrosion. . 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. Their voltage depends on the number of individual cells These records should contain: they contain.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. The specific gravity reading of the electrolyte should not be HOW TO GET MAXIMUM LIFE OUT less than 1. Check the electrolyte level before placing a Thepilotcellshould be changed occasionally to distribute any electrolyte loss over the battery battery on charge. Check power cables and wiring for damage. your battery representative determine the nature of the problem. Maintain good battery cable connections. This data should be noted to help ascertain work environ. or damaged cell . . . Test the battery before placing it back into service. l Visually Inspect for loose terminal connec.260. Keep the battery clean. charging the battery. dry and in good condi- l Actual Operating hoursof the battery. Their capacity varies depending on the application. Each test should be dated for future Batteries normally range from 6 volts to 72 volts. If battery Check with your local battery supplier for complete troubles occur. Record these results. l Test Date. Do not over charge a battery. Battery Representatives should determine ijlhis tion in specific gravity reading between cells is necessary. When lifting a battery. tions as to size and capacity and weight. If . Keep metal objects and tools away from the top putting it on charge.

. . . . . .. . .. .... . . . .. 13-1-4 Switch Side) -)Q’ PL-9 so-i0 Transduce. . Forward and Reverse Switches. . SM-587 Copyrighted Material Dee 94 Intended for CLARK dealers only Do not sell or distribute ... Remove and Replace . 13-1-3 Transducer. . Tilt and Auxiliary Switches... GROUP 13 Section 1 Multi-Function Control Handle Switches Contents Reach. Remove and Replace .. . .. 13-l-2 Lift and Lower Switches.... . .. ... Remove and Replace.. . .. \> Harness so-7 sq7 Lift/Lower Switch ~.. . . .. .....

Cable Guides and Marking Tapes: IMPORTANT Cables must be positioned so all tape markers are aligned with or hidden under clamps or guides. Connect wires to the new switch and install switch into plastic housing. wire insulation.e.etc. Remove wires from switch connections. 2.. If not. Place housing . switch Installation 1. The handle grip has two halves (switch side and heel side). Dee 94 13-1-2 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . TILT AND AUXILIARY SWITCHES Switch Remove & Replace These switches (1) are located in a separate housing within the control handle..GROUP 13 Reach. 3. Remove fasteners (2 & 3).. Assemble handle being certain to tighten fasten- ers (2) thru (3) securely. Pull harness wires free of their retainer slots in handle (heel side). 5. electrical shorts and possible damage to equipment may result. 3.. i. Carefully push wires into their retainer slots . 3. Multi-Function Control 2. see opposite illustra- tion. Remove switch housing (6) from handle. IMPORTANT Connector Plugs and Receptacles are permanently labeled with the proper PL (Plug) and SO (Socket/Receptacle) number for easy identification. 4.. Switch Removal 1. Provide some wire slack in the housing before removing a switch. Carefully pull wires “taugt” but not so tight as to cause damage to the connections. Switches REACH. Plug #PL-6 plugs into pin socket ##SO-6. Pull switch from housing. 6. Remove inner fasteners (4 & 5). A CAUTION If disconnected. Clamps. using a “blunt” instrument so as not to damage into handle (heel side). match plug number with appropriate receptacle number before making a connection. Tilt & Aux. 4.

2. both lock washers. and switch adjustor. Remove switch. See opposite illustra- tion. See Page 1. 1. 1. Installation spring. 3. 4. Disconnect switch (to be removed) from the wire harness.Switches GROUP 13 UP (LIFT) AND DOWN (LOWER) SWITCHES Switch Remove & Replace These adjustable switches control lift and lower func- witch tions of the upright and are mounted to a bracket on the left side of the handle bracket. 3. Refer toGROUP 19. washer and cam. / Adjustor Bolt 2. Remove cam fastener. Remove fasteners securing switch and switch adjustor to bracket. switch Removal. L Washer Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Connect switch harness assembly Socket SO-7 to main wire harness Plug PL-7. See illustration below. Section7 for switch adjust- ment procedures. Install new switch assembly and route wires as illustrated below and on Page 4. Remove switch adjustor bolt.

GROUP 13 Switches

-#‘oG
ml -Y /
4
I IIl-I
Assemble horn “switch”

clearance for the reach,
tilt & aux. switch holder.

Route Harness
as shown -W

Wire #l OG Aux 2 Switch Wire #65 Aux 2 Switch

Route Harness

Tilt Switch Horn Switch

3-Wires Each Side

tioned with all

hidden under

Dee 94 13-l-4 SM-587
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute

Transducer, F & R Switches GROUP 13
TRANSDUCER, FORWARD AND Transducer Installation
SWITCHES l Install new transducer to the transducer plate.
Install transducer and transducer plate assembly
Forward and Reverse Switch l

to bracket.
Remove & Replace
l Route the transducer’s 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.

l Disconnect switch harness assembly Plug PL-8
(to be removed) from the main wire harness
Socket SO-8. Refer to illustration on page 1.
l Remove clamp screw and remove the trans-
ducer clamp assembly harness from the clamp.
l Remove adjustor screw and lock washer secur-
ing the switches, switch adjustors, lock washers
and springs to the switch bracket.
Switch Installation
l Installnew switch, switch adjustors, lock wash-
ers and springs in the reverser order of removal.
Secure the sub-assembly with adjustor screw(s)
and lock washer(s).
l Route switch wires as shown in illustrations on
Page 1 and Page 4.
l Connect switch harness assembly Plug PL-8 to
main wire harness Socket SO-8.

Transducer Remove & Replace
Transducer Removal
l Disconnect transducer harness Socket SO-10
from the main wire harness Plug PL-10.
l Remove clamp screw and remove transducer
clamp assembly harness from the clamp.
l Remove fastener switch securing the transducer
and transducer plate to the bracket.
l Remove nut and washer securing transducer to
transducer plate.

SM-587 Copyrighted Material
13-1-5 Dee 94
Intended for CLARK dealers only
Do not sell or distribute

GROUP 16

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

CLEANING, INSPECTION & TESTING PROCEDURES

Torque Cable Fasteners
to:
150 lb.in. (16.9 N*m)

Refer to:
Group 16, Section 7

Torque Cable Fasteners
to:
75 lb.in. (8.5 N*m)
Torque Cable Fasteners
to:
150 lb.in. (16.9 N*m)

Dee 94 Copyrighted Material
16-2-l SM-587
Intended for CLARK dealers only
Do not sell or distribute

GROUP 16 Motors

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.....:~:::::~::::::.
. . . . . . . . . . . . ::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::

Remove all Jewelry before
working on truck.

:::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::
..:.:.:.:.:.:.:.:.:.:::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::
:.:.:.:.:.:.:.:.:.:.....~.......:.:~.~.:~~~.:.:.~.:.!.:.:.~.:.:.~.~.:.:.:.:.~.~.:.:~.~~.~
:: :::: ::::::::<
.............. ..

Always wear Safety Glasses

DischargetheCaDacitorsbeforeworkinpontruck Discharge Capacitors

l Be sure the battery is unplugged.
l Discharge capacitors using a 100 ohm, 10 watt
resistor connected between the Positive and
Negative power terminals on the SCR control.
Hold the resistor in place for2 seconds before
removing.

A 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.

SM-587 16-2-2 Dee 94
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute

Motors GROUP 16

Electric Motor Maintenance

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.

l Air clean (blow out) open motors using clean,
dry (moisture-free) compressed air at [207 A sudden drop or consistent trend toward low
kPa] 30 psi. maximum air pressure. Air clean values of insulation resistance give evidence that
all inner areas around commutator and brushes, insulation is deteriorating and that failure may be
including cooling air vents and fan. Wear imminent.
safety glasses.

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.

Disconnect Truck Battery,
Discharge the Capacitors - Refer to Group 19

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.

Extreme Service: Dusty or Sandy Locations Flour Mills
Cement Plants Coal Dust Areas
Lumber Mills Stone-Crushing Areas
SM-587 16-2-5
Copyrighted Material Dee 94
Intended for CLARK dealers only
Do not sell or distribute

GROUP 16 Motors
General Brush & Commutator 7. Check brush shunt for good contact with
Inspection brush holder. Be sure shunt is not damaged or
burned since this may cause brush spring to
1. Remove brush cover(s) and remove brushes carry current and lose tension.
from brush holders. Clean brushes and hold-
ers. Check brush holders for damage. 8. Clean and check brush box and connector
screws. Tighten if loose. Be sure brush box
2. Inspect condition of brushes. Remove each shunt connection is tight.
brush from brush holder and inspect brushes
and commutator for worn condition and 9. If brushes do not need to be replaced, and
uneven wear. commutator is in good condition, install
brushes and brush springs into brush holders.
3. Clean commutator surface. Wipe commuta-
tor with a dry, lint-free cloth.
DO NOT USE LUBRICANT OR SOLVENT Be sure brush spring is correctly placed on brush
ON COMh4UlYATOR. holder and that brush isfree to slide in brush
box.
4. Check appearance of commutator surface
where brushes ride Inspect commutator bars
for burned, damaged or raised areas. The best 10. Install brush cover on motor case.
signs of good commutation are a dark brown
highly-polished commutator and uniform 11. Check and tighten all motor bolts. Check
glossy brush-wearing surfaces. lower nut on each terminal post. It should be
installed finger-tight, then tightened another
5. Measure and make a record of brush length at 114 turn with a wrench.
each inspection. The record will verify amount
of brush wear and indicate if there is enough
brush length remaining until next scheduled
inspection.
6 In general brushes must be replaced when
worn to approximately half of original length.

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

Dee 94 16-2-6 SM-587
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute

Motors GROUP 16

Brush Inspection Chart

REPLACE BRUSH

-i

IF SPRING TENSION IS NOT THE SAME
FOR EACH BRUSH, REPLACE SPRINGS.

REPLACE BRUSH IF IF BRUSH PIGTAIL
PIGTAIL IS LOOSE IS LOOSE AT THE
IN THE BRUSH. BRUSH HOLDER -
TIGHTEN SCREW.

REPLACE BRUSHES
WHEN WORN TO

Typical Illustration

Dee 94 Copyrighted Material
16-2-7 SM-587
Intended for CLARK dealers only
Do not sell or distribute

.GROUP 16 Motors Typical Inch Pound Pointer Typical Foot Pound Pivoted Torque Went h Scale Handle Pointer IMPORTANT Improperly Torqued Fasteners Can Cause Damage. Dee 94 16-Z-8 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Use an appropriate torque wrench and tighten all fasteners to the torques specified in the illustation on the following page.

Motors GROUP 16 Cable (or) Wire Harness IMPORTANT Xamps must be jositioned so all rAPE MARKERS ire aligned with )r hidden under he clamps or :able guides.in.Z.3 Nom) - Dee 94 Copyrighted Material 16-2-9 SM-587 Intended for CLARK dealers only Do not sell or distribute .W: IJ1Torque ------__-- Drive Motor Cable Fasteners to: 150 Ib. :::::::::::::::: ::: j::::::::::: :::::::::::::::: :::::::::::::::: y::::::::::::: :::::::::::::::: :::::::::::::::: :::::::::::::::: :::::::::::::::: y::::::::::::: TM.in.:>g#:. \ /I i ! i \ IL 2 Wire Harness \ :. (11. ?.9 N*m) Al Torque Cable Guide Nut to 100 Ib. (I 6.

. ... ........... ..... .... ... . ... .... . . .......... ... . . .. . . .. ... ... .. ...... . . ... .......... . .. ....... ... .. . . . ..... . .. .. . ........ .... . .. .... .. ......... ..... . ... 16-3-7 Changing Brushes . 16-3-8 Motor Reassembly . ... ..f.... . . .. . . . . . ... . . . ... .. .. 16-3-5 Component Inspection & Trouble Shooting . ... ... ...... .... .. .. .ELqRK Material Handling Company GROUP 16 Section 3 Traction Motors 24 & 36 VOLT Contents General Information . . ...... ... ....... .... . .... . .......... .. . ..... ... ... . . . .. ... .. .. . ..... 16-3-9 & 10 Inspection Charts . .... .... .. .. ... .. . .. ... . ... . .. . . ... . ... . ..... . .. . . . .... . ....... ....... .... . ... .... ......... . . . 16-3-6 Testing .... . .... . . . ..... .... .. . ......... .... .. .... .. 16-3-11 24 & 36 Volt Ventilated and Enclosed Motors Note: Open Motor has no band. . .. .... .. . .I.. ... ... . .. . ... ... .. ... .. . ..... ... ... . . . . . . . . ....... ... .. .. ..... . . 16-3-3 Motor Disassembly . . . . . ..... .. . .. .. .. .... .. .... .. .. .. . ..... 16-3-8 Specifications .. ... .......... . ... ..... .. “‘tgl m 3/8-l 6 UNC-2A Terminals 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. Typical Inch Pound Torque Wrench Pointer SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Use a Torque Wrench to tighten Terminal Connections. Debris remoJed with air pressure can cause injury. Remove all Jewelry before working on truck. Reduce air pressure to 30 PSI (207 kPa).

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. Severe Service: Extended operating hour day of indoor hours. age. Good Commutation: A dark uniform coloring pattern at the brush wearing surface. The coloring pattern will be: . long-life and trouble-free operations. pitted. scored or signs of burning or heavy arcing between bars. . corrective action can be taken before a major component is damaged beyond serviceability. Uneven film. Poor Commutation: The surface of the commutator appearing rough. Extreme Service: Dusty or Sandy Location Flour Mills Cement Plants Coal Dust Areas Lumber Mills Stone-Crushing Areas Dee 94 Copyrighted Material 16-3-3 SM-587 Intended for CLARK dealers only Do not sell or distribute . The brushes and commutator should be inspected for even wear and good commutation. . Bar edge burning. . 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. or constant us- material handling. Carbon dust bridging between bars. is related to the time spent making inspections and correcting minor problems as they occur. If this is done. Streaky film with commutator wear. Thekeytoplannedmaintenanceofthebmshandcommutatoris recognizingundesirablebrush and commutator conditions.

Install jaw pullers as shown. Q Brush Holder Field Coils & Pole Shoes >ommutator End Head Motor Housing Armature Assembly Drive End Head SM-587 16-3-4 Dec94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .GROUP 16 Motors 3. Remove brushes.. head with bearing.pusharmatureout of bearing andco tor end head 7. 4. c from drive end head. Remove drive end mutator. Remove two screws from commutator end head.. 2.. Remove four screws 1. =S 6. Remove bearing cap (if m equipped) from com. Remove commutator end head and .

remove l Use a hammer and chisel or drift punch to drive bearing from end head. Once the fan has been pressed onto Remove the drive end head retaining bolts or the armature. then press the bearing out of the end head. Use a small propane torch to heat the and field coil assembly. for the most part. Use a brush hook to reach into the motor and lift the brush springs. or spline is damaged when removing l Press or drive the spline retaining pin out of the the end head. Remove sary to remove the ventilating fan and /or drive end head. Although locating marks IJ YJ II are not always necessary because of locating pins in some motors. Pull the brushes out of the brush hold- ers. removed as quickly as possible.Eitherpositionthebrushesoutsidethemotor or remove the brush retaining screws and re- move the brushes from the motor. When the fan becomes loose on the shaft. protect the end of the armature shaft with a nut or a thick flat washer. Almost all motors have a slip fit bearing at the commutator end. Scribe or center punch locating marks in the end heads and the &me. area of the fan around the shaft.Motors GROUP 16 TRACTION MOTOR Disassembly Remove the cover band (if so equipped) from the commutator end of the motor. it should be remove bearing from shaft with a bearing puller. cast iron or cast Remove bearing from head. it must be heated to be removed screws. usually has to be replaced. Dee 94 Copyrighted Material 16-3-5 SM-587 Intended for CLARK dealers only Do not sell or distribute . Use caution and do not damage the armature. aluminum. Theventilat- ing fan is. they can save a lot of time when the motor does not have locating pins. Remove the snap ring. On some motors the spline out of shaft. denced by the puller becoming loose. A puller is installed and a slight pressure exerted Pull the armature assembly from the housing against the fan. Remove Spline If the bearing remained in the end head. andtheend head l There will be occasions when it will be neces- canberemovedwithverylittletrouble. it’necessary. bearing is retained with a snap ring. splines from the the armature shaft. Remove the drive end head (the bearing may or Remove Fan may not remain on the shaft). Remove the commutator end head retaining Ventilating Fan screws or bolts. without damage. the armature or the drive spline shaft and spline. as evi- If the bearing remained on the armature shaft. Remove Retainer Pin If theshaft. When a puller is used.

Check for loose commutator bars. ture shaft. The commutator stiffness caused by the lubrication but should can be checked for loose bars by lightly tapping turn smoothly. l. Brushes should be inspected for uneven wear and Commutator End Head signs of overheating. Poor Commutation: The surface of the commu- tator appearing rough. must be replaced. 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. 1. if worn out. Check security of fan. Checkmountingholesforany strippedorcmsed l Carbon dust bridging between bars. 3. 1. Check for grounded circuits using a test light. A contrasting changed. Check bearing recess for any signs of wear. Check the armature for grounded circuits by appear or feel good. Drive End Head l Bar edge burning. all of the bars with the handle of a plastic or it should be replaced.GROUP 16 Motors Component Inspection & Trouble Shooting After the motor components have been thoroughly burning or heavy arcing between bars. pressed out of end heads. the armature is Brush and Commutator grounded. 2. Bearings should also be wooden handled screwdriver. they should be inspected for the coloring pattern will be: following: l Streaky film with commutator wear. 3. Good Commutation: A dark uniform coloring pattern at the brush wearing surface. pitted. i. Check brush holder insulation for cracks or any l Discolored brush springs.e. 1. If the test light lights. Check bearing recess for any signs of wear. Feel for binding or gritty effects and 2. 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. signs of burning. threads or broken studs. 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. Although the bearing may . l Ball bearings that have been pulled off of shafts. Armature Bearings 1. which case. Check bearings by turning them with your fin- gers. The brushes and commutator should be inspected for even wear and good commutation. l Discolored brush shunts 2. damaged or removed from dull thud or vibration will indicate a loose barin armature shaft. the armature must be replaced. The cleaned and dried. scored or signs of SM-587 16-3-6 Dec94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Check brush holders and springs for wear. Uneven film. If the bearing turns very freely. Refer to the Brush Chart on page 16-3-11.

5. the Frame and Field As- Jre sembly should be checked for grounded. anopencircuit tocheckshortedandusuallyresults is indicated. Dee 94 Copyrighted Material 16-3-7 SM-587 Intended for CLARK dealers only Do not sell or distribute . rigging. open or shorted circuits. Ifthe bulb fails tolight. If a grounded condition exists. the armature windings is indicated. under coil connections and around ter- minal studs.Motors GROUP 16 4. and remove any copper buildup or filings between commutator bars Open Circuit and at the commutator riser. Grounded and open circuits can be Lights checkedusinga test light. an open or short circuit in the sound and these are no signs of overheating. the strip or condition of all other insulation such as brush blade will vibrate and the blade will get hot. Most commercial growlers incorporate a test light as shown in opposite illustra- tion. Generally. Check commutator bars for any signs of burn. from a dull undercutting tool. Shorted Circuit ing. 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 deep burned sections are evident. either in l Shorted windings in series coils are very diffi- the brush track or on the riser ends of the cult to detect. If a winding is shorted. the serviceability of the coils is ques- l Check for shorted windings by slowly rotating tionable. This l Check between all connecting terminals with condition will cause an armature test leads. coil can be presumed good. Standard Winding Armatures are tested on a Frame and Field Assembly growler (see illustration below) using a steel strip or hacksaw blade to locate any shorted l Check the condition of all insulation. if the coil insulation is commutator bars. Burned or charred insulation is a result the armature in the growler while holding the of coil overheating due to overloading condi- strip or blade so that it passes over each armature tions. insulation on the field coils appears blackenedor charred. groundedor shortedcoil windings. the test light undercut prior to testing. check for will light. Hacksaw Blade TESTING Frame and Field Assembly After thorough inspection. Check core slot. If the windings.

however. Protect brush rigging. the inside of the motor can be given an Bearing Installation additional coat of insulating varnish. the connections tions. connect the solder from the undercutting operation. and tested to the specifica- l Prior to installing thejield coils. Press against the inner race when installing on- lutely clean anddry. 0. Whenever ball bearings are pressed into an end we recommend using a class “H” Polyurethane air head or onto a shaft. trouble shooting. nal operation is to lightly sand the commutator with a fine sandpaper to remove any burrs left l After field coil installation. there is evidence of a grounding condition caused by NOTE the dirt. 2. Red glyptol can be used if a better material is not available. Before spraying field coils. the fi- insulation. 1. Soldering l Resurface the commutator by taking only light guns cannot provide the heat cuts each time. Pole Shoe Screw Removal & Installation (Field Coil Removal & Installation) SM-587 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . The connections should then be tinned with a soldering iron.GROUP 16 Motors FRAME AND FIELD SERVICE NOTES REASSEMBLY If theinside of the motor is exceptionally dirty and Reassembly is the reverse of disassembly.005”. make sure they are abso. This is readily available race that is absorbing the pressure. heads. When testing motors. The motor should be connected as specified in to break. Good solder connections are important due to the vibrationcharacteristicsencountered by thesemotors After Assembly which can cause cold or poorly soldered connections . EndHeads having slip-fit bearings are normally FIELD COIL INSTALLATION retained by a snap ring. always press against the drying insulating varnish. tions must be made at the motor terminals. under various brand names from electrical repair or Press on the outer race when installing into end parts houses in aerosol type dispensers. faces and end head seats to keep varnish off. concentration required and soldering torches can damage the l If re-slotting/undercutting is necessary. joint making sure the solder is flowing properly to avoid a cold soldered joint. pole shoe to a shaft. Always install new snap ring(s). which require soldering should be buffed or . When changing brushes NOTE When changing brushes the commutator must be We do not recommend using a serviced as follows: soldering gun or torch. the voltmeter connec- wire brushed clean to remove any oxidation.

7” (165.75” Forward Vehicle Direction C.W.E.L. Reverse Vehicle Direction Brush Data 1 Brush per Holder 4 Brushes per Motor Min.E. l Minimum Diameter for RESLOTTING: 2.92” C. 583 Motor Specifications l Frame Size: 6.42” (10. (340 gm) Brush Drop Grade: H803 1.D.51 kg) l Internal Bearings are sealed and lubricated with high temperature grease for the life of the bearing.C. Diameter for REPLACEMENT: 2.): 43 lbs.OVolts @ 7 1 Amps Motor Brush Dee 94 Copyrighted Material 16-3-9 SM-587 Intended for CLARK dealers only Do not sell or distribute .W. Length of Worn Brush 0. (825 gm) Max.1 mm) Diameter .67 mm) Max. Motor Insulation l Armature components.Motors GROUP 16 24-Volt Motor Specifications This motor is equipped with Standard Winding Connections and meets latest revision of U. NEW 2. Class H .D. Force per Worn Brush 12 oz. Force per New Brush 29 oz. Commutator Servicing Diameters ROTATION: REVERSIBLE l MaximmDiameter. l Weight (Approx.80” l Min. Class H l Commutator components. (19.

583 Motor Specifications l Frame Size: 6.): 43 lbs.E. Class H ROTATION: REVERSIBLE l Commutator components. Diameter for REPLACEMENT: 2. Fsulation l Armaturecomponents.5” (165.42” (10.92” I Minimum Diameter for RESLOTTING: 2.0 Volts @ 71 Amps SM-587 16-3-l 0 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .L.D.GROUP 16 Motors 36-Volt Motor Specifications This motor is equipped with Standard Winding Connections and meets latest revision of U.80” Min.51 kg) l Internal Bearings are sealed and lubricated with high temperature grease for the life of the bearing. Force per Worn Brush 12 oz. CommutatorServicing Diameters Forward Vehicle Direction Maximum Diameter. Force per New Brush 29 oz. Reverse Vehicle Direction Brush Data l 1 Brush per Holder l 4 Brushes per Motor l Min. Length of Worn Brush 0.W. (19.C. NEW: 2.W.D. Class H C. (825 5) l Max.67 mm) l Max.75” C.E.1 mrn)Diameter l Weight (Approx. (340 5) l BrushDrop Grade H803 Motor Brush 1.

REPLACE SPRINGS. GROUP 16 Brush Inspection Chart REPLACE BRUSH I IF SPRING TENSION IS NOT THE SAME FOR EACH BRUSH.42" REPLACE BRUSHES WHEN WORN TO *_. II I I REPLACE BRUSH IF OIL SOAKED I 0. NEW BRUSHES Copyrighted Material 16-3-l 1 SM-587 Intended for CLARK dealers only Do not sell or distribute .

Pa. to rwnfocing of commutotw and mpid bwsh weor. Con. atching of hailing edgo of rommutotor bar. tar and. spots . Pot- dition is rare bui ton covu flashover if not hked. nl0t. Check the chart below for possible muses. COPPER DRAG.l of condumm per dot. The number of these mork. Carbon Products General Electric Company East Stroudsburg. WATCH FOR THESE DANGER SIGNS STREAKING on the commutator swfoce sipnols Ihe THREADING al tommutm~r whh firmlims rowIts GROOVING b o mechanical condition cowed beg8nnmg of s*rio”s met01 nand*r to Ihe carbon whan lxmsiva mudnansfnoccum h usually kodr by abrasive motwiol in the brush or otmor- brush.. on obnormol build-up of commutator PlYCH BAR-MARKING produces bw w burn. condition of rommutatorr in industry. lf grooves form. GEA-7 COMMUTATOR CHECK CHART FOR COMPARING COMMUTATOR SURFACE MARKINGS SATISFACTORY COMMUTATOR SURFACES LIGHT TAN FILM over entire commutator MOlYLED SURFACE with random film pot. b quite occ. on lh* commutota surfor*. --\ .d to numb.. HEAVY SLOT BAR-MARKING con involve mattiol.. ingr equolr half or all 410 numbw of pohr on the motor. tern b r&ted to number of conductors per dot. start corrective action.ptobfc. BLOT BAR-MARKING. . 18301 Copyrighted Material c Intended for CLARK dealers only Do not sell or distribute . pppmn on bon in o d&k panem preo of efficient and normal commute- ohen seen on (I well-functioning machine. forms most often at Iroiling +* of bar. if uniform. o sfiihdy do&f HEAVY FILM cpn oppeor over entire swfoc* is one of many normal condtionl tam is pmbabfy most heqwdy obrmed fffm. phere.

...... . . . . . .. . . . .. . ..~pria~Handling GROUP 16 Section 5 Pump Motors 24 & 36 VOLT Contents General Information . . . ... . .. ... .. ....... . ... . . . . . . .. ..El!‘!‘RIC lVl. . . .. Mounting Bracket 3/8-24 UNF-2B -1 Dee 94 Copyrighted Material 16-5-l SM-587 Intended for CLARK dealers only Do not sell or distribute . ... .. .. . . . . . . . ... ... . . ... ... . . ... 16-5-3 Motor Disassembly . .. . . . . ... . . ...... .. . . . . .... .. .. .... .. . . .. . . .. . . .. .. . ... ...... . . . ... . . ... ... . .. . .. . 16-5-5 Component Inspection & Trouble Shooting . . . .. .. . ... 16-5-8 Specifications .. . . .. .. . . ... . . .. .... .. . . . . . . .. ...... ... ... ... . ... .-.. .... 16-5-11 24 & 36 Volt Ventilated and Enclosed Motors 3/8-l 6 UNC-2A - Bearing Bearing I . ... . .. .. . ..... . ..... ... .. ... ... .. . . . .... .. . .. . .... . . .. .. . ... ..... ... .... . ... . . .... . . . . .. . . . . .... .... . ... . .... . ... .. . . ... .. .. . .... ..... .... 16-5-8 Motor Reassembly . ...... .. .... . . . .. . .. .. . .. .... . ... ... . ... .. 16-5-9 Inspection Charts ...... . ... . . 16-5-7 Changing Brushes .. . . .. . . . .. .. . . . .. . . .. ... ... .. ..... .. 17 - Name Plate 0 0 Snap -t 112-l 3 UNC-2B A . . ... ... . . . . . . . . . . ... . ... . ... .. ..... . . .. .. . .. .. ... .. .... . . ... . .. . . .. . . . .. .. . ... . . . . . .. ... 16-5-6 Testing .. . ... .. . ......... . . ....... ..... . . ..

Use a Torque Wrench to tighten Terminal Connections. Typical Inch Pound Torque Wrench Pointer SM-587 16-5-2 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Reduce air pressure to 30 PSI (207 kPa). Debris remo2ed with air pressure can cause injury. Remove all Jewelry before working on truck.GROUP 16 Motors A WARNING Wear eye protection and protective clothing when drying with air pressure.

or constant us- material handling. corrective action canbe takenbefore amajor component is damaged beyond serviceability. scored or signs of burning or heavy arcing between bars. Extreme Service: Chemical Processing Freezer Operation Processing Plants (Poultry. Bar edge burning. long-life and trouble-free operations. is related to the time spent making inspections and correcting minor problems as they occur. pitted. If this is done. . Uneven film. Good Commutation: A dark uniform coloring pattern at the brush wearing surface. The brushes and commutator should be inspected for even wear and good commutation. age. Poor Commutation: The surface of the commutator appearing rough. Extended operating hour day of indoor hours. Operating Conditions Operating environment of lift truck motors varies widely: The service frequency shall depend upon the severity of operating conditions. The coloring pattern will be: . Normal Service: Severe Service: Basically an eight. Streaky film with commutator wear. . Meat) Dee 94 Copyrighted Material 16-s-3 SM-587 Intended for CLARK dealers only Do not sell or distribute . Carbon dust bridging between bars. . The key to planned maintenance of the brush and commutator is recognizing undesirable brush and commutator conditions.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 The goal of any maintenance program.

housing. Disassembled View T Bearing Bearing Field Coils & Pole Shoes Housing Commutator End Head Drive End Head SM-587 16-5-4 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . . Remove brushes. Remove the com.GROUP 16 Motors 1. Remove screws from 2. end head. Remove drive end head with bearing.. + 4 3. Remove screws-b drive end from commutator head. pull arma- mutator end head ture out of and . Screw 5. 4.

l Remove the commutator end head retaining screws or bolts. When a puller is used. l Separate the bearing from the end head. Separate the armature and drive end head as an assembly from the frame and field coil assembly. This operation is usually accomplished by press- ing the armature out of the drive end bearing. Pull the brushes out of the brush hold- ers. coupling. then press the bearing out of the end head. Use a brush hook to reach into the motor and lift the brush springs. l Separate the armature from the drive end head. Remove the snap ring. Dee 94 Copyrighted18-5-5 Material SM-587 Intended for CLARK dealers only Do not sell or distribute . l Scribe or center punch locating marks in the end c- heads and the frame. Either position the brushes outside the rush I prin! s motor orremove the brush retaining screws and remove the brushes from the motor. protect the end of the armature shaft with a nut or a thick flat washer. The motors have a slip fit bearing at the commutator end. or spline is damaged when removing the end head. The bearing is retained with a snap ring. Use caution and do not damage the armature. Although locating marks are not always necessary because of locating pins in some motors.Motors GROUP 16 ELECTRIC PUMP MOTORS Disassembly l Remove the cover band (if so equipped) from the commutator end of the motor. l Remove the drive end head retaining bolts or screws. they can save a lot of time when the motor does not have locating pins. the armature or the drive spline usually has to be replaced. The end head and bearing may have to be removed with a puller. If the shaft. and the end head can be removed with very little trouble.

scored or signs of SM-587 16-5-6 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Check brush holder insulation for cracks or any l Discolored brush springs. i.e. gers. Check security of fan. A contrasting armature shaft. Uneven fti. 2. Brush and Commutator The brushes andcommutator should be inspected for even wear and good commutation. threads or broken studs. pages. pressed out of end Most commercial growlers incorporate a test heads. if worn out. 1. Feel for binding or gritty effects and excessive looseness or wobble. Check bearing recess for any signs of wear. Check the armature for grounded circuits by and races must be replaced. Check bearings by turning them with your fin- 1. or side loaded in such a way light as shown in illustration below. NOTE Ball bearings that have been pulled 3. Brushes should be inspected for uneven wear and Commutator End Head signs of overheating. signs of burning. If the test light lights. Check bearing recess for any signs of wear. pitted. Checkmountingholesforanystrippedorcrossed l Carbon dust bridging between bars. A good bearing 2. Bearings should also be all of the bars with the handle of a plastic or changed. the armature must be replaced. Drive End Head l Bar edge burning. off of shafts. Good Commutation: A dark uniform coloring pattern at the brush wearing surface. 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. 0. Thecommutator turn smoothly. 1. Check for grounded circuits using a test light. they should be inspected for the coloring pattern will be: following: l Streaky film with commutator wear. the armature is have been brinelled and will fail grounded. Poor Commutation: The surface of the commu- tator appearing rough. l Discolored brush shunts 2.GROUP 16 Motors Component Inspection & Trouble Shooting After the motor components have been thoroughly burning or heavy arcing between bars. damaged or removed from wooden handled screwdriver. The cleaned and dried. the bearing races ture shaft. 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. Check for loose commutator bars. within a relatively short period of service. Check brush holders and springs for wear. dull thud or vibration will indicate a loose bar in which case. can be checked for loose bars by lightly tapping it should be replaced. If the bearing turns very freely. Bearings Armature 1. Refer to the Brush Chart on the following 3. as to apply pressure on the balls .

under coil connections and around ter- minal studs. the serviceability of the coils is ques- l Check for shorted windings by slowly rotating tionable. either in l Shorted windings in series coils are very diffi- the brush track or on the riser ends of the cult to detect. Check commutator bars for any signs of burn. Standard Winding Armatures are tested on a Frame and Field Assembly growler (see illustration below) using a steel strip or hacksaw blade to locate any shorted l Check the condition of all insulation. grounded or shorted coil windings. If a grounded condition exists. the strip or condition of all other insulation such as brush blade will vibrate and the blade will get hot. the test light undercut prior to testing. insulation on the field coils appears blackenedor charred. Most commercial growlers incorporate a test light as shown in opposite illustra- tion. and remove any copper buildup or filings between commutator bars Open Circuit and at the commutator riser. 5. coil can be presumed good. the armature windings is indicated. Burned or charred insulation is a result the armature in the growler while holding the of coil overheating due to overloading condi- strip or blade so thatitpasses over each armature tions. rigging. 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. from a dull undercutting tool. If a winding is shorted. the Frame and Field As- Jre sembly should be checked for grounded. If the windings. Generally. This l Check between all connecting terminals with condition will cause an armature testleads.anopencircuit tocheckshortedandusuallyresults is indicated. If deep burned sections are evident. open or shorted circuits. if the coil insulation is commutator bars. Dee 94 Copyrighted Material 16X3-7 SM-587 Intended for CLARK dealers only Do not sell or distribute . Hacksaw Blade TESTING Frame and Field Assemblv After thorough inspection. Shorted Circuit ing.Motors GROUP 16 4. Check core slot. Grounded and open circuits can be Lights checked using a test light. Ifthebulbfails tolight. check for will light. an open or short circuit in the sound and these are no signs of overheating.

1. When changing brushes NOTE When changing brushes the commutator must be We do not recommend using a serviced as follows: soldering gun or torch. Red glyptol can be used if a better material is not available. make sure they are abso. concentration required and soldering torches can damage the l If re-slotting/undercutting is necessary. always press against the drying insulating varnish. faces and end head seats to keep varnish off. 2.GROUP 16 Motors FRAME AND FIELD SERVICE NOTES REASSEMBLY If theinside of the motor is exceptionally dirty and Reassembly is the reverse of disassembly. Pole Shoe Screw Removal & Installation (Field Coil Removal & Installation) SM-587 16-5-8 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . and tested to the specifica- l Prior to installing thefield coils. the voltmeter connec- wire brushed clean to remove any oxidation. Whenever ball bearings are pressed into an end we recommend using a class “II” Polyurethane air head or onto a shaft. nal operation is to lightly sand the commutator with a fine sandpaper to remove any burrs left l After field coil installation. Always install new snap ring(s). tions must be made at the motor terminals. the fi- insulation.005”. Good solder connections are important due to the After Assembly vibration characteristics encountered by these motors which can cause cold or poorly soldered connections l The motor should be connected as specified in to break. EndHeads having slip-fit bearings are normally FIELD COIL INSTALLATION retained by a snap ring. which require soldering should be buffed or l When testing motors. 0. trouble shooting. the inside of the motor can be given an Bearing Installation additional coat of insulating varnish. connect the solder from the undercutting operation. the connections tions. Press against the inner race when installing on- lutely clean anddry. Protect brush rigging. This is readily available race that is absorbing the pressure. there is evidence of a grounding condition caused by NOTE the dirt. pole shoe to a shaft. Soldering l Resurface the commutator by taking only light guns cannot provide the heat cuts each time. Before spraying field coils. The connections should then be tinned with a soldering iron. however. under various brand names from electrical repair or Press on the outer race when installing into end parts houses in aerosol type dispensers. heads. joint making sure the solder is flowing properly to avoid a cold soldered joint.

Force per Worn Brush 12 oz.1 mm) Diameter l Weight (Approx.75” Circuit and Rotation l Single Rotation l CCWDE.51 kg) l Internal Bearings on Pump End and Commutator End.80” l Min. Bearings are double sealed and lubricated with high temperature grease for the life of the bearing.5” (165. 583 Motor Specifications l Frame Size: 6. Class H l Commutator components. NEW 2.92” l Minimum Diameter for RESLOTHNG: 2.67 mm) Length l Min. Brush Data l 1 Brush per Holder l 4 Brushes per Motor l Max.42” (10. Class H . + to Battery Positive.L. (19. Force per New Brush 11. GROUP 16 24-Volt Pump Motor Specifications This motor is equipped with Standard Winding Connections and meets latest revision of U.0 Volts @ 71 Amps Motor Brush Dee 94 Copyrighted Material 1 C-5-9 SM-587 Intended for CLARK dealers only Do not sell or distribute . (825 gm) l Max. to Battery Negative. Length of Worn Brush 0.7n n> 7 29 oz.13”(28. Motor Insulation l Armature components. Diameter for REPLACEMENT: 2.): 43 lbs.Commutator Servicing Diameters l Maximum Diameter. . (340 gm) l Brush Drop Grade: H803 1.

42” (10. (340 gm) BrushDrop 1. Length of Worn Brush 0. Motor Counlinz l A coupler is used to connect the motor to the pump. Commutator Servicing Diameters l Maximum Diameter. Diameter for REPLACEMENT: 2. - l to Battery Negative. Force per New Brush 1.): 43 lbs.67 mm) Length-6 l Max.1 mm) Diameter l Weight (Approx.80” l Min. (825 gm) Max. Bearings are double sealed and lubricated with high temperature grease for the life of the bearing.13”(28.0 Volts @ 71 Amps 7 Grade H803 Motor Brush SM-587 16-5-l 0 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Force per Worn Brush 12 oz. Class H CCWDE.L.GROUP 16 Motors 36-Volt Pump Motor Specifications This motor is equipped with Standard Winding Connections and meets latest revision of U. l Commutator components. One half the coupler attaches to the motor and the other half to the pump.51 kg) l Internal Bearings on Pump End and Commutator End.5” (165.92” l Minimum Diameter for RESLO’ITING: 2. 583 Motor Specifications l Frame Size: 6. Class H + to Battery Positive. NEW: 2.75” Brush Data l 1 Brush per Holder l 4 Brushes per Motor l Min. (19.7mm) l l 29 oz. Circuit and Rotation Jnsulation Single Rotation l l Armature components.

REPLACE SPRINGS.Motors GROUP 16 Brush Inspection Chart REPLACE BRUSH v CHECK TENSION OF EACH SPRING IF SPRING TENSION IS NOT THE SAME FOR EACH BRUSH. 0. NEW BRUSHES Dee 94 Copyrighted Material 16-5-l 1 SM-587 Intended for CLARK dealers only Do not sell or distribute .42" 1 REPLACE BRUSHES WHEN WORN TO HERE. BRUSH HOLDER - TIGHTEN SCREW. REPLACE BRUSH IF IF BRUSH PIGTAIL PIGTAIL IS LOOSE IS LOOSE AT THE IN THE BRUSH.

nching of hailing edge of ~ommu+a+or bar. h usually fwdr by abrasive material in the brush or o+mos_ brush. ings wuofs half or all +fta numk of p&r on +fw motor.riow m. Con. mark. appmm onbanin a dafinih panem or. if uniform. If grooves form. pherm.. COPPER DRAG.v for possible cousm. WATCH FOR THESE DANGER SIGNS 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. 18301 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Pot- din is ram but can couw Rashorn if no+ &ted. The numbw of +ft. spo+s -. condition of commu+q+orr in industry.+al nondw to the carbon whan lxcwsiw me+ol hondw occur. forms mos+ okm 01 boiling edgo of bar. Carbon Products General Electric Company East Stroudsburg.r weire surfoc* is one of many nomwl conditions +em is probably mod fmqwn+fy observed fib.s. s+w+ correc+iw action. Pa. +em is r&+ed lo numbw of conductors per Jo+. a sfiphdy darker HEAVY FILM <on oppeor ov.a+ed +o numkr of <onduc+urI par Jo+. nl. is quite accep+abfc. on +fw commu+a+or wfoc*.0 of efficient and normal commvto- ohen seen on a well-funaioning machine. on abnomwl build-up of comnw+&o~ PIYCH BAR-MARKING +x&w bw or burn. HEAVY SLOT BAR-MARKING can involve mottiol. GEA-7 COMMUTATOR CHECK CHART FOR COMPARING COMMUTATOR SURFACE MARKINGS SATISFACTORY COMMUTATOR SURFACES LIGHT TAN FILM ov. Check the chart b4o.r entire commutator MOYYLED SURFACE wf+ft mndom film pat.. +or and. SLOT IAR-MARKING. +o resurfacing of ~ommu+a+w and rapid brush wear.

...l6-7-5 Motor Disassembly ........................................ 16-7-9 Motor Reassembly ...................................................................... ......... 16-7-9 24-Volt Specifications and Brush Data ... .......... Material Handling CMRK Company GROUP 16 Section 7 Auxiliary/Steer Pump Motors 24 & 36 VOLT Contents General Information ..............................................16-7-10 36 Volt Specifications and Brush Data ................................. 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 .............................................................................................................................................................. 16-7-6 Component Inspection & Trouble Shooting ...................................16-7-11 Brush Inspection Chart ....................................... 16-7-8 Changing Brushes ....................................................................................... 16-7-3 Trouble Shooting Prior to Disassembly ........... ..

Always wear Safety Glasses Use a Torque Wrench to tighten Terminal Connections. Typical Inch Pound Torque Wrench Pointer SM-587 Dee 94 Copyrighted Material 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). Remove all Jewelry before working on truck. Debris removed with air pressure can cause injury.

Bar edge burning. The key to planned maintenance of the brush and commutator is recognizing the undesirable brush and commutator conditions. . .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 The goal of any maintenance program long-lifeand trouble-freeoperations is related to the time spent making inspections and correcting minor problems as they occur. Severe Service: Extended operating hour day of mostly hours. Poor Commutation: The surface of the commutator appearing rough. Extreme Service: Chemical Processing Freezer Operation ProcessingPlants (Poultry. Streaky film with commutator wear. Meat) Dee 94 Copyrighted Material 16-7-3 SM-587 Intended for CLARK dealers only Do not sell or distribute . corrective action canbe takenbefore amajor component is damaged beyond serviceability. Good Commutation: A dark uniform coloring pattern at the brush wearing surface. or constant us- indoor or out door age. Carbon dust bridging between bars. material handling. Uneven film. If this is done. w Normal Service: Basically an eight. pitted. scored or signs of burning or heavy arcing between bars. The brushes and commutator should be inspected for even wear and good commutation. The coloring pattern will be: . . Operating Conditions Operating environment of lift truck motors varies widely: The service frequency shah depend upon the severity of operating conditions.

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 .ush Cover f r1 .GROUP 16 Motors e Br.

First touch the motor problem is external to the motor. go to item 3.Motors GROUP 16 AUXILIARY/STEER MOTORS (PERMANENT MAGNET TYPE) The permanent magnet motor differs from conven. Ammeter PoDwcer SUPPlY Dee 94 Copyrighted Material 16-7-5 SM-587 Intended for CLARK dealers only Do not sell or distribute . Do Not Make A ditions then it can be assumed the original Permanent Connection. turn. freely go to item 3. then hold the motor leads on the power supply for a longer time. applied and the shaft running free. TROUBLE SHOOTING PRIOR TO DISASSEMBLY 1 Read the nameplate to become familiar with the enough to observe if the shaft turns. proceed to item 2A. drop or squeeze the motors as this can tional D. separated while doing this. A higher leads quickly to the power supply just long current indicates a faulty armature. If the shaft turns it should be taken apart as described herein. Keep motor leads normal. Do not make motor unfit for further use. If the motor sounds 2 Try to turn the shaft by hand. motors in that the field winding has been cause damage to the ceramic pole pieces and it will replaced with ceramic magnet pole pieces. especially the rated voltage. Obtain a power source to load current. If the motor sounds noisy. If it does motor.C. 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. connect an ammeter in thecircuit as shown below. impact. If the motor turned freely. If the motor meets the above con- produce the rated voltage. Withratedvoltage 2A The shaft could be tight for a number of reasons. If the shaft won’t turn. 3.

GROUP 16 Motors MOTOR DISASSEMBLY . around the commutator and windings. A CAUTION 7. 11.g. tion. Do not pull part way out and release. coverpins out of engagement in motor housing. motor is disassembled. Air clean inside of motor around brushes and armature or the permanent commutator. the stator ring assembly. Disconnect brush assembly lead. SM-587 16-7-6 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . the motor disassembled. if necessary. Caremust be taken when the permanent magnet . If marks are not visible. A CAUTION mutator cover. (motor housing) in any mechanical holding device 8. Loosen motor assembly thru bolts at commuta- Do not place the stator ring tor end of motor and remove bolts from motor. and armature shaft positioned pressed air to remove brush dust and dirt from vertically. Support and hold stator housing firmly on the be held by clamping on the end cover (a second person is suggested). magnets. if this is 1. Remove brush cover band segments by prying and cause severe damage. Remove commutator end cover. carefully pry on cover to loosen. the magnets will pull the cover band. Before disassembling motor. 4. The drive end bearing may now be inspected. These marks will be used motion on the armature be at assembly continuous. (iron. Remove and save bearing spring washer fi-on Observe how brushes are assembled in brush holders. Note position of the brush lead (shunt).. 12. that the armature be removed only with the motor housing . vise) during the dis. housing. Remove any carbon dust or dirt from brush ring should be disassembled in an area free of ferrous assembly. Motor may 10. since it can be distorted. NOTE . it is recommended pressed air. With Using a pry bar. note that there are match marks on the stator assembly housing and the com. To avoid damage to either the 3. steel) metal chips. The armature should be blown off with com. mounting bracket. the cover bore. care Tap lightly on pry bar. Use a brush hook to reach into motor and lift brush springs. must also be taken not to drop 9. Scribe a match mark on drive end cover and (e. Remove pump drive coupling segment from motor shaft end. Remove drive end (pump mounting) cover. Lift brush assembly from brush holder. This fact dictates motors 5. armature back into the stator 2. 6. assembly or assembly opera- . using dry (moisture-free) com. use a scribe It is important that the pulling tool to make match marks. Permanent distortion or other damage will result. Remove the brushes as follows: l Remove brush spring clip from its mounting on top of brush assembly. Loosen and remove clamping screw in brush done. since the magnet pole pieces will attract ferrous metals. Pull armature out of assembly in one quick IMPORTANT motion.

Steer Pump Motor 16.212 Spring Washer. Steer Pump Motor 16.258 Frame.Motors GROUP 16 16. Steer Pump Motor Commutator End 16. Steer Pump Motor 16. Steer Pump Motor Brush Hole 16.: 16. Steer Pump Motor Drive End 16.274 Stator.218 Brush Kit.234 Terminal Kit.209 Armature.258 J STEER PUMP MOTOR 16.208 \ 16 .232 Cover.208 Bearing. Steer Pump Motor Dee 94 Copyrighted Material 1 S-7-7 SM-587 Intended for CLARK dealers only Do not sell or distribute .200 Motor Assembly.211 Bearing. Steer Pump Motor Drive End 16. Steer Pump Motor Commutator End 16.238 Brush Holder Kit. Steer Pump Motor 16.223 Cover.259 Frame. Steer Pump 16. Steer Pump Motor Brush Hole 16. Steer Pump Motor Commutator End Bearing 16.

should also have a small amount of drag or stiffness caused by the lubrication but should 2. Although the bearing may appear l Check the armature for grounded circuits by or feel good. Poor Commutation: The surface of the cornmu- tator appearing rough. damaged or removed from can be checked for loose bars by lightly tapping armature shaft. all of the bars with the handle of a plastic or wooden handled screwdriver. scored or signs of SM-587 16-7-8 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . grounded. Checkmountingholesforanystrippedorcrossed l Bar edge burning. Brushes should be inspected for uneven wear and 2. Feel for binding or gritty effects and Armature excessive looseness or wobble.GROUP 16 Motors Component Inspection & Trouble Shooting After the motor components have been thoroughly cleaned and dried. Good Commutation: A dark uniform coloring pattern at the brush wearing surface. The Drive End Head coloring pattern will be: 1. Commutator End Head l Carbon dust bridging between bars. off of shafts. Check brush holders and springs for wear. Check for loose commutator bars. A good bearing 1. Check security of fan. heads. if worn out. l Discolored brush springs. l Discolored brush shunts 3. Loose com- turn smoothly. Check bearing recess for any signs of wear. Thecommutator changed. the armature is service. 2. pitted. Check for grounded circuits using a test light. Check bearings by turning them with your fin. or sideloadedin such a way Most commercial growlers incorporate a test as to apply pressure on the balls light as shown in illustration below. they should be inspected for the following: burning or heavy arcing between bars. 1. Uneven film. mutator bars will usually be indicated by exces- it should be replaced. signs of burning. pages. gers. Check bearing recess for any signs of wear. Bearings Refer to the Brush Chart on the following 1. and races must be replaced. Brush and Commutator The brushes and commutator should be inspected for even wear and good commutation. threads or broken studs. If the test light lights. the bearing races placing one test lead of the test lamp on the have been brinelled and will fail commutator and the other test lead on the arma- within a relatively short period of ture shaft. A contrasting NOTE dull thud or vibration will indicate a loose barin Ballbearingsthathavebeenpulled which case. pressed out of end 3. l. Bearings should also be sivewearorbumingononebar. Check brush holder insulation for cracks or any signs of overheating. i.e. l Streaky film with commutator wear. If the bearing turns very fi-eely. the armature must be replaced.

5. the final and at the commutator riser. an open or short circuit in the armature windings is indicated. L. Standard Winding Armatures are tested on a NOTE growler (see illustration below) using a steel Bearing Installation strip or hacksaw blade to locate any shorted 1. the armature in the growler while holding the Press on the outer race when installing into end strip or blade so that it passes over each armature heads. Check commutator bars for any signs of burn- ing. Press against the inner race when installing on- to a shaft. Dee 94 Copyrighted Material 16-7-g SM-587 Intended for CLARK dealers only Do not sell or distribute . from a dull undercutting tool. After Assembly . and tested to the specifications. EndHeads having slip-fit bearings are normally retained by a snap ring. If deep burned sections are evident.Motors GROUP 16 4. the strip or blade will vibrate and the blade will get hot. Whenever ball bearings are pressed into an end windings. stator 1. REASSEMBLY Reassembly is the reverse of disassembly. This operation is to lightly sand the commutator with condition will cause an armature a fine sandpaper to remove any burrs left from tocheckshortedandusuallyresults the undercutting operation.alwayspressagainsttherace l Check for shorted windings by slowly rotating that is absorbing the pressure. Lights . and remove any copper buildup or filings between commutator bars l If re-slotting/undercutting is necessary. If a winding is shorted. check for cuts each time. either in the brush track or on the riser ends of the commutator bars.005”. headorontoashaft. Check magnets to be sure they are securely mounted and have no cracks. When testing motors. r Hacksaw Blade 2.Switch WHEN CHANGING BRUSHES / Growler When changing brushes the commutator must be NOTE serviced as follows: Ifthearmaturehasbeenturnedand l Resurface the commutator by taking only light undercut prior to testing. The motor should be connected as specified in Jre trouble shooting. core slot. 0. the voltmeter connec- tions must be made at the motor terminals. Always install new snap ring(s).

l Weight (Approx. .): 43 lbs.92” + to Battery Positive.75” ++ -- Brush Data 1 Brush per Holder 4 Brushes per Motor Min. (19. Diameter for REPLACEMENT: 2. (825 gm) Max.80” l Min. 583 Motor Specifications l Frame Size: 6. Class H.L. Force per Worn Brush 12 oz.0 Volts @ 71 Amps Motor Brush SM-587 16-7-l 0 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .67 mm) Max.GROUP 16 Motors 24-Volt Auxiliary/Steer Pump Motor Specifications rhis motor is equipped with Standard Winding Connections and meets latest revision of U. Bearings are double sealed and lubricated with high temperature grease for the life of the bearing. l Maximum Diameter.42” (10. NEW 2. l Grade: M-8 Magnets l 4-Magnets l 4 Poles MotorInsulation l Armature components. l Minimum Diameter for RESLOTTING: 2. Length of Worn Brush 0.5” (165.51 kg) l Internal Bearings on Pump End and Commutator End. l Single Rotation CommutatorServicing Diameters l CCWDE. to Battery Negative. Force per New Brush 29 oz. (340 gm) Brush Drop Grade: H803 1.1 mm) Diameter . Class H Circuit and Rotation l Commutator components.

583 S Motor Specifications Frame Size: 6.80” . Motor CouDling l A coupler is used to connect the motor to the pump.67 mm) l Max.1 mm) Diameter Weight (Approx.92” . Class H l Single Rotation l Commutator components. (825 gnI) l Max. NEW 2. . Min.51 kg) Internal Bearingson Pump End and Commutator End. Width 1 Brush per Holder .8 mm)1 l 4 Brushes per Motor l Min. Minimum Diameter for RESLOTTING: 2. Length of Worn Brush 0.75” Brush Data . Maximum Diameter. Force per Worn Brush 12 oz. Bearings are double sealed and lubricated with high temperature grease for the life of the bearing.0 Volts @ 71 Amps Dee 94 Copyrighted Material 16-7-l 1 SM-587 Intended for CLARK dealers only Do not sell or distribute . Class H l CCWDE.812” (20. Commutator Servicing Diameters + to Battery Positive. to Battery Negative.L. Force per New Brush 29 oz. Diameter for REPLACEMENT: 2. . Insulation Circuit and Rotation l Armature components. 0.): 43 lbs.5” (165.42” (10.Motors GROUP 16 36-Volt Auxiliary/Steer Pump Motor Specifications This motor is equipped with Standard Winding Connections and meets latest revision of U. (340 gm) l Brush Drop Grade HO03 Motor Brush 1. (19. One half the coupler attaches to the motor and the other half to the pump.

REPLACE SPRINGS. NEW BRUSHES SM-587 16-7-l 2 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .42" 1 REPLACE BRUSHES WHEN WORN TO HERE. BRUSH HOLDER - TIGHTEN SCREW.GROUP 16 Motors Brush Inspection Chart I I REPLACE BRUSH IF SPRING TENSION IS NOT THE SAME REPLACE BRUSH IF OIL SOAKED FOR EACH BRUSH. 0. REPLACE BRUSH IF IF BRUSH PIGTAIL PIGTAIL IS LOOSE IS LOOSE AT THE IN THE BRUSH.

m~innnar. condition of related to number of conduc+ors per slot. HEAVY SLOT BAR-MARKING can involve mote&al. forms most ohen at hailing edge of bar.lopinQ so h7t “ou Mk. and. Con. etching of trailing edge of commuta+or bar. on abnormal build-up of commutator PITCH BAR-MARKING produces low or burned spots -.. appears on bon in a definite pattern areo of efficient and normal commute- ohen seen on a well-fundioning machine. tern is related to number of conductors per slot..“. “hOI i”~pw+on o+ WV-. em”..obondicot.*.ir. . SLOT BAR-MARKING. if uniform. h usually leads by abrasive moteriol in the brush or otmos- brush. Onion..dL.. 18301 Intended for CLARK dealers only Do not sell or distribute . o+ som.” on*m. Carbon Products General Electric Company Copyrighted Material East Stroudsburg. ‘or.” rmditions. The number of these mark. tar and. . d++I. If grooves form. star+ corrective qction.p0. is quite acceptable.“~rrinp can tkprop.ondition.q”. to resurfacing of commutator and rapid brush wear. Check the chart below for possible causes..a. COPPER DRAG. Pa.. GEA-7053 COMMUTATOR CHECK CHART FOR COMPARING COMMUTATOR SURFACE MARKINGS SATISFACTORY COMMUTATOR SURFACES LIGHT TAN FILM over entire commutator MOTTLED SURFACE with random film pat. Pot- dition is rare but can cause Rashover if not checkd. <an worn ywWk.” MaInO” in. a slightly darker HEAVY FILM con appear over entire surface is one of many normal conditions tern is probably most frequently observed film.. CAUSES OF POOR COMMUTATOR CONDITION F. WATCH FOR THESE DANGER SIGNS 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..+I. ings equals half or all the number of poles on the motor. on the ~ommutotor surface. phere. pmdunir.l. Tk.+* commwt* cgn.

.................................. Line & Pump Contactor Illustration ...................................... 17-1-3 Forward & Reverse Contactor Illustration ..........................17-l-9 Control Panel SM-587 Copyrighted Material 17-1-1 Dee 94 Intended for CLARK dealers only Do not sell or distribute ..................................................................... 17-1-4 Parts Inspection ........... Material Handling Cl!!JRK Company GROUP 17 Section 17 Contactors Contents Forward & Reverse Contactor Illustration ............................................................................................................... 17-1-8 Disassembly ............................................................................................................................................. 17-1-2 Disassembly .................................. 17-1-7 lA........................................... 17-1-9 Parts Inspection .. 17-1-6 Reassembly .. 17-1-5 Forward & Reverse Contactor Illustration .................................................... 17-1-9 Reassembly .. .............................................................................................

5 f Support Spring-& L ----.Lock Washel I 8‘2.7 Washer I l. Lock Washer Bolt sclE%v- Q%J. J Bracket (Not Serviceable) Coil Base Forward I Reverse Contactors Dee 94 17-l -2 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . -I Insulator (If Conductor * & =.GROUP 17 Contactors r ---------. ------_-.

Pull insulator and core bushing from core. Do not use sandpaper or file tips. Re.) 12. 8. old ones. 3. (washer. Inspect contact tips. Remove coil from base. etc. Disassemble the contactors. 9. Check armature and movable contacts for free. of support and remove support from vice.). Look for any worn or broken should be replaced with a new one. movable contacts. 15. 5. Hold pressure on Cover (B) to install a new contace set. Disconnect wiring from contactor coil termi. Remove way. Tips must be replaced before they wear through 13. . Any damage armature as it fits into a recess in the bottom of must be corrected by tip replacement. Disassemble the opposite (Reverse) contactor in same manner. Remove Bracket (D) from coil and base. Check for any restrictions to movement and for 10. these parts.Contactors GROUP 17 Forward / Reverse Contactor A WARNING 6. the armature. Remove and discard lower contacts. insulators (C)for ease of reassembly. 21. Inspectforevidenceof any contaminants on tips (paint. Inspect armature core insulators for cracks. seats and spring). There are four screws 20. Press downward on Cover (A) and completely back out cover screws until they are free of the Disconnect battery before contactor base. Remove and discard upper contacts. Replace damaged parts with new ones. Remove assembly fi-om truck. Disconnect connecting buss bars from contacts. etc. location and orientation of each part. carefully observe and then remove Cover (A) from the assembly. Not the position and location ers from contacts. Disconnect power cables from contactors. An insulator found to lx cracked or 2. and damage. tion on page 2. insulators. SM-587 Copyrighted Material 17-l-3 Dee 94 Intended for CLARK dealers only Do not sell or distribute . paper or cloth material. Remove mounting bolts securing Forward & 17. . note dom of movement by depressing movable are location of the buss bars. support sub-assembly (armature. per cover. base plate that is attached to the truck. working on contactor tips. Do not remove cover yet. Hold Bracket (D) with one hand and remove which would impair operation. ing. eroded surfaces. using minimum pressure to hold support. Set cover and screws to one side. Now remove Cover(B) and screws. lockwashers and spac. Loosen cover screwson bothcontactors. 19. Look for evidence of tip weld- 11. 2. Move power cables out of the of each part for proper reassembly. Note location of contacts so the new breaks. Inspect springs for damage. Refer to illustra. contacts and the large with a screwdriver or small rod. Loosen and remove nut freeing core parts 1. Remove and inspect Insulators (C) for cracks retum of parts by action of spring. To remove and replace contact tips: 14. Remove armature core with spring from bottom nals. 4. ReverseContactorAssembly tothecontrolpanel 18. dirt. etc. Again. If parts are found to be damaged. The return spring should come off with the . 16. onesmay be installed to thesame location as the they should be replaced with new ones. Secure support in a vice equipped with soft jaws and damage copper base. Press downward on Cover (B) and disconnect Before attempting to disassemble a contactor screws from base. contacts. spring movebolts with washers. 1. 7.

GROUP 17 Contactors r --------me Lock Washer Bolt s Lock Washer .z E3 7 Washer l. ---------- Conductor p-- Insulator L-_-_--l Bracket (Not Serviceable) Coil Base Forward / Reverse Contactors SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .

to 2. locate white bushing over armature stem and insert armature thru bottom of support position- . 31. bushing becomes “egg” shaped (out-of-round). Be certain the notches in the buss bar coil. Replace damaged parts with new. and stationary contacts properly seat with the screw guides of each contactor support. it should be replaced with a new bushing. upper insulator. aged). Install spring into coil recess. Install both coils onto contactor base. in. Inspect all four places to be certain this thin washer is . 27. in four places to retain the washer. If the from the vice. IMPORTANT 30. Replace damaged parts with new ones. . 29. Be certain the bracket alignment pins wardon thelefthandsideofthereversecontactor properly seat in the holes on the top side of each support. 25. Inspect the small white bushing for wear. opposite page. Movable Contact Assembly over its bracket. Inspect the thin washer located on the armature for cracks. Inspect coil for damage. positioning support over bracket. 23. etc. locate Brackets (0) on each coil and onto the the forward contactor support and extend out- base. Install spring and upper spring seat. Reassemble the contactors. lockwasher and nut onto armature stem. Material on the armature stem has been “up set” ing armature “tab” into support slot.4 N*m). (2. ner. SM-587 Copyrighted Material 17-1-5 Dee 94 Intended for CLARK dealers only Do not sell or distribute . Again. etc. etc. Inspect coil terminals for damage.away from cent of base. . hold the support. Install the long lower buss bar and stationary point outward . upper con- properly retained and free to rotate about the tact.Contactors GROUP 17 Forward / Reverse Contactor-continued. The 28. and security of mounting. armature stem. 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. .0 scoring. be certain the armature “tab”ispointing inward toward the center of the contactor base. Now locate the Reverse Contactor Support and . Now.D. breaks. . Inspect spring seats for damage (cracks. Inspect alignment holes to be certain they are Refer to the boxed illustration on perfectly round and not “egg” shaped (dam. Remove support and movable contact assembly bushing I. must be perfectly round. . . secure the Forward Contactor Assembly Support into the vise using minimumpressure to 22. Terminal connectionsmust 32. 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. Assemble the Reverse Contactor Support and Movable Contact Assembly in the same man- 24. Now locate the Forward Contactor Support and The coil has four blind alignment Movable Contact Assembly over Bracket (D). contactor support The cable end of the buss bar should extend outward on the right hand side of 26.. Inspect the “cone” surface of the armature and IMPORTANT the corresponding surface in the base plate for Torque Nut to: 18 to 20 lb.).

1 Lock Washer Bolt GQ.Lock Washe 8g 7 WasheN Conductor III- ! Insulator k+ Fastener m Lock Washer Insulator Contact Spring Seat Bracket (Not Serviceable) Forward I Reverse Contactors 17-l -6 SM-587 Dee94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .-. Contactors GROUP 17 -- r __---.

SM-587 Copyrighted Material 17-l-7 Dee 94 Intended for CLARK dealers only Do not sell or distribute .. 35. 34. Position Insulators (C) over the buss bar/con- tacts and supports as shown in illustration on opposite page. Make certain the contacts are seated properly in the insulators. Make certain covers. Use a bar or rod to move contacts. 36. Install the short buss bar and stationary contacts (having threaded holes in one end) in the same manner as previously described. upper buss bar/contacts over the insulators. and position the Power Cable Bolts (with lo&washers. and washers) thru the upper buss bar/contacts and spacers.6 to 2.Contactors GROUP 17 Forward / Reverse Contactor-continued- 33. Tighten bolts finger tight into the lower buss bar/contacts.. Assemble spacer. (1.0 Nom). buss bars & contacts are in alignment and press both covers downward with one hand . Tighten cover screws to: 14 to 18 lb. Install Forward &Reverse Contactor Assembly to panel base plate. Be certain the notches in each bar-fit properly to the screw guides of each support. Be certain the opening in the bottom of the insulators face downward and that the insulators are properly seated in the slots of the supports. Check to be sure all parts are in proper alignment. Be sure movement is free of binding and that tips are in correct orientation and tips contact correct mat- ing parts. Assemble covers (A & B). in. hold in this position and install all cover screws until snug. 37. 38. 39.

GROUP 17 Contactors &-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 Dee 94 17-1-8 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .

Be sure return spring is in the tion on page 8. Remove contact studs from cover. Lift armature assembly with movable contact set from coil frame. 2. etc. washer. Inspect contact tips. Put top cover over spring and install cover with a screwdriver or small rod. return spring on top of armature shaft. Inspect for evidence of any contaminants on located properly. 3. To remove and replace contact tips: 1. Remove lock nut. When assembling cover to base 2. Be careful not to disassemble or loose other parts under contact Disconnect battery before tips on armature assembly. Assemble contactor by putting moving contact ti location and orientation of each part. Any damage binding. Look for any worn or (frame) make sure it is installed eroded surfaces. carefully observe 9. 4. in correct orientation and tips . Be certain contact tips are must be corrected by tip replacement. with thepositive sign (+) markings ing. Remove lock nut and lockwasher from each stationary contact stud. Refer to illustra.) Use a bar or rod to move contacts which would impair operation. Removecover.Contactors GROUP 17 I-A.Besure to note locationofspring seat and spring under cover. Line & Pump Contactors 7. Look for evidence of tip weld. insulating washer A WARNING and spring fi-om armature stem. dirt. Tips must be replaced before they wear through contact correct mating parts. paper or cloth material. tips (paint. and be sure movement is free of . and damage copper base. 5. Install new studs and secure with lock washers and lock nuts. working on contactor tips. new contact set onto stem Before attempting to disassemble a contactor and secure with lock nut. dom of movement by depressing movable are 10. assembly armature shaft into coil plunger with 1. Do not use sandpaper or file tips. 6. Observe location of compo- nents upon removal. 8. Check for any restrictions to movement and for IMPORTANT return of parts by action of the spring. . Check armature tid movable contacts for free. cover recess. Observeposition of positive (+) murking on the cover. to mstall a new contace set. SM-587 Copyrighted Material 17-l-9 Dee 94 Intended for CLARK dealers only Do not sell or distribute . Install spring. Tighten lock nuts firmly on each stud. Loosen andremove two cover moun ting screws securing cover to coil frame. mounting screws. contact set.

.................. .. Thermal Protector and Pulse Monitor Trip (PMT).......................................... ...2 Connect the Battery .................................................................3 8 Reach / Retract.............. .............. ......... ...........................3 4 Lift...................1 Material Copyrighted Rev Aug 94 Intended for CLARK dealers only Do not sell or distribute .... ....lO Steering Function (Continued)......................... ..4 0 Reach / Retract (Continued). ..............................4 Close the Key Switch ...........6 Close the Key Switch (Continued) ....... ....................Page OPERATIONAL SEQUENCE #1.... ......................1 2 Brake Switch & Static Return to Off (SRO) Checks......................................... ..................4 2 Tilt....................................... ... ......... .............. ..1 8 Turning 'OFF' the Transistors.......................... .................. ..................... MaterialHandling CMRU Company Group 19 SECTION 2 ELECTRICAL SEQUENCE OF OPERATION Sequence .......5 0 SM-587 19-02..........2 6 Plugging (continued)....3 2 Solenoid Functions.............. ............................ .....2 8 Plugging (continued).... .......... ...................... .1 4 Energizing the Directional Contactors...... ..........16 Turning ON the Transistors.4 4 Tilt (Continued)................ ... .....2 2 1A Contactor Operation....... ........................ ............... .... ........................ .......................... ............4 8 Side Shift (Continued).....2 4 Plugging..... ............................... .................. ..... ................... ............................... Capacitor Charging and Flyback...........8 Steering Function......... ............ ......2 0 Accelerator... ........... .......3 0 Travel Speed Limit................................. ......................3 6 Lower.. ....... .4 6 Side Shift (Optional)......

OPERATIONAL SEQUENCE #l This standard schematic is shown with all switches and contactors in their normal 'OFF' position. The four basic areas of circuitry are identified. TRACTION CONTROL STEER and AUXILIARY CONTROL HYDRAULIC CONTROL ACCESSORY Rev Aug 94 19-02-2 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . No circuits are operating.

. . . -45 45 . . .. . . .. .. . ... .... .. .. . ..._. . .. ... ... 2 ...__.. 12 .. .. ... . ....____. . . 24 . . ... ... .... . ... . 2 . . ...+ 12 ----41 Fp86 t..... ..... . . . .. TB. 0 . .... ... .. . . .??. . cT810 FUNCTION . ..O . . . . .. . .. .... ... * ..... . _NO... .. .. ....... . . ... . .. .... . ..... .. .... . ./.. . .. . .. EVT 15 CARD :... 12 . . I j . .. $ +XE 0 . . .. .. ..... . . . .. .... . _.. .. . . Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .. . . .. . SWITCH>. ...&.%. . . . ..:I .. . . .. . . .. j__. ... . . . .. .. ... .. ......... . .. .____. .. ... .. . .. . . . ....: . . . 6. . . .._.... ... .. .. ... . .... . 2 .. . . . 0 ...‘.. ... . .. 6.. .. .. 58 .___. .____. . . HYDRAULIC lo..... ... . ... . .. 2 .. .. . . ...)* pB. . . .. . . .i _.. .. . . .... . l2 I I . .. .. . . . .. .. .... .. ... . _... . . . . .. . . . li 12 12 12 .... . ....... .. ..3 _.. ... 2 r- I f- ).. . 2.. . .. . .. . ..... .. . ... .. .. .. ._. ...O . ... .___... . .. . .. .. R ~15~------+ 23 ------23 G 1111111111111111__11I 10 12 .. . .. ....+.58 .... . . .z CcnrrRcc ..... .. . .. 2 .... ..... . . . ... ..D CONTROL 12 18 a FUNCTICN .... .. . . ... . . .. .... . ........ . . . . . -. I ... . .. . . .. ... m4 py..._. . ... . ... . . ..

supplies a controlled capacitor charging current through the white wire at terminal PZ-14. and negative through wire #13. The horn is operated by pushing the horn button which will supply battery voltage to the horn through wire #25. J. to the control panel negative cable terminal. The Negative circuit to the accelerator will be completed through wire #13 to the control panel NEG cable terminal. When the 1C capacitors are charged to battery volts. Voltages Present: A. control fuse 2FU and wire #12 on trucks equipped with solid state transducer accelerator. Note: Trucks equipped with potentiometer will not have battery positive connection. Battery voltage across 1C capacitors E. Battery positive on wire #25 J. It is normal for Status Code -51 to be displayed for about 2 seconds during the charging time. Battery positive will be applied to terminal PB-1 of the EV-T15 control card through wire #2. Battery positive on wire #12 Rev Aug 94 19-02-4 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . The accelerator will supply an output voltage corresponding to the handle position through wire #29 to terminal TB-1 of the EV-T15 control card. B. OPERATIONAL SEQUENCE #2 Connect the Battery A. Approximately 3. control fuse 2FU and wire #12 to the key switch. Battery positive D. G. Battery positive F. H. F. D. the flow of the charging current will stop. Battery negative G. when the battery is initially plugged in. The negative circuit will be completed from terminal PZ-3 of the EV-T15 card through the brown wire. The capacitors will charge to battery volts in approximately 2 seconds. The EV-T15 card.7 Volts with handle in neutral H. Battery Positive will be applied to the accelerator through wire #2. to the positive side of the 1C capacitor of the EV-T15 and PS-1C capacitor of the EV-T5PS power steer control. Battery positive B. C. Battery negative C. E. Note: Status Code -51 will be displayed if the 1C capacitors do not charge to above 85% battery volts. Battery Positive is supplied through wire #2. through an internal circuit.

... .. .. . .. .. .._.. 56 . .58 __ _ . . ... 5 .. .... ........ .. . ...... . . 46 1_________. . 0 .......... ... . ...56 I’ ..O_____+ a.*m3 PA6 .... +T6. 5 ....... . .. . ... ... . ..... oTB.... ...... v4_. 4 o . . ... .. . . 26 ._ . +-+...... .. ... ...__... 40. . . ....... ..........3 Pi! : :........ .+ . .. 20 ... . .5 . .. . ...... 26. . . ... .. ... ..... .... . .. ...... ......__. ..... . . ....__.. ... .... 0 . . 0 ..___.a . . .. ... ...~ . .. . ........ .................. .. .....__....* TB.. ..... 5 . 1 TILT * lo. .___.... ... ... .2 pA.20 . 6-----6 .. .. ..... ... ....... t . ...y’ P. .. ... 0 ... . .. 3 6 ...... .... . j... ............ j 23 -23 ‘*Fe5 py5 y---y iP.. ... I.... .J..... 5 .... .... .. .. ...___..._._.. 0 .. .O 61 iL---. ...... ...... _. . ._+r.. ....... ..... ....... .. .............. .. ... i....* p&( PAZ -_I.. . ... 0 .....% .. .. .30 ..... ..__. ..... .. +a SOLEN3lD ........ . 3 __________I____ SL-3 ... ....... 5 ... . . . . ... . . . ..... . .+ .. . .... .. .. ..... ... ........... . ..p... .... .... . . * TBS ... 2 $ ........ .... .. .~ 0 .... ....?.. ... 27 .... ._ _ _.... 34 .13 ............ t....... ... ....... . ..... i. -.... ....... . ...&. .... ._....._ .. .... . &d&%.. ... . {.. ... ... ..... . ..4 o . .... ..._...... . . ... ...._. . ... .S3 . .. . . .___.._ _ _...s m..._.... . .. ST010 P & _________... . .. ....... _L RZbCH 55 .. . .. . ... ......... .. . o ........ ... .. ... . 20 ... 26 ...M P. ..... -45 45 ........ ..Ta. .... ‘.. __.. .... . i. ... 35 ......4 .. I j j----.. .... . ............ ..... ..... . ._..... . ..... . ... .. .! .... . ..... . . ... i i i . ....._ _...... 4.. .. Sk2 .2 i 10--x+ s1 16 16 jlTB6 FUNCTION axrFcL .. .... ... _. .. ... . . 3 . \/: . ._.....* T86 PA3 -... .3 0 i 61 61 SL-1 5 ... . .. ....... ...* TO4 py.. ..... i....... ...._____.. ... . .... ......----__65 _--_-----65-----~~T~... .. .._...______------.. ...55 ..... ..... . . .. ...: ....... ... . .. _....+.... 6 . %. 5 .... 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 ..... ......i... .. . .. .. 0 ..<TB....... ... ..... . .. + .. . .._. ...... . . 3 .. . ...... . .... 8 .... .. ............... ___... .. ......S { _.4.... ... .....3 . ......... 26 ______... 10 -/* IA PB6 pyo JlG i q.??. .. .... ...3 304b ... .B...... .. ... .... +-c ._. ... ... .. 26 .. .. .. 2 o ... . 24 ... 27 ..... : 26 20 ... .j.. P_ PS-IC :... ... ... .. ... ... . ...O .. .. .. ....+_____ 54 ___+. 0 .??... ... ... ... .. . ._.. 2-2-2 s-L’29 - f.. ... .. ... ........... .. . . i30 i i ... . r2 24/M VOLTS .d TBge..._. . .... ..._.I....._. ... 0 . .____.. ... . .. 3 1 AUX2 +______---.._.... ._.. ............. ....?... 26 ... .. ...........A!. 2 o . ...____... ...._. . .. .... .. ._... . .. ...... . ........ 0 _. ./. +. .... 0 ...... . . ... 6.....

OPERATIONAL SEQUENCE #3

Close the Key Switch

A. Closing the Key Switch will supply battery positive to terminal
TB-4 of the EV-T15 control card, Line and 1A contactor coils,
terminal TB-15 of the Solenoid Control, all hydraulic function
switches, Brake Switch, Pump Contactor coil and all solenoid coils
and the Steer Lock Switch through the #lO wires. The card will
check the battery volts at this time to see if it corresponds with
the voltage setting within the card.

Note: Status Code -15 or -16 will be displayed if the battery
voltage is less than or higher than the preprogrammed
battery voltage setting, function #15.

B. The negative circuit to the solenoid control will be completed
through wire #13 at terminal TB-1 of the Solenoid Control card.

C. If the 1C capacitors are fully charged, the EV-T15 control card
will complete the circuit from wire #24 at terminal PB-2 to
battery negative. This will energize the line contactor coil in
turn closing the line contactor power tips.

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.

F. The negative circuit to the steer control will be completed
through the internal black wire connected to the PS-NEG terminal.

G. The EV-TSPS control card will supply a positive voltage through
wire #92 from terminal 4PL5 to the steer transducer's red wire.
The negative circuit for the steer transducer is completed through
it's black wire and wire #91 to terminal 4PL7 of the EV-TSPS steer
control.

Voltages Present:

A. Battery positive on all #lO wires.
B. Battery negative.
C. Approximately 11 volts across the coil.
D. Battery positive.
E. Battery positive.
F. Battery negative.
G. Approximately 15 volts.

Rev Aug 94 19-02-6 SM-587

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
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2. .....................“f
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...................... 35 .............i.:*,,I,~ -13 -13
L-lo _i.,6. ____
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SM-587 Copyrighted
H3RN SWITCH Material Aug 94
Intended for CLARK dealers only
Do not sell or distribute

OPERATIONAL SEQUENCE #3

Close the Key Switch (Continued)

H. The EV-T15 control card checks the battery condition by checking
the battery volts between terminal PB-1 and battery negative. If
the battery is not discharged, the card will supply a voltage
signal from terminal PA-2 through wire #26 to terminal TB-7 of the
Solenoid Control.

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.

Note: Status Code -50 will be displayed if the capacitor
voltage does not remain above 85% battery volts after
the line contactor closes.

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.

Note: If the truck hours exceed the preprogrammed maintenance
reminder hours (functions 19 & 20), a Status Code -99
will be displayed for about 1 second between the 8888
display and the -01 display.

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.

Rev Aug 94 19-02-g SM-587

Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute

BATTERY

r2 *HIwe
2 24136 VOLTS
S FUM?hKITORA

2FU
P \... . .. . .. . .. . . .. . . . .. . . . . . . . . .
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c 10 10 10 ---+TBlS~ ‘26 -26

j-b TB14 Two _..20 .._................... 2. . . . . . . . . . . . . . . . .._..... 1
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___________,O_____+ b------65 ---------65-----~rTB,2

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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

A. Rotating the Steer Tiller turns the Steer Transducer, generating a
pulsed signal. This signal is sent to the EV-T5PS steer control
card through the transducer's white wire and wire #93 to terminal
4PL6.

B. The EV-T5PS card then supplies a gate voltage to the transistor
through the internal red wire turning the transistor 'ON'.

C. Current flows from the battery, through the line contactor,
current sensor, steer motor armature, transistor and back to
battery negative.

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.

E. The current flowing through the steer motor armature interacts
with the magnetic flux of the permanent magnets in the motor
causing the armature to rotate.

F. When the gate voltage to the transistor is removed, the transistor
turns 'OFF'.

G. Because the battery and capacitor no longer have a circuit through
the steer motor, the current stops. This induces a collapsing
magnetic field in the armature coils resulting in a voltage surge.
This voltage, opposite to battery voltage, is applied to the PS-
3REC.

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:

Too quick to measure.

NOTE: If the Brake Switch is open (operator not standing on
the brake pedal) and no signal is received from the
Steer Transducer or Solenoid Control, the Steer Motor
will not start.

Rev Aug 94 19-02-10 SM-587

Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute

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SM-587 KIRNSWITCH
Copyrighted Material Rev Aug 94
Intended for CLARK dealers only
Do not sell or distribute

OPERATIONAL SEQUENCE #4

Steering Function (Continued)

J. Current will continue to flow from battery positive through PS 1c
capacitor to battery negative during the transistor's OFF-time
This current will charge the capacitor back to battery voltage

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:

1. Steer Transducer (Operator Steer demand).
2. PS-Current Sensor (Steering Load demand).
3. EV-T15 Control (Drive Ready signal).
4. Solenoid Control (Aux Hydraulic Function demand).
5. EV-T5PS Thermal Protector.

Note: When more then one signal is present, the highest RPM
demand signal has the- priority on ON-time demand.

L. The internal circuitry in the EV-T5PS card monitors the steer
motor current through the green and yellow PS-sensor wires and the
applied motor voltage through the white/red and white/green wires.
This circuitry will override any of the above first four signals
if the current exceeds a preset Current Limit value (non-
adjustable).

M. The EV-TSPS card monitors the temperature of the transistor
through the internal gray and black wires of the thermal
protector. If over-temperature conditions are detected, the card
will over-ride the percent ON-time control circuit to limit the
maximum current through the transistor.

N. If over-temperature conditions exist, the EV-T5PS card will send
a signal on wire #40 from terminal 4PL4 of the steer control to
terminal PY-9 of the EV-T15 control card. The EV-T15 control card
will sense the signal at terminal PY-9 and display a Status
Code -90 on the Dash Display representing that the steer control
is in thermal cutback.

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:

J. Battery voltage across the capacitors.
K. NA
L. NA
M. NA
N. Battery Negative
P. NA

Rev Aug 94 19-02- 12 SM-587

Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute

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12 12 131
HORNSWITCH
Copyrighted Material Rev Aug 94
SM-587
Intended for CLARK dealers only
Do not sell or distribute

OPERATIONAL SEQUENCE #5

Brake Switch & Static Return to Off (SRO) Checks

A. Stepping on the brake pedal will increase the pressure in the
brake lines and closes the brake pressure switch.

B. Battery volts will be supplied through the #15 wires to terminals
TB-2 & TB-3 of the EV-T15 control card, common terminal of the
directional switches and the directional contactor coils.

C. The control will not allow the truck to start until the following
SRO checks are satisfied:

1) Voltage at terminals TB-2 and TB-3 of the EV-T15 control card
must be greater than 50% battery voltage. (Status Code -01)

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)

3) Checks the accelerator input voltage at terminal TB-1 of the
EV-T15 control card. Must be greater than 3.0 volts. (Status Code
-08)

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.

Note: The battery state of charge is displayed as a 3 digit
positive number dependent on the battery condition, and
the LED above the battery symbol will be 'ON'.

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.

Rev Aug 94 19-02-14 SM-587

Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute

48 .. ..... .TBS ....35 . .. . ...O_. ...... 56 ...______--___. .... ..._..... 26 ______.. ............?....._... 55 ... ......... ..+ TB3 t-10._........... .. ...... y..? ....._.. 56 ... S6 :._....*._..__. . +...... .. . . .... . /..25 .......+a / SOLENOID 12 i FUNCTKN lo-~ s1 16 16 .......___________....___________..........._..?. ....o _____+.._....2. 2FU <\ f.__............ .. .........S._______ j.O_$ .......................+T&4 12 38 ___..... .. 0 -s??!K.....1 I 131 SM-587 Copyrighted Material Rev Aug 94 Intended for CLARK dealers only Do not sell or distribute ...... .. .. *Tm icxzsrrm ....(f i J_e TILT lo. ..._..... 35 . ... . 38 .. 23----23 12 . .............. 55 ..... 24/36 VOLTS mER IFU s WM'PM3TORA ax ......._... .+. ..O _____ d b______65 ^________ 66 _____+Ta.: _~ lo-$ s3 ..66 .3 =I*13 13 12 e-i_ AUX2 ‘.... . ... .-%Ttm P ....___....__.. ...... ..__... 46 .. ... . .!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 . 46 .._.. .......? _....._....... 10 _v4 ........._____....~~~. -45 45 ....._..__..... .. . IFEACH 0 ..._... T6.. n.... ......... 26 ..o _____+... .s j ..... ...

shorted power transistors. (Status code -48) 3) The current sensor is present in the power circuit and the green and yellow wires from the sensor are connected to terminals PZ-12 and PZ-13 of the EV-T15 control card. battery positive will be applied to terminal TB-5 of EV- T15 control card through wire #6. The BV-T15 control card monitors the current flowing through the directional contactor coil circuits. open the normally closed contactor tips and close the normally open tips. This checks for shorted 1A contactor driver. See explanations l-3 above. With the forward switch closed. D. lo-13 volts across the forward contactor coil. the control will be shut OFF. (Status Code -09) D. B. 23 REC or welded forward or reverse contactor tips. Note: If battery voltage is applied to both terminals TB-5 and TB-6 at the same time. Voltages Present: A. C. Moving the multi-function control lever towards the front of the truck will close the forward switch. This will energize the forward contactor coil and in turn. Status Code -23 will be displayed if the current is less than a preset value. (Status Code -46) 2) T2 voltage must be below 88% battery volts. E. Battery positive at terminal TB-5 B. it will complete the circuit from the forward contactor coil to battery negative through wire #27 at terminal PB-4 of the EV-T15 control card. or welded 1A contactor tips. (Status Code -42 or -43) C. NA E. The EV-T15 control will now make the following start-up checks: 1) T2 voltage must be above 12% battery volts. When the EV-T15 control card senses battery positive at terminal TB-5 and 0 volts at terminal TB-6. This checks for shorted forward or reverse contactor drivers. NA Rev Aug 94 19-02-16 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . OPERATIONAL SEQUENCE #6 Energizing the Directional Contactors A. shorted #3 REC.

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B. the line contactor. N/A F. C. F. The EV-T15 control card applies a gate voltage from terminal PZ-4 and PZ-3. Battery positive. The transistors turn 'ON' completing the drive motor circuit to battery negative. to the gates of both transistors. Less than 3. C. Battery positive at terminal PZ-9 (T2). N/A Rev Aug 94 19-02-18 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . through the 1FU fuse. 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. Note: Status Code -24 will be displayed if T2 voltage is less than 88% battery volts. The interaction of magnetic energy between the motor fields and the armature causes the armature to rotate.OPERATIONAL SEQUENCE #7 Turning ON the Transistors A. sensor. the closed directional contactor tips and through the transistors to battery negative. The amount of current flowing out of the capacitors will depend on the percent ON-time of the control. Voltages Present: A. A signal from the accelerator at terminal TB-1 of the EV-T15 control card starts an internal time delay which controls the oscillator in the card. E. through the red and brown wires respectively. Not measurable. Current now flows from the battery. B. E. D. drive motor armature and field windings. D. Current will also flow from the 1C capacitors through the same drive motor circuit to battery negative.5 volts at terminal TB-1. is at battery positive. through the blue wire at terminal PZ-9.

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sensor and armature. The magnetic energy of the drive motor field collapses. Voltage Sequence: Too quick to measure. The current stops flowing because . Rev Aug 94 19-02-20 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . This reverse voltage forces current to flow through the #3 REC. OPERATIONAL SEQUENCE #S Turning ‘OFF’ the Transistors. Note: The purpose of the #23 REC is to filter the generated voltage spikes created by the #3 REC turning 'ON' and 'OFF'. The control now removes the gate voltage and the transistors turn 'OFF'. will be about two to three times as great when operating in the transistor range. Capacitor Charging and Flyback A. continues to drive the armature during the transistor's OFF-time.the battery and capacitors no longer have a circuit through the drive motor. B. compared to battery current. D. This current. Battery current will continue to flow into the 1C capacitors during the transistor OFF-time because the line contactor is closed and the 1C capacitors have been partially discharged. called 'FLYBACK CURRENT'. This current will stop flowing when the 1C capacitors are charged to battery voltage. C. This collapsing magnetic field induces a voltage across the field that is opposite to battery voltage. Note: Average drive motor current.

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Others N/A Rev Aug 94 19-02-22 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . A. If the control is overworked. dropping out (opening) the contactor tips. The control will quickly re-close the proper contactor in a 'LOOK AGAIN' mode and drop out the contactors (PMT) if the problem still exists. 0. E. B. Less than 0. If the transistors fail to turn OFF. To reset the PMT. the truck should be able to reach sufficient speed for 1A contactor operation. Voltages Present: A. A switching technique that controls the pulse rate and/or length of the pulse is used to control the speed and/or power of the truck. 3. The internal oscillator circuit of EV-T15 control card will increase the pulse rate and/or length of pulses as accelerator input signal is decreased. The current sensor continuously monitors the motor current and signals the control to shorten the pulse length during high motor currents. Increased pulse rate and/or longer pulses produces more speed and/or power. The rate and length of pulses is governed by the accelerator and the current sensor. As the control cools. the #3 REC stops conducting. When the transistors are turned ON. B. D. Moving the multi-function control handle farther towards the front of the truck changes (decreases) the accelerator input signal at terminal TB-1 of the EV-T15 control card. Resistance in the TP will increase and reduce the current limit regardless of accelerator position. the transistors and the built-in thermal protector (TP) will get hot.5-4-O volts at creep speed. the TP will automatically return the current limit to the preset value as defined by the C/L setting of the EV-T15 control card. the card opens the circuit from terminals PB-4 and PB-5 to battery negative so the directional contactor coils de-energize. C. The blue wire to terminal PZ-9 of the EV-T15 control card allows the control to sense pulsing.4 volts across the TP is severe cutback. greater than 3. the key switch must be opened and re- closed with the directional switches and accelerator in neutral. Note: Even at reduced current limit during thermal cutback. OPERATIONAL SEQUENCE #9 Accelerator. This reduction in current limit is called 'Thermal Cutback'.5 volts or less at top speed.5 volts across the TP is no cutback. Thermal Protector and Pulse Monitor Trip (PMT) Turning the transistors ON and OFF produces a pulse.

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B. squelching (limiting) the arc at the 1A tips as they begin to open. Moving the multi-function control handle fully forward will signal the EV-T15 control for maximum drive motor speed / power demand. lo-13 volts across the contactor coil terminals. OPERATIONAL SEQUENCE #10 IA Contactor Operation The transistor circuit is capable of delivering approximately 100% of available battery voltage to the drive motor. 0. Voltages Present: A. NA Rev Aug 94 19-02-24 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . The control will continue to pulse until the 1A contactor tips are fully closed as sensed by blue wire at terminal PZ-9 of the EV-T15 control card. This feature of EV-T15 is called a Full Power Transition. When the motor voltage stops increasing. E. The 1A contactor power points (tips) close completing the bypass circuit. Moving the multi-function control handle partially back towards neutral will signal the EV-T15 control card to turn 'ON' the transistors and de energize the 1A contactor. A. C. Turning 'ON' the transistors provides an alternate path (up to current limit) for current to flow and thus. 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. to the 1A contactor coil negative terminal. Note: The EV-T15 has a built in thermal hold-off feature. D. B. After a short time delay. F. NA C. the card starts the 1A time delay. 1~ will not close if the control is in severe thermal cut-back. NA D. F.5 volts or less. For full speed and/or power. E. the card completes the circuit from terminal PB-6 through wire #41. Battery volts across the drive motor. This energizes the 1A coil. The control continuously monitors the change of motor voltage through the blue wire at terminal PZ-9 of the EV-T15 control card. the 1A contactor is closed to bypass the transistor panel and apply full available battery voltage to the drive motor.

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Note: The truck will be coasting forward. While the handle is in it's neutral position. OPERATIONAL SEQUENCE #11 Plugging Controlled plugging (using the reverse power of the drive motor as a brake) is attained when changing direction from forward to reverse (or reverse to forward). The multi-function control handle is moved from forward. D. Rev Aug 94 19-02-26 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . opening the forward switch. B. opening the drive motor circuit. A. The control stops functioning because the voltage has been removed from terminal TB-5 of the EV-T15 control card. The forward and IA contactor coils are de-energized and the contactor tips return to their normal position. C. both the directional switches are open.

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Rev Aug 94 19-02-28 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . The control senses that the truck has been moving and that the handle has been moved through neutral. voltage is applied to terminal TB- 6 of the EV-T15 control card. This will change the drive motor circuits to the reverse direction. J. H. The operator moves the multi-function control handle through neutral to reverse. closing the reverse directional switch. F. 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. The control now gates ON the transistors. open the normally closed contactor tips and close the normally open tips. This causes the plugging logic in the control to take over. With the reverse switch closed.OPERATIONAL SEQUENCE #ll Plugging (continued) E. This will energize the reverse contactor coil and in turn.

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This slow pulsing will bring the truck to a smooth. K. This voltage causes the #4 REC to conduct and thus. Rev Aug 94 19-02-30 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . changing the voltage of terminal Al to positive with respect to terminal A2 of the drive motor. The control also over-rides the 1A timer section and will not allow the 1A coil to be energized during the controlled plugging operation. The voltage polarity at the armature will return to normal and the truck will start to accelerate normally in the opposite direction. The motor armature now becomes a generator because the drive motor fields have been reversed and the armature is driven against the magnetic effects of the field.OPERATIONAL SEQUENCE #ll Plugging (continued) As the transistors are turned ON. N. M. L. provides a path for the generated current. Note: The plugging distance can be controlled by changing (regulating) the position of the multi-function control handle (accelerator). controlled stop. This generated current flows through the current sensor signaling the W-T15 control card to over-ride the main oscillator section of the control allowing only a predetermined slow pulsing. The control is locked into the plugging mode. The control senses that the truck has stopped by monitoring nearly zero current through the current sensor. as defined by the preset 'PLUG' setting of the control card and by the accelerator position. The voltage polarity reverses across the armature of the motor. the truck is continuing to travel in the forward direction because of inertia.

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C. the truck will always accelerate at the normal C/A rate. may accelerate at a slower rate than the normal C/A as defined by the preset 'Speed Limit C/A' setting of the W-T15 control card. The full speed range of the truck is achievable only when the speed limit switches are closed or defeated by presetting the 'Speed Limit' control card settings with the proper values. Battery negative. Approximately 6 volts. A. Voltages Present: A. B. when starting in a speed limit mode.OPERATIONAL SEQUENCE #12 Travel Speed Limit The EV-T15 control is capable of three (3) separate Speed Limit functions. The truck is equipped with at least one speed limit switch on the upright. Raising the upright above the free-lift stage will open the SL-1 speed limit switch. The truck. B. The E!V-T15 control card senses the absence of battery negative at terminal PA-6 and will limit the drive motor voltage as defined by the preset 'Speed Limit' setting of the control card thus limiting the maximum speed of the truck. Note: If the 'Speed Limit C/A' is set at a lower value than the normal 'C/A'. Note: When the speed limit switch is re-closed the truck will revert to the normal operation and speed. C. NA Rev Aug 94 19-02-32 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .

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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. In Operational Sequence #3. TB-5. Terminals TB-3. The solenoid control is connected to battery negative through the #13 wire at terminal TB-1. Note: LED #2 (RH5) of the solenoid control will be turned 'ON' if fault exists. Notes LED #2 (RH5) of the solenoid control will be turned 'ON' if the lift interrupt Is activated. Rev Aug 94 19-02-34 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Battery positive at TB15. Note: LED #1 (RH4) of the solenoid control will be turned 'ON' if fault exists. Note: LED #1 (RH4) of the solenoid control will be turned 'ON' if fault exists. TB-6 and TB-8 must be battery volts for fault not to exist. reach or aux 2 (side shift) switches are closed at the same time. closing the key switch applied battery positive to terminal TB-15 of the solenoid control. TB-6 and TB-8 must be battery volts. TB-4. Note: LED #1 (RH4) and LED #2 (RH5) of the solenoid control will be turned 'ON' if fault exists. Approximately 10 volts. For solenoid coils connected in parallel. Terminals TB-3. C. A. C. the control will not allow any solenoid functions to operate. 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. Note: If any of the hydraulic control switches are closed within 1. lower. both coils must be open to be detected as a fault. Voltages Present: A. See explanations l-4 above. B.5 seconds of closing the key switch.OPERATIONAL SEQUENCE #13 Solenoid Functions The Solenoid Function Control card in conjunction with the EV-TSPS steer control and the EV-T15 control provides for lift. tilt and side shift function control and for lift interrupt. 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. TB-5. extend. retract. Terminal TB-10 through terminal TB-14 of the solenoid control must be at 0 volts. TB-4. B. Battery negative at TBl. 3) Checks for open solenoid and contactor coils or wires anytime that the multi-function control handle is in hydraulic function neutral. 4) Checks for shorted drivers anytime that the multi-function control handle is in hydraulic function neutral.

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This signal will keep the internal hour meter energized during lift operation. B. Battery positive. Battery positive. Current will now flow from battery positive. C. D.2 volts. B. Rev Aug 94 19-02-36 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . battery positive will be applied to terminal TB-14 of the solenoid control through wire #5. E. Pulling the multi-function control lever towards the operator will close the up switch. it will complete the circuit from the pump contactor coil to battery negative through wire #28 at terminal TB-8. through the 1FU fuse. As the operator pulls farther back on the multi-function control lever. 1. C. battery negative at the A terminal. Voltages Present: A. 'close the normally open tips.OPERATIONAL SEQUENCE #14 Lift A. it in turn will rotate the hydraulic pump which will supply oil flow to the main hydraulic lift valve. F. Battery positive at the S terminal. the up switch will open removing battery positive from terminal TB-14 of the solenoid control. 0 volts at TB-14 and battery positive at TB-8. The interaction of magnetic energy between the armature windings and the field coils will cause the pump motor armature to rotate. the now closed pump contactor tips to the pump motor and back to battery negative. The pump contactor will open and the hydraulic pump motor will coast to a stop. Battery positive will be applied to terminal PY-13 of the EV-T15 control card through wire #61. With the up switch closed. F. When the solenoid control senses battery positive at terminal TB- 14. Battery positive. D. This will energize the pump contactor coil and in turn. HYDRAULICS: As the armature rotates. When the multi-function control lever is returned to neutral. the spool valve is opened and diverts the oil to the lift cylinders causing them to extend and raise the forks. E.

.. ___________. ...56 . . ..... .. . ... ...'.. T6. ... .. ... . 30 301 10 " 41-41 i. .. . . . .. .. .. I CI SW587 KX=iNSWlTCH Copyrighted Material 19-262-37 m Rev Aug 94 Intended for CLARK dealers only Do not sell or distribute . .. .3__________ -_. . . . . ..... 36 ..... .+ 10_+ .. . . . ... . PA3 . . .. .S?... ... ... . . ......"f""""""' 46 . .. ...&--___. 0 i *F 15 * 27-27+FS4 PA2 * . 20 . . . . 5* . -_. ..f-. 48 .. . .... .46 .. . .___. . 40 40- t- ISW SWITCH 12 10 15-15 i'T83 PM.. .. . ._.PBG w9*...... . .54 ____k____.. . .. . ... .S?.. ... . . . i :. : i0 61 13 ACCELERATOR H-T 7-i 7 -12-12-12 /.. . 0 _&.4.........._.i .. .. .'... ._i... ._. ... .. . -12 12 . .... .. .S6 ."__~_. SL-3 6 6 . ...o ______..__________... .~. ... .... ..... . . ... ... 15 0 j. .o _____+. . .. . . 0 -&. . ._...... ... 44-13 SL-2 lB-157~62 PA4....~. ...%.... .... ... . 36 .. .. .... .. . . ._. ....T85 .. .____.34 ... ._..~. . .13 --_--___-. . .. . ... . 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.__. . .Ry$q 12y-q-13J 2 2 2 12 10 10 VAL *IA 24-24 i'"2 m*.... .. . .. .... ... ..56 ... .. 26 26 *R 15 " 23-23 1 12 10 1: ..... .. . ..... . ..S5 ___....... .. ...2 o .. . ... .*m PAS.20 ."... .... ....

it will complete the circuit from the Sl (lower) solenoid coil to battery negative through wire #18 at terminal TB-6. The hour meter will accumulate hours independent of lower function. B. Voltages Present: A. Rev Aug 94 19-02-38 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . through the Sl lower valve and the spool valve to the hydraulic sump tank. Battery volts across the solenoid coil. Pushing the multi-function control lever away from the operator will close the down switch. open the oil's path. When the multi-function control lever is returned to neutral.2 volts. the spool valve will be opened and allow oil to flow from the lift cylinders. D. Battery positive. 1. With the down switch closed.OPERATIONAL SEQUENCE #15 Lower A. HYDRAULICS: As the multi-function control lever is pushed further away from the operator. B. C. the down switch will open removing battery positive from terminal TB- 13 of the solenoid control. D. This will energize the Sl solenoid and in turn. The Sl solenoid will open to close hydraulic oil's path. 0 volts at TB-13 and battery positive at TB-6. C. When the solenoid control senses battery positive at terminal TB- 13. The cylinders will retract and the forks will lower. Note : The EV-T15 will not record operating time on the internal hour meter for lower function. if any of the motors is operating while performing lower function. battery positive will be applied to terminal TB-13 of the solenoid control through wire #35.

..... . .. .. 0 -$ ..... . . ...... .. ... .. . .. .: 40 . . ... .. .. 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 i”do c 2 50 :. . . . 38 ... . .~a...4a . . ..... . . ..... .. . . .. . . ... . . . .. .... . +. ACCELE. ... . . .. ... . . ._._.y%?q ‘2~~q-“.S6 . .. ...‘.. ... . . 12 1) ...... /1 2 2 2 r *I. ...___. . ... . 13 ... . .. . . . . .. . . . 1 . . .. ...*Pm Pm.. f .. . . 0 ~_$ ...... +..... I 131 SM-587 Copyrighted H. .... . . .... . PB3 -i 30 12 10 10 ” 24 -24 $Fa2 1:II-I 10 ” AIA 41-41 . ... .s . 4a .A?” 12-12-12 f. . .. . . ... ....... ...)RN SWITCH Material Rev Aug 94 Intended for CLARK dealers only Do not sell or distribute . . . . 50 50 50- 12 i-l0 10 10 c 2 IC EG 12 10 10 2 12 10 10 2 h.! :. . . 15-15yTTB2 ___ . . ._. . . .. . . ... . . . . .__.. ... .. 4” “D ~ ~ ! I 2 0 .T63 . . .

1. D. Battery positive. Voltages Present: A. B. battery positive will be applied to terminal TB-11 of the solenoid control through wire #55. This will energize the S3 solenoid coil and in turn. Battery voltage across the S3 solenoid coil. C.OPERATIONAL SEQUENCE #16 Reach / Retract A.2 volts. Battery positive. When the solenoid control senses battery positive at terminal TB- 11. 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. Depressing and holding the reach button on the side of the multi- function control lever will close the reach switch. open the oil path to reach cylinders. B. Note: The reach switch must be held closed during the entire reach/retract operation. With the reach switch closed. Rev Aug94 19-02-40 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . it will complete the circuit from S3 (aux) solenoid coil to battery negative through wire #38 at terminal TB-4. battery positive will be applied to terminal TB-14 or TB-13 of the solenoid control through wire #5 or wire #35. C. D.

. .34 . .. . il 12 r 10 -10 I-w 10 2 -50 50 .i I 12 c=L ......3c .j . ..... .. .-. . .... ...._. r2 f 2 2 STEER 2FU ILOCK SWITCH _. ..IA *L 41-41 24-24 ids2 :*I?36 .. .o _@ ...P 113 10 " 20 28~T88 10 "" S' 18 ..... .. . . .12 Y SEN- Pi3 Pi Piipi2 Pi6 pi5 STEER wEY c_____________________________-_ _Flx 8WITCH _ 16x7 4PL5 4PL6 4PL1 4PL3 4PL4 4PL2 +r t T ? t 1 I ! 12 i 10 2 yE& gz$ I)1loj” :. SL-3 6 6 . .. .. .w. ._...___13 __________ ___..._. 2. .........1..S6 . p*3 .'i SM-587 Copyrighted HORNSWITCH Material 19-&41 mm Rev Aug 94 Intended for CLARK dealers only Do not sell or distribute ... BPS-TP I r ir 12 2 I PSNEG r . . 2 0 ..4. ...Q __. .&..._______ ___.. ..... .^ 5oA I 12 10 10 2 51 12 10 ACCELERATOR r-i 7 I-t 12 10 I= 10 " ... 61 61 ERAKE EiWITCH SL-1 12 10 15-15 +33 PM.. . ... . .. PY8 l : 30 40 40 30 lo-l0+TB4 PY13 . f 44-13 SL-2 15-15iTw P.. ... TB5 PA5cf______ 54 _______. ... . ... 8 8 r_ 186 27-27+Pe4 PAZ : 26 261 12 10 1:3 I /. 48 . . ... ...... . .....~c . . ....). 2.... . ...

F. H. 0 volts. Voltages Present: E. The EV-T15 control card will stop accumulating time on the internal hour meter because of reach/retract operation. When the solenoid control senses battery positive at terminal TB- 14 or TB-13 and also at terminal TB-11. When the EV-T5PS steer control senses the signal at terminal 4PL2. The S3 solenoid will open to close hydraulic oil's path from the reach cylinders. When the multi-function control lever is returned to neutral and the reach switch is released. if the steer motor is operating while performing reach function. G.12 volts. NA G.12 volts on wire #20. 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. Note : The EV-T15's internal hour meter will accumulate hours independent of reach/retract function. Battery voltage. H. it will send a signal from terminal TB-9 through wire #20 to terminal PA-3 of the EV-T15 control card and to terminal 4PL2 of the EV-T5PS steer control. the reach and up or down switch will open removing battery positive from terminals TB-11 and TB-13 or TB-14 of the solenoid control. The EV-T5PS steer control will reduce the steer motor speed to idle speed or coast to a stop. Rev Aug 94 19-02-42 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . it will turn ON the steer motor at maximum speed.OPERATIONAL SEQUENCE #16 Reach / Retract (Continued) E. 10 . When the EV-T15 control senses the signal at terminal PA-3. F. it accumulates hours on the internal hour meter during the reach operation. J. J. 10 .

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .

Battery voltage across the solenoid coils. C. Note: The tilt switch must be held closed during the entire tilt operation. C. Rev Aug 94 1g-02-44 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . battery positive will be applied to terminal TB-10 of the solenoid control through wire #45. Voltages Present: A. Battery positive. D. With the tilt switch closed.OPERATIONAL SEQUENCE #17 Tilt A. D. 1. This will energize the S3. Depressing and holding the tilt button on the side of the multi- function control lever will close the tilt switch. S5 and S6 solenoid coils and in turn. battery positive will be applied to terminal TB-14 or TB-13 of the solenoid control through wire #5 or wire #35. 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. Battery positive.2 volts. open the oil path to tilt cylinder. B. With the up switch or the down switch closed. When the solenoid control senses battery positive at terminal TB- 10. B. it will complete the circuit from S3 (aux) solenoid coil to battery negative through wire #38 at terminal TB-4 and from S5 and S6 (tilt) solenoid coils to battery negative through wire #48 at terminal TB-3.

. . : 26 261 10 1 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .. ..-_..CARD.. 3 _________.*PEt2 Pl33. . j 44-13 SL-2 15-15yTB2 pA4... TBS . .F%. ... 34 . .__. i .IA 41-41 i*m PYB . . . T03 PI%. I I 10 " *L 24-24 .j 30 10 " . . : 20 20 27-27-a PAZ. 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 . 40 lo-10+TB4 WI3 -61 61 / SL-1 1: 1'0 15-15 j .S. .+____ 54 ___-____..___ 6-6 + T86 PM. i 12cnx-13_J II 29...EVT!.3__________ .. TBI..___ SL-3 6 6 i .

The EV-T15 control card will stop accumulating time on the internal hour meter because of tilt operation. H. J.12 volts.OPERATIONAL SEQUENCE #17 Tilt (Continued) E. Rev Aug 94 19-02-46 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . if the steer motor is operating while performing tilt function. Battery voltage. the tilt and up or down switch will open removing battery positive from terminals TB-10 and TB-13 or TB-14 of the solenoid control. it accumulates hours on the internal hour meter during the tilt operation. When the EV-T15 control senses the signal at terminal PA-3. it will turn ON the steer motor at maximum speed. When the multi-function control lever is returned to neutral and the tilt switch is released. Note : The EV-TlS's internal hour meter will accumulate hours independent of tilt function. it will send a signal from terminal TB-9 through wire #20 to terminal PA-3 of the EV-T15 control card and to terminal 4PL2 of the EV-T5PS steer control. 10 . G. The EV-TSPS steer control will reduce the steer motor speed to idle speed or coast to a stop. When the solenoid control senses battery positive at terminal TB- 14 or TB-13 and also at terminal TB-10. The S3. NA G. F. Voltages Present: E. S5 and S6 solenoids will open to close hydraulic oil's path from the tilt cylinder. J. F. 55 and S6 solenoid coils and the signal from terminal TB-9 of the solenoid control. 0 volts. After a short time delay the solenoid control will remove the voltages from the S3. 10 .12 volts at terminal 4PL2. When the EV-T5PS steer control senses the signal at terminal 4PL2. H.

. . . . . . : ACCELERATOR --. . . . . . . . . .. . . . . . . . . . . . . . : 5 i g . . . . . . TR? . . . . . . . . . . . . . . . . . . . . ai lo-i- 1.YG . . . .i g T_Fm r-3 G : .~ . . . . . . BATTERY r2 bWlk-<( 2 24/36 VOLTS STEER 1FU s WM'PMOTOR /I w" 2FU i%H L lJ----EFl 61- I i 1’61 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. . . . . . . . . . . . . . 61 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 . . . .: . -_ i3 10 1lJ-1()wm PYt3 _:6. . . . . . . . . . . . . . . .

D. 55 and S6. This will energize the S3. C. and S7 and S8 solenoid coils and in turn. B.OPERATIONAL SEQUENCE #I8 Side Shift (Optional) A. With the side shift switch closed. D. 1. With the up switch or the down switch closed. It will also complete the circuit from S7 and S8 (side shift) solenoid coils to battery negative through wire #58 at terminal TB-5. When the solenoid control senses battery positive at terminal TB- 12. Rev Aug 94 19-02-48 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Depressing and holding the side shift button on the side of the multi-function control lever will close the side shift switch. 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. battery positive will be applied to terminal TB-14 or TB-13 of the solenoid control through wire #5 or wire #35.2 volts. Battery positive. battery positive will be applied to terminal TB-12 of the solenoid control through wire #65. Voltages Present: A. open the oil path to side shift cylinder. it will complete the circuit from S3 (aux) solenoid coil to battery negative through wire #38 at terminal TB-4 and from S5 and S6 (tilt) solenoid coils to battery negative through wire #48 at terminal TB-3. Battery positive. B. Note : The side shift switch must be held closed during the entire side shift operation. Battery voltage across the solenoid coils. C.

..__ 23 -23 1: SM-587 Copyrighted HORN SWITCH Material Intended for CLARK dealers only ..... .‘i Rev Aug 94 Do not sell or distribute .PLS 4PL6 4PL1 iPL3 4PL............... L l L 1 1 1 PM PU PLl PI...4PL7 ..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 ---------............ 61 ACCELERATOR --‘*...2 FL6 PL5 STEER r____-_______________‘-_________- SWITCH +_ ........ . 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..__ SL-3 ___-____13 ---------. 4PL2 I? T T T 1 7 1 12 10 2 10 50 1A T2 ..

When the EV-T5PS steer control senses the signal at terminal 4PL2. The EV-T15 control card will stop accumulating time on the internal hour meter because of side shift operation. S6. NA G. if the steer motor is operating while performing side shift function.12 volts.OPERATIONAL SEQUENCE #18 Side shift (Continued) E. The EV-T5PS steer control will reduce the steer motor speed to idle speed or coast to a stop. When the multi-function control lever is returned to neutral and the side shift switch is released. G. it will turn ON the steer motor at maximum speed. After a short time delay the solenoid control will remove the voltages from the S3. 0 volts. Note : The EV-T15's internal hour meter will accumulate hours independent of side shift function. J. and S7 and S8 solenoid coils and the signal from terminal TB-9 of the solenoid control. the side shift and up or down switch will open removing battery positive from terminals TB-12 and TB-13 or TB-14 of the solenoid control. When the EV-T15 control senses the signal at terminal PA-3. S5 and S6. H. J. 10 . S5. H. Rev Aug 94 19-02-50 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . it will send a signal from terminal TB-9 through wire #20 to terminal PA-3 of the EV-T15 control card and to terminal 4PL2 of the EV-T5PS steer control. it accumulates hours on the internal hour meter during the side shift operation. When the solenoid control senses battery positive at terminal TB- 14 or TB-13 and also at terminal TB-12. 10 .12 volts at terminal 4PL2. The S3. F. Voltages Present: E. S7 and S8 solenoids will open to close hydraulic oil's path from the side shift cylinder. Battery voltage. F.

3__________ ____ -15 F -15 "7 ~~~~.&$_5.__________.*pB6 PW l : 40 40- -10 lo-_10+m PY13 .".sMYp&.r__'.O .______. _____+_%____sB --- 10 13 II” 10 10 131 SM-587 l2 &&/ITCH .3__________ __-_ -152-e PA5c.""~ 2 2 2*=1 TBI cf t -10 Y AL 24-24 $PB2 PB3.i 30 30- 12 10 -10 " AlA 41-41 .~~~~: ::r-_i R -15 10 ..3WlTCb I 12 10 -15 15-15 +TEn PA6. . Copyrighted Material & Rev Aug 94 Intended for CLARK dealers only Do not sell or distribute . 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 ~"""""".. t-2 2 24/36 VOLTS STEER 1FU s FuwmToR /I -4 2FU %ki P\ Sl- . 44+13d -15 pn4hf______.34 ___sl..ggr j3 j3 26 2o 13 10 10 __________. ... 61 I3FlAKE 61-------t .54 ___-___.

Material Handling CMRIC Company EV-Tl5 SM-587 19-03-O 1 Sept 93 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .

EVT 15 CARD 2 2 9 PBl POSSIBLE CAUSE *Defective brake switch or no brake line pressure. TB4 of battery receptacle. *Open circuit between battery positive and terminal TB3. /-a . . static return to off (SRO) lock 2 2 -4 PBI out. should be less than 60% of battery volts.Check for loose connections or broken wire between key 15 15 -q TB3 switch and positive side of the brake switch.Check that the brakes are releasing and no air in the brake STATUS INDICATION CRITERIA system. TB2 to be held closed.Disconnect wire #6 at TB5. *Defective oscillator card.Disconnect wire #6 from TB5 and check for short circuit This Status code will be displayed when voltage at TB5 is between TB2 and wire #6. RECALL No -02 CIRCUIT Traction SYMPTOM EVT 15 CARD Forward contactor will not pick up. SM-587 19-03-02 Sept 93 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . STATUS INDICATION CRITERIA . . BRAKE 10 10 -4 TB4 . . SWITCH 4- POSSIBLE CAUSE *Forward directional switch closed on initial power up (closure 10 lo --. STATUS CODE DESCRIPTION MEMORY Forward directional switch is closed on initial power up. MEMORY STATUS CODE inp~ESCR’PT’oN -01 brake switch No No RECALL CIRCUIT Traction SYMPTOM Forward or reverse contactor will not pick up. KEy SWITCH c / . . Measure voltage at TB5.Check for loose connections or broken wire between SWlTCH c brake switch and terminal TB3.Check for mechanical interference in the foot pedal assembly. P *Short circuit between TB2 and TB5. 15 J-6 -4 TB5 . Replace or adjust forward directional switch to insure that it opens when directional handle is returned to neutral. key switch or brake switch). greater than 60% battery volts at initial power up. This Status Code will be displayed when TB3 is less than 50% battery volts.Check for hydraulic leaks in the brake system. 15 15 -4 TB3 *Forward directional switch is welded closed or misadjusted 15 15 --. . I- *Defective brake system. Return directional handle to neutral and then select t forward direction.Check brake switch to insure proper closure.

--------“I 13 - -1s+-&. This status code will be displayed when voltage at TB5 and TB6 are less than 60% of the battery volts.5 . *Defective oscillator card.---6 TB6 LLI . SWITCH + POSSIBLE CAUSE *Reverse directional switch closed on initial power up (closure 10 10 --. static return to off (SRO) 2 2 -4 PBI lock out. CIRCUIT Traction SYMPTOM ACCE!_ERAKR Forward or Reverse contactor will not pick up. EVT 15 CAR0 L--_ . Check forward or reverse switch to insure closure when direction is selected. Return directional handle to neutral and then select k reverse direction. 15d---6 TB5 *Defective directional switch. This status code will be displayed when voltage at TB6 is greater than 60% battery volts at initial power up. . and TBl is less than 2. 15 15 -4TB3 *Reverse directional switch is welded closed or misadjusted to 15 15 -4 TB2 be held closed. DESCRIPTION MEMORY STATUS CODE Accelerator input voltage is below threshold before the FWD RECALL No -06 or REV directional switch closes. Measure voltage at TB6.Disconnect wire #8 at TB6. key switch or brake switch).Check all control wires and connections shown in Figure. should be less than 60% of battery volts. .-A TBl 29kci!!r POSSIBLE CAUSE *Accelerator (transducer / pot) is misadjusted or defective. i *Short circuit between terminals TB2 and TB6. REV 15 --s -4 TB6 -Replace or adjust reverse directional switch to insure that it opens when directional handle is returned to neutral.7 volts with directional handle in neutral. )Open circuit between directional switch(s) and battery positive STATUS INDICATION CRITERIA or between directional switch(s) and TB5 or TB6. volts.STATUS CODE DESCRIPTION MEMORY No -03 Reverse directional switch is closed on initial power up. should be approximately 3. RECALL CIRCUIT Traction SYMPTOM EVT 15 CARD Reverse contactor will not pick up. Adjust or replace accelerator.Check accelerator input voltage at terminal TBl.Disconnect wire #8 from TB6 and check for short circuit STATUS INDICATION CRITERIA between TB2 and wire #8. SM-587 19-03-03 Sept 93 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . 15--/. . Status code disappears when directional handle is moved away swrr~ -/L from neutral to close directional switch. TB4 of battery receptacle. .

r. STATUS INDICATION CRITERIA *Defective oscillator card. .7K ohms.Disconnect wire #29 from TBl._. 15~-----8 TB6 . Replace. For transducer.~ I i -12 13 - EVT 15 CARD POSSIBLE CAUSE *Accelerator misadjusted or defective. STATUS INDICATION CRITERIA *Short circuit from battery positive to TBl.‘* * L--. Voltage should be greater than 4.Disconnect wire #29 from TBI and measure voltage at wire #29 to negative. 15---p. DESCRIPTION MEMORY STATUS CODE No Accelerator input voltage too low on power up after initial RECALL -08 key switch closure or on re-closure of brake switch with sufficient time delay to initiate SRO checks. .8 volts for transducer type accelerator.5 volts. resistance should be greater than 4.. DESCRIPTION MEMORY STATUS CODE Accelerator input voltage too high. CIRCUIT Traction SYMPTOM ACCELERATOR Forward or Reverse contactor does not pick up.. *Short circuit between battery negative and TBl.Check for broken wires or loose connections or open :-..Check accelerator input voltage at TBl.8 volts to less than 0. TBl . if not replace oscillator card. Adjust or replace accelerator to insure that the voltage at TB1 will vary from 3. _.-. should be approximately 3.0 volts. check for open circuit voltage from wire #29 to battery negative.0 volts and either the battery . RECALL No -07 CIRCUIT Traction SYMPTOM ACCaEFATcFl Forward or Reverse contactor picks up but control will not 13 - operate when control handle is moved toward high speed or EVT. This status code will be displayed when the accelerator input voltage at TBl is higher than 3. .Disconnect wire #29 from TBl. .1 status code -07 is displayed then disappears when the vehicle starts to accelerate.._._.2 volts when the control handle is moved into high speed. swrrcH -I. When potentiometer is used.----6 TBS *Open circuit between battery negative and TBl. to negative._. Should be greater than 3.8 volts with handle in neutral. Should be zero volts for potentiometer type and less than 3. Measure voltage from TBl receptacle or key switch has been opened.5cA.. Adjust or replace accelerator. SM-581 19-03-04 Sept 93 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . This status code will be displayed when the accelerator input voltage at TBl is less than 3._..Check for broken wire or loose or corroded connection at WHT / BROWN wire to terminal PZl._.8 volts. . TBl 29 G!!- POSSIBLE CAUSE *Accelerator misadjusted or defective..1 accelerator / voltage supply in the circuit shown in figure.Input voltage at TBl should be less than 3.8 volts.

15 d-6 -e TB5 *Short circuit between battery positive and TB5 and / or TB6. . 1 36 35. *Forward or Reverse directional switch welded closed or mis- adjusted to be held closed.tstoo. Replace or repair battery. Voltage should be less than 60% of battery are greater than 60% of battery volts at the same time.Check battery for proper open circuit voltage as outlined Battery Limit Volts in figure and charge battery if required. MEMORY STATUS CODE Battery vo.Check each battery cell for proper voltage.38 for 36 volt battery).Disconnect wires #6 and #8 and measure voltage at TB5 This status code will be displayed when voltage at TB5 and TB6 and TB6. *Defective oscillator card. figure.95VICell BA-TTERY < *Defective battery. f Nominal Minimum . STATUS INDICATION CRITERIA *Bad wire / connection on terminal PBl. volts. sM-587 19-03-05 Sept 93 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .Check function #15 for proper adjustment for battery being used. 1 CIRCUIT Traction SYMPTOM EVT 15 CARD Forward or Reverse contactor will not pick up.Replace or adjust directional switches to insure that they open when control handle is returned to neutral.95 volts per cell. Repair or replace wire or connection.1 *Incorrect oscillator card adjustment. if not replace oscillator card.) Should be greater than 1. Adjust to proper settings (22 . .4 greater than 1.Check voltage from terminal PBl to battery negative.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.95 volts per cell at initial start up. REV .o~ESCR~PT~oN No RECALL -15 CIRCUIT Traction SYMPTOM EVT 15 CARD Forward or Reverse contactor will not pick up. This status code is displayed when the battery volts are less than 1. STATUS INDICATION CRITERIA . BRAKE SWITCH POSSIBLE CAUSE I.95 volts per cell.STATUS CODE DESCRIPTION MEMORY Both Forward and Reverse directional switches are closed at RECALL bb -09 the same time. should be 24 23. T i . (See table in above . +I1 POSSIBLE CAUSE *Discharged battery. I Volts 0 1.26 for 24 volt battery and 34 .

. 36 43.8 being used. If voltage excessive.Check function 15 for proper adjustment for battery 24 28. Adjust to proper setting (22 . check battery charger for proper output voltage. STATUS INDICATION CRITERIA This status code is displayed when the card type selection value is set to an invalid number. Adjust to proper setting (22 . POSSIBLE CAUSE *Invalid card type selection. STATUS INDICATION CRITERIA . *Open current sensor wire circuit.4 V / Cell POSSIBLE CAUSE *Incorrect oscillator card adjustment.24).40 volts per cell at initial start up.Check battery for proper open circuit voltage per table in figure. greater than 2. (see table in above figure.Check for broken wire (green wire) at weld to current sensor and along length of wire.) . .STATUS CODE Battery vo.2 *Battery over charged or incorrect battery used. -17 i SYMPTOM Forward or Reverse contactors will not close.26 for 24 volt BATTERY battery and 34 .tstoohigDhESCR’PT’ON MEMORY RECALL No CIRCUIT Traction SYMPTOM Forward and Reverse contactor will not pick up.Check function #17 for proper card type. 5x-587 19-03-06 Sept 93 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .Check for loose plug or pin or corrosion at terminal This status code is displayed when the battery volts are PZ12 on the oscillator card.36 for 36 volt battery). Nominal Maximum Battery Limit Volts Volts @I 2. . DESCRIPTION 1 MEMORY STATUS CODE 1 Invalid card type selection.

Status code may BRAKE t alternate between code 23 and code 24. terminal PZ9. 3) Defective F or R contactor coil./-27 F _ 4 PB4 I-- . a) Coil not locked into position.Remove plug B.Check for status code in both directions of truck operation. Repair or replace. Repair. If value not correct. perform code 23 checks. *Open motor circuit . (See status code 23) SWITCH 1. OK and checks for status code #24 OK. . if the problem is not found. w-587 19-03-07 Sept 93 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . if the problem is not found. I--. then replace card.Check for loose or corroded connection at plug or pin at of battery volts and the F and R driver is energized. STATUS INDICATION CRITERIA .F or R power tips fail to close because: 1) Welded normally closed power tips. Complete checks for code 23.Check for open circuit or loose connection in motor circuit from the Al connection to the A2 connection on the control panel and from the Sl connection to the S2 connection on the contactors. I 4) Loose contactor coil assembly. replace coil. Value should be lo-14 ohms. . This status code is displayed when the current draw in the If status code 23 is present in both directions. continuity forward or reverse contactor coil circuit is less than 100 mA. (Less than 88% of battery volts). No -24 CIRCUIT I Traction SYMPTOM Control does not operate. . Complete checks for 24. Repair or replace. 15 -. 4 PB5 check for R coil. This status code is displayed when T2 voltage is less than 88% . POSSIBLE CAUSE *Defective F or R contactor. RECALL No CIRCUIT Traction SYMPTOM EVT 15 CARD Forward or Reverse contactor will not pick up. .STATUS CODE DESCRIPTION MEMORY Forward or Reverse contactor coil current low. perform check for code 24.Check for open circuit or loose connection between PB4 and positive side of F contactor coil and between PB5 and positive side of R contactor coil.Check for open circuit between positive side of F or R contactor coil and terminal TB2. . Gpen circuit in the T2 sensing circuit.Check for broken wire (Blue wire) or loose or corroded STATUS INDICATION CRITERIA connection and / or terminal at T2. . POSSIBLE CAUSE -Defective F or R contactor coil circuit. BRAKE 2) Binding contactor tip or armature assembly. *Defective oscillator card. Check ohmic value from PB4 to positive side of F coil.If above checks are OK and checks for status code #23 are OK. STATUS CODE DESCRIPTION T2 voltage too low. then replace oscillator card. Repair or replace. Make same 15 +L23 . Status code may alternate between code 23 and code 24. *Defective oscillator card.

Voltage may be dropping below 14 volts at terminal PBl when one of the motors is under load. then can only be closed by opening and closing the key switch.STATUS CODE DESCRIPTION Shorted coil driver for Line contactor -26 SYMPTOM Forward or Reverse contactor will not pick up. -27 CIRCUIT I 1Traction SYMPTOM Forward or Reverse contactors open and close. STATUS INDICATION CRITERIA This status code is displayed when the oscillator card power *Defective oscillator card. .Insure that the wire connection at terminal PBl is tight and EVT 15 CARD not corroded. EVT 15 CARD t jKc/ SWITCH I POSSIBLE CAUSE *Defective coil driver internal to oscillator card.Check battery to insure proper state of charge. Charge the battery. supply is less than 14 volts. . 10 -& 24 ----j--o 132 STATUS INDICATION CRITERIA This status code is displayed when there is a shorted Line contactor coil driver.Replace oscillator card. *Loose connection at terminal PBl. .Replace oscillator card. STATUS CODE DESCRIPTION Oscillator Card power supply is less than 14 Volts. SM-581 19-03-08 Sept 93 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . POSSIBLE CAUSE *Discharged battery. .

6 . brake drag and ambient temperature etc._I ._.Check for loose or corroded connection or broken wire between: VI0 wire at thermal protector and PZ2. At room temperature TCONNECTCR (25 C or 75 F) measure resistance between VI0 and WHTNIO wires.. r”-“--” I ITP 1 \ 1 I I I i I I POSSIBLE CAUSE i I I I *Open thermal protector circuit.. replace oscillator card.7‘_“_“_.Check for voltage between terminal PY7 and negative with motor not operating.-. Q WHTNIO wire at thermal protector and PZ5. RECALL No CIRCUIT Traction SYMPTOM No power to traction motor in control range.. . v ._“_.Check for loose or corroded connection at terminal PZ12.-. status code should disappear. Replace transistor if ohmic value is greater than 1300 ohms. EVT 15 CARD .Check for loose connection or broken wire (green wire) l Pi!12 at weld on current sensor and along length of wire. SENSOR ~2 0.--..6 volts.. - POSSIBLE CAUSE Qpen sensor wire circuit to PZ12. RECALL No Cl RCU IT Traction - SYMPTOM Reduced or no power to traction motor in control range.-. STATUS INDICATION CRITERIA control is in thermal cut-back. STATUS CODE DESCRIPTION MEMORY -41 Open Thermal Protector or Control Over Temperature. motor current..-. . 0 0 PZ5 PZ2 OSCILLATOR CARD .8 volts.-.-..-.Disconnect wires from PZ2 and PZ5.Allow control to cool.6 volts with no current flowing in the motor circuit.. Review duty cycle.. 2 Repair or replace as necessary. 5 0 3 5 *Defective thermal protector (part of transistor). SM-587 19-03-09 Sept 93 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . If greater than 1. application._.. I I i. STATUS CODE DESCRIPTION MEMORY -42 Motor current sensor input missing. . STATUS INDICATION CRITERIA This status code is displayed when voltage between PY7 and negative is greater than 1. *Defective oscillator card. This status code is displayed when the voltage between PZ2 and PZ5 is greater than 1.

_.84 volts with no current flowing in motor circuit. replace oscillator card._.. Voltage from T2 to battery negative as measured at terminal PZ9 is less than 12% battery volts.Check for loose connection or broken wire (yellow wire) at weld on current sensor and along length of wire. .84 volts. RECALL Yes -44 CIRCUIT Traction SYMPTOM r”-“-“-’ . ~~-587 19-03-10 Sept 93 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . If less than 0._.-. !. POSSIBLE CAUSE Qpen sensor wire circuit to PZ13._.. No field test is possible._. STATUS INDICATION CRITERIA This status code is displayed when voltage between PY7 and negative is less than 0._. then can only be I r iiy --i i closed by opening and closing the key switch.. j l pz9 PZ4 EVT 15 CARD STATUS INDICATION CRITERIA This status code is displayed when.NG I POSSIBLE CAUSE *Transistors defective...Check for open circuit or loose or corroded connection between the transistors and terminal PZ4 (red wire).-. . I Forward or Reverse contactors open and close.Check for loose or corroded connection at terminal PZ13...Check for voltage between terminal PY7 and negative with motor not operating.-.. Replace transistors. EVT 15 CARD . -._. RECALL No -43 L Cl RCU IT Traction SYMPTOM A No power to traction motor in control range. . .‘2 j ‘--&-’ s 1 I q..._.STATUS CODE DESCRIPTION MEMORY Motor current sensor input missing. i I .Turn-off time for transistors is out of specification. the transistors fail to turn OFF.._. + PZ13 *Defective oscillator card.. DESCRIPTION MEMORY STATUS CODE Transistors did not turn OFF properly.~~~._~ @ . during control operation._. 7 .

._. --J I then can only be closed by opening and closing the key switch.G__. terminal T2 (#3 REC power terminal)._. L.Check for open wire (blue wire) or loose connection at . = ! ! I l.._.Check for corrosion on plug / pin at terminal PZ9.. STATUS INDICATION CRITERIA *Defective transistors.._. . Repair or replace._.. 0 r-. j ._._. This-status code is displayed when the transistors fail to gate ON.PZ9 PZ4 . .Intermittent or open transistor gate.._.-.~_i .-._.. . R .._. Replace oscillator card.. A Forward or Reverse contactor will open and close.I .-_.Check for shorted transistors.~._: .Check for 1A contactor coil being energized due to E’._._.-. then open and I I f 4.. Repair or replace.Check for corrosion on plug / pin at terminal PZ4. ..4 3.. .._. .-4. Replace transistors after above checks show no problem found.) CIRCUIT Traction SYMPTOM ‘A-t/ A Forward or Reverse contactor will not pick up.._. T* i ‘--&J s 1 N33 POSSIBLE CAUSE *Defective transistor circuit.. PZ9 PZ4 . _--_.__x!?__.-. ._..-. STATUS INDICATION CRITERIA This status code is displayed when the voltage at T2 is greater than 12% of battery volts...‘T 15 CARD shorted driver. DESCRIPTION MEMORY STATUS CODE Transistors did not turn ON properly RECALL YeS -45 CIRCUIT Traction SYMPTOM I-“-“-‘-.&..__. SM-587 19-03-11 Sept 93 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . -._._._. *Defective oscillator card.-! P . Repair or EVT 15 CARD replace. POSSIBLE CAUSE . Field test may or may not show defect.-. Repair or replace.~_-_-: f :“--’ JG i *Defective transistor.Check for open wire (red wire) or loose connection between the transistor and terminal PZ4... *Defective 1A contactor. Replace transistors. I 7 I :___-.Check for welded 1A contactor power tips. (Less than 12% of battery RECALL -46 volts. DESCRIPTION MEMORY STATUS CODE I% Look ahead test for T2 volts..

85% battery volts at initial start up. .Check for welded forward or reverse contactor power tips. DESCRIPTION MEMORY STATUS CODE Capacitor volts low after Line contactor closes. RECALL No -50 CIRCUIT Traction SYMPTOM Forward or Reverse contactor picks up. *Defective 1FU power fuse.Check for shorted 3 REC snubber (23 REC).Check for shorted 3 REC. POSSIBLE CAUSE *Defective Line contactor. Repair or replace. .Check for loose or open connection in cables from battery positive to contactor panel positive. . Repair. Forward or Reverse contactor will not pick up. Readjust. STATUS INDICATION CRITERIA *Defective oscillator card. *Defective 3 REC circuit. Replace card.Check for adjustment of steer interlock switch holding Line contactor power tips open. .Check for Forward or Reverse coil being energized due to shorted driver. POSSIBLE CAUSE *Defective forward or reverse contactor. . .Check for open line contactor power tips and / or contamination. STATUS CODE DESCRIPTION MEMORY RECALL No -48 Look ahead test for T2 volts (Greater than 88% battery volts) Cl RCU IT Traction l- SYMPTOM Fg.Check for sluggish operation of forward or reverse contactor. . .Check for loose or open connection in bus bars from 1FU power fuse to Line contactor power tips. STATUS INDICATION CRITERIA This status code is displayed when capacitor volts are less than . Repair or replace. . 34-587 19-03-12 Sept 93 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .Check power fuse for open circuit. This status code is displayed when the voltage at T2 is greater than 88% of battery volts. Control does not operate. Replace.

Check for loose or corroded connection at terminal PBl.Disconnect the positive cable and 4PL plug from the steer control.Check to insure that the steer interlock switch closes after the line contactoh power tips close. . . 34-587 19-03-13 Sept 93 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . If status code disappears. . -Open circuit in capacitor precharge circuit. STATUS INDICATION CRITERIA This status code is displayed when the transistors fail to turn . . STATUS CODE DESCRIPTION Transistors fail to turn OFF during plugging cycle. *Transistors defective. Repair or replace.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. .Check for loose connection or broken wire (BLACK) at 1 FU power fuse or along the length of the wire. 85% battery volts at initial start up. No field test is possible. POSSIBLE CAUSE *Open T2 circuit.Check capacitor bank per component checking section.Check for loose connection or broken wire (WHT) at #3 REC heat sink or along the length of the wire. that are present on the truck have the proper voltage suppression. -Defective steer control. between the transistors and terminal PZ4 (red wire).STATUS CODE DESCRIPTION MEMORY Capacitor volts low before Line contactor closes RECALL No -51 (precharge). . If status code -44 does not appear.Try to operate in opposite direction. Replace transistors. . . including horns. .Check that any and all coils.Check for short from terminal PZ9 (blue wire) to battery negative. check for open motor circuit or intermittent directional contactor power tips. STATUS INDICATION CRITERIA . repair steer control. Repair or replace. then opens and can only close by opening and closing the key switch. . Cl RCU IT Traction SYMPTOM Line Contactor does not close.Check for loose or open connections in capacitor circuit. . Yes -53 CIRCUIT Traction SYMPTOM Forward or Reverse contactor opens and closes. *Misadjusted / defective steer interlock switch.Turn-off time for transistors are out of specification.Check for open circuit or loose or corroded connection OFF during plug cycle. This status code is displayed when capacitor volts are less than *Unsuppressed voltage spikes.Check for loose or corroded connection at terminal PZ14. . POSSIBLE CAUSE *Defective capacitor.

SENSOR A2 POSSIBLE CAUSE *Unsuppressed voltage spikes. No -54 CIRCUIT I Traction SYMPTOM Control will not operate POSSIBLE CAUSE *Defective oscillator card. at the sensor. .Check that any and all external coils that are present on the truck have the proper voltage suppression. -57 SYMPTOM Forward or reverse contactors open and close. truck will not run at all). reverse or 1A contactor coil driver is shorted internal to the oscillator card.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. R or 1A contactor coil driver. is at battery This status code is displayed when the voltage input to positive.Insure that the green wire connects to terminal PZ12 with no open circuits and that the yellow wire connects to terminal PZl3 with no open circuits or loose connections. STATUS INDICATION CRITERIA This status code is displayed when either the forward.STATUS CODE DESCRIPTION Shorted F. EVT 15 CARD . *Reversed yellow and green current sensors wires (if wires are reversed. SM-587 19-03. STATUS CODE DESCRIPTION Current sensor input voltage polarity check.Replace oscillator card. t . STATUS INDICATION CRITERIA Insure that the yellow wire. . terminal PZl2 is positive in relationship to terminal PZ13. *Reversed power cable connection. *~------. then can only be closed by opening and closing the key switch. 4 Sept 93 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . .Insure that the battery negative cable connects to the panel NEG terminal and the motor A2 cable connects to the panel A2 terminal.

Replace dash display / handset. .Check for broken wire(#2) or loose or corroded connection from power fuse to terminal PBl.Check for broken wire (#lo) or loose or corroded L connection from key switch to terminal TB4. STATUS CODE DESCRIPTION MEMORY Maintenance Reminder code. Note: Amount of travel speed reduction is determined by the setting of function #21.Check for broken wire (WHT / BROWN) or loose or corroded connection from key switch to terminal PZl. 10 lo -4TB4 . Truck may run at a reduced speed and status code -99 will flash on the display. STATUS INDICATION CRITERIA . terminals TB4 and PZl of the oscillator card when the key switch is turned ON.Check for open or intermittent key switch. *Open circuit between oscillator card ‘Y’ plug and dash display or handset. . voltage is present between terminals PBl (positive) and PZl (Negative). RECALL No Blank CIRCUIT Traction SYMPTOM Display screen on dash display or handset is blank. -99 POSSIBLE CAUSE Truck has accumulated the number of hours as preset in functions #19 and #20. r DESCRIPTION MEMORY STATUS CODE No display on Dash Display or Handset. F EVT 15 CARD POSSIBLE CAUSE 2 2 PBI PZl *Positive or negative control voltage missing. .If truck does run but no display. check for open circuit or This indicates a lack of voltage to the oscillator card and / or loose connections between each wire between the ‘Y’ plug dash display. . *Defective dash display / handset. Perform required PM maintenance and reset functions 19 and 20 to next desired maintenance hour number. Insure that with the key switch ON.r SWITCH i- . RECALL bb -99 CIRCUIT Traction SYMPTOM -99 status code is displayed for about 3 seconds when key switch is first turned ON. STATUS INDICATION CRITERIA This status code is displayed when the number of accumulated truck hours exceeds the preset maintenance hours as set in function #19 and #20. The EVlOO / EV-T15 handset is required for all function setting changes. SM-587 19-03-15 Sept 93 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . f . Battery voltage must be present between and dash display / handset.

&r&:Handling GROUP 19 Section 4 Oscillator Card Settings Typical Illustration Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .Cl!!lRKWl.

GROUP 19 Oscillator Card AWARNING Drive wheel must be off the floor before any adjustments are made. before A Always wear Safety Glasses Sep 93 1942 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Raise rear of truck and block it on both sides. Typical Illustration Remove all Jewelry working on truck.

F02 Creep Speed 090-110 7.EV-T15 Settings GROUP 19 NPR (24 Volt Truck) EV-T15 Card Factory Settings hnction No.8-3% F03 Controlled Acceleration & 1A Tiie 006-008 - F04 Current Limit 218-222 - F05 Plugging Distance (Current) 135-145 655 .8 Sec.6 .0. C/L w/Speed Limit F18 Steer pump Time Delay 001-003 l-2 Set F19 Maintenance Hours (l=l hour) 050 50 hours F20 Maintenance Hours (l=lOO hours) 002 200 hours F21 Maintenance Speed Limit 000-001 Function Disabled F22 N/A N/A N/A F23 Speed Limit JR Compensation 005 - F24 Speed Limit Comp Start 000-001 Function Disabled F25 N/A N/A N/A F26 N/A N/A N/A F27 N/A N/A N/A F28 Last Fault Flag 016-030 Next Fault Location SM-587 19-4-3 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Description Actual Value Factory Setting FOl Speed Limit C/A 006-008 0.687 Amps F06 1A Drop Out 255 Function Disabled F07 Plug % On Time Adjustment 35-40 - FOS N/A N/A N/A F09 N/A N/A N/A FlO N/A N/A N/A Fll Speed Limit 1 154-156 - F12 Speed Limit 2 000-001 Function Disabled F13 Speed Limit 3 000-001 Function Disabled F14 Internal Resistance Compensation 026 0.88 Volts Drop F15 Battery Volts 024 24 Volts F16 Pedal Position Plug 095-105 - F17 Card Type Selection 022-024 Std.7% .

35% .65% F03 Controlled Acceleration & 1A Time 008-011 0.1.GROUP 19 EV-T15 Settings NPR (36 Volt Truck) EV-TIS Card Factory Settings Function No. F04 Current Limit 218-222 - F05 Plugging Distance (Current) 150-160 - F06 1A Drop Out 255 Function Disabled F07 Plug % On Time Adjustment 35-40 - F08 N/A N/A N/A F09 N/A N/A N/A FlO N/A N/A N/A Fll Speed Limit 1 (up to 270 MPH) 157-159 - Fll Speed Lit l(271 MPH & above) 169-171 - Fl2 Speed Limit 2 000-001 Function Disabled F13 Speed Limit 3 000-001 Function Disabled F14 Internal Resistance Compensation 020 1.856 .24 .14 Volts Drop (up to 270 MPH) F14 Internal Resistance Compensation 026 0. C/L w/Speed Limit F18 Steer pump Time Delay 001-003 1-2 Set F19 Maintenance Hours (l=l hour) 050 50 hours F20 Maintenance Hours (l=lOO hours) 002 200 hours F21 Maintenance Speed Limit 000-001 Function Disabled F22 N/A N/A N/A F23 Speed Limit IR Compensation 005 - F24 Speed Limit Comp Start 000-001 Function Disabled F25 N/A N/A N/A F26 N/A N/A N/A Dee 94 19-4-4 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . F02 Creep Speed 045-055 6.88 Volts Drop (271 MPH & above) F15 Battery Volts 036 36 Volts F16 Pedal Position Plug 095-105 - F17 Card Type Selection 022-024 Std.6.36 Sec.1.024 Sec. Description Actual Value Factory Setting FOl Speed Limit C/A 011-015 1.

................................. 19-5-6 SM-587 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute ...........................t$h\Handling GROUP 19 Section 5 Steering Control Adjustments EV-T5PS Contents Preparation and Safety ..7 ............................................... 19-5-4 Adjustment Steps 6 ............................ 19-5-5 Adjustment Step 8 .................................................. 19-5-2 Adjustment Steps 1 .............................................................5 ................................. 19-5-3 Adjustment Steps 4 ........................................ELRRIC ~...........................3 ..................

Raise rear of truck and block it on both sides. before A Always wear Safety Glasses Dee 94 19-5-2 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Typical Illustration Remove all Jewelry working on truck.GROUP 19 Steer Control A WARNING Drive wheel must be off the floor before any adjustments are made.

Steering Compensation Steer Compensation Trip Pot Current Compensation Steer Control Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . TurnMaxSpeedtrimpotfullyclockwise(CW).Steering EV-TSPS GROUP 19 Steer Control Adjustments SC-POS 1. Turn key switch ON and step on brake pedal. Maximum Speed Trim Pot Current Compensation rypical Illustratiotl Steer Control SC-POS 3. 2. Turn Steer Comp trim pot fully clockwise 0%.

Measure motor out voltage between M+ and M. 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 .GROUP 23 Steering EWT5PS SC-POS 4. Turn Current Comp trim pot fully counter- clockwise (CCW). Steer Compensation Current Compensation Current Compensation Trim Pot lypical Illustration Steer Control SC-POS 5.power terminals on steer control.

6 +/-0. Turn Idle Speed trim pot until motor output voltage is: 9.2 (24~VoltTruck) 13.Steering EWT5PS GROUP 19 SC-POS 6.2 (36-Volt Truck) Idle Speed Trim Pot Steer Compensation Current Compensation Steer Control 7. Rotate Steering Tiller clockwise (CW) or Counter Clockwise (CCW) to the steer stop and hold at steer stop.2 +/-0. SM-587 19-5-5 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .

Remove blocking and lower truck to ground.4 +/-0.GROUP 23 Steering EV-TSPS SC-POS 8. Typical Illustration Dee 94 19-5-6 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .2 (24-Volt Truck) 17.5 +/-0. Turn Current Comp trimpot clockwise (CW) until motor output voltage is: 12.2 (36-Volt Truck) M+ Steer Compensation Current Compensation Current Compensation Trim Pot rypical Illustration Steer Control 9.

Cl!!lRK Wl~~.~~Handling GROUP 19 Section 6 Wiring Diagrams NPR-345 WY TypicalIkstrario~~ SM-587 19-6-lMaterial Aug 93 Copyrighted Intended for CLARK dealers only Do not sell or distribute .

P 26 26 l TB6 10 *6l .lO~~~~~~ .20.. . s . 61)“‘~_““~_~___.lBll 10-I -46 TnT 46 lT8l0 10 . Wiring Diagram Steer Lock Battery Switch \ Accelerator 1 .62 I 10 .64-----d-B.___~~~~~~~.~ ~-~~_~~~~~.67 16 16 *TM ~~~~~~~~~~.24~~-~~n~~~ 12 ____a__ PA6r ---.-r-w.m2 lo-Q=!&6 66 . 1 J PYl3 81 61 I- SL-l_ PM 44 13 - 6L-2 PM. 10 rm Horn Switch ckukMuterialHMdlingco. .17. ~~~.22 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .~-~~r m 10 . NPR 15D.lo-~~---~PL----. 12-m-----* 16-=6 PA3 W W 10 10 10 llB16 l87* -28 28- 10-1k6 6 OTB14 Tm* -20 w 1oyi=... -13 13 ._ 66mm--w-m--w-66-w.lo-~~~~-~L-----.!&26 26-*l813 lm.

_ .P Q- : - . - 6 d I b Lb!% P c- %- Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . ..

Up (Lift )& Down (Lower) Switches and Transducer Adjustments Contents Safety.................... .............. Cable Guides and Switch Side) -)e’ Marking Tapes: IMPORTANT Cables must be positioned with all tape markers aligned with or hidden under clamps or guides.. c PL-9 Aectrical shorts and possible damage to equipment may result.............. .. ............. ........ If you do not......................................~ . ... SO-G Latch plug number with socket number jefore making a connetion... 19-7-7 Multi-Function Control Hand Qble ............................................ 19-7-3 Transducer Adjustment ... . 19-7-4 Forward............... ..... 19-7-2 Switch Adjustments ................... Reverse Switch Voltage Check & Adjustments ........... Arrows must face in direction shown p$TT%F Switch - SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . See below.. ......... .... Clamp Tilt and Auxiliary Switches + guide x Markmg Tape Clamps...................................... GROUP 19 Section 7 Forward & Reverse Switches.

Remove all Jewelry working on truck.GROUP 19 Control Handle A WARNING Drive wheel must be off the floor before any adjustments are made. before A Always wear Safety Glasses Dee 94 19-7-2 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Raise rear of truck and block it on both sides.

. Reverse. Up (Lift) & Down (Lower) Switch Adjustment Objective: Switch must fullv actuate when the roller is at the hiah noint of the cam. 4. Do not over adjust. no load on the forks and drive wheels off floor). Pre-adjust the switches so that the switch lever roller iust touches the low m-ofile of the cam and so that the switch lever. operate the lift pump at a point just before the SM-587 19-7-3 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Tighten the switch mounting bracket screws iust enough to Cam Low Profile allow the bracket to be moved "LID“and “down” bv hand but not so loose that the bracket will move on its own. end of the bracket “up” or “down” as needed to l Battery “unplugged”. is just touching but not depressing the switch plunger that is under the lever. so Reverse Suritch that the switch plunger is being fullv deuressed when the switch lever roller is on the high hartof s’cre the cam. Adjust each switch. l The lower solenoid will not operate until just before the lift valve is in position to start metering hydraulic Step 1 Each switch must be adjusted so that the . the UP (Lift) switch end.) Do not adjust to the point where the switch lever is being bent. IMPORTANT: do not adjust the switch op- erating (turn on) point with the switch screw adjuster. 0 Truck on blocks. 2. This will require moving the switches toward or away from the cam with the screw adjusterandmoving theswitchmounting bracket “up”or “down”relative to the cam. drive wheels off floor. m r Up (Lift) Switch Up and Down Switch Adjustment 1. (The switch lever will be parallel to the switch body. 3. l The lift pump will not operate until just before the lift valve is in position to start metering hydraulic flow to the lift cylinders. with the screw adjuster. Loosen the switch mounting bracket screw on l Upright fully lowered. Move the up switch l Key switch “off ‘. key switch ON.Control Handle GROUP 19 Forward.. ‘Just Touch” The adjusbnent ismude with the adjusting screw of each switch.. Set the truck up in operational condition Truck Condition (battery plugged in.. refer to example.. switch arm just touches the switch plunger with the arm roller in contact with the cam surJace.

TRANSDUCER ADJUSTMENT Step 2 l Measure accelerator voltage at wire #29 on terminal TE31 of traction control oscillator card and battery negative.5 and 6. Tighten the bracket screw described in switch actuation noints. This may be necessary end of the bracket “up” or “down” as needed to because the adjustment of the UP (or Down) operate the lower solenoid valve at a point just switch is changing slightly as you are perform- before the lift valve starts metering flow from ing the adjustment to the DOWN (or Up) cylinder. #I 3 Battery Negative -. Recheck the UP (Lift) and DOWN CLowerl cylinder. Tighten the bracket screw. Loosen the switch mounting bracket screw on time. lowering solenoid valve come on at the proper 5. Check that the adjustments of both switch plung. 8. switch. If the lift pump and Step 1. repeat Step 2. If one or both do not. theDOWN switch end. Move thedown switch. screws without distrubting adjustmenta. repeat Steps 4. If they are not.GROUP 19 Control Handle lift valve starts metering hydraulic flow to the 7. A TBl’ lwl Oscillator Card Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Securely tighten the switch mounting bracket ers are operating as set in Step 2. 6. proceed to Step 7.

50 and 3. Sep 4 l Measure voltage between wires #29 and #13. Usinczthe bodv of the transducer. A CAUTION To prevent damage to wiring: Loosen wires #29 & #13 by pulling them part way thru cam “slot”. slowly rotate body clockwise and then counterclockwise by hand (voltage will increase and decrease as the body is rotated). Note when in this position the wire harness will be on the toI Transducer Wire Harness 1 Transducer Body SM-587 Dee94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .75 volts.Control Handle GROUP 19 Lock Nut l TLUTI key switch ON. This is know as the “neutral point” OI maximum accelerator voltage position. Do not rotate the body to the extent thal wires are pulled out (or damaged). Stop rotation when voltage registers between 3. l Loosen Lock Nut holding transducer to mounting plate. DO NOT STEP ON BRAKE PEDAL.

Verify acceleratorvoltageis between 3. tighten Lock Nut securing transducer in position.GROUP 19 Control Handle itep 5 l With transducer at the “neutral point”.75 volts and..20 volts.50 and 3. 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. . r / Forward Switch Reverse Switch 19-7-6 SM-587 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Verify accelerator volts are less than 0.

lsdII Capacitor SM-587 19-7-7 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . see below. Battery Negative TB6 Wire #F T2 TB5_ Wire #6 .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.

GROUP 19 Control Handle Step 8 l Step on brake pedal.seeoppositeillustration. k. m n Capacitor l-l-l- TB6 7 Wire #8 \ TB5 Wire #6 ’ / TBI _/ Wire #29 Step 9 . Move control handle to neutral posi- tion. If voltage at one and/or both wires is battery volts. wire #8 and wire #29 with respect to battery negative (wire #13). Measure directional switches and accelerator voltages at wire #6. NOTE Adjusting the screw counterclockwise will operate the switch closer to neutral posi- tion of the control handle. Adjusting the screw clockwise operates switch further away ww from neutral position.Direc- tional switch voltage at wire #6 and wire #8 must be zero (0). Dee 94 19-7-a SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Battery Negative --. turn the “adjustment screw(s) as required to open (deactivate) the forward and/or reverse switches.

Reverse Switch SM-587 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . hold handle in this position. When switch oper- ates. l Now. Step IO l Move control handle extremely slowly to operate the forward switch. hold handle in this position. When switch oper- ates. verify forward switch voltage is battery volts (measure voltage at wire #6). l Now. l Monitor and note “specific accelerator voltage” corresponding to forward switch operating po- sition.Control Handle GROUP 19 ForwardandReverse Switch Adjustment-continued.40 and 3. verify forward switch voltage is battery volts (measure voltage at wire #S). This accelerator voltage (wire #29) must be between 3. This accelerator voltage (wire #29) must be between 3. l Monitor and note “specific accelerator voltage” corresponding to reverse switch operation posi- tion.60 volt.60 volts. Forward Switch Step 11 l Move control handle extremely slowly to operate the reverse switch.40 and 3.

as required to obtain “specific accelerator voltage” of 3. Forward Switch Reverse Switch Adjustment Screw AdJustmentScrew Step 13 l Plug in connectors.60 volts (+O.GROUP 19 Control Handle Step 12 To adjust actuation (operating) positions of Forward and/or Reverse Switches: l Rotate the adjustment screw(s). Dee 94 19-7-l 0 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .40 .40 to 3.60 volts corresponding to the actuation positions of both switches.3. The voltage measure at the “actuation moment “of each switch must be 3.OSvolts apart maximum).

....... ................ .. 19-8-2 Inspections . ............ .................. 19-8-4 Always wear Safety Glasses Remove all Jewelry before working on truck Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . ... .. ............... ................................................................................................. GROUP 19 Section 8 Periodic Electrical Checks Contents Preparation ...

Remove Front Console Cover . . . .GROUP 19 Periodic Electrical Inspection 1. . Move truck to service area. Tilt forks forward until fork tips touch the floor. Fully lower pantograph. Carefully lift cover a little forward and upward until the cover is free of the control. Slip boot off cover lip and tuck bottom of boot into cover hole. Front Console\ Cover \ Dee94 19-8-2 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . l Remove key. . l Disconnect truck battery. 2. . Turn key switch off. 3. Park truck on a flat level surface. Remove fasteners securing cover to truck. Extend pantograph.

Periodic Electrical lnpsection GROUP 19 . Discharge the CaDacitors Discharge Capacitors . A WARNING Discharging the capacitors without using specified resistor could cause serious injury to yourself and bystanders. 10 watt resistor connected between the Positive and Negative power terminals on the SCR control. SM-587 19-8-3 Dee94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Remove console cover from truck. 4. Hold the resistor in place for 2 seconds before removing. A CAUTION Using a shorting device without a “resistorload”could cause damage to the control. Discharge capacitors using a 100 ohm. Be sure the battery is unplugged. .

Cable (Steer Control Neg.semble Back-to-Back TC-NEG.) TC-NEG. must be adhered to or equipment damage may result. when install- Match the plug number with the appropriate ing a wire harness or electrical cables. When (Socket/Receptacle) number for easy identification.e. Cable (BAT. s must face in direction shown. receptacle number before making a connec. clamps. electrical shorts and possible damage to the equipment may re- sult.GROUP 19 Periodic Electrical Inspection 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. Be sure to follow the A CAUTION instructions. possible electrical shorts and control damage may result. correctly installed. If you do not. - L-Tape Marker (Stamping: DT06-6P) PL-6 Plug I Pin(s) (Used on Wire Harness’s and Power Cables) (Stamping: DT06-6S Torque specifications (where noted) for mounting hardware. If the instructions are not specifically followed. Assemble Front-to-Front . etc.. If you do not. where notedinthis manual. Cable (Pump Motor “A”) TC-NEG.) ire 13C & 13D (Main Harness) EXAMPLE e 13B (Main Harness) Dee94 19-8-4 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . the tape marker will be hidden by the mounting clamp (guide).NEG. i. Special Instructions have been illustrated to show proper installation of multiple cable and wire connections. Plug #PL-6 plugs into pin socket SO-6. etc. ossible shorts and equipment damage may result. tion..

Periodic Electrical lnpsection GROUP 19 Power Cables l Cables having small cuts in the casing may be r Repairable Damage {n\ repaired with electrical tape. Subsequently. Cable unfit for further service. A shorter cable or harness will not fit. size and has the proper connector. l Cables having damage as shown in illustration below should be removed immediately and re- placed with new. Be certain the replacement cable is the exact same length. Make absolutely certain the cable end is properly crimped and its connection properly torqued upon installation. or if it is routed incorrectly. electrical shorts and damaged components may result if the replacement part is the wrong one. If either a harness or cable is routed improperly. it will not fit. Everycableand wiring harness Power Cables having small on this truck is manufactured to an exact specification. Broken Wires -I SM-587 19-8-5 Dee94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .

Typical Inch Pound Torque Wrench Pointer Typical Foot Pound Pivoted Torque Wrench Scale Handle Pointer 19-8-6 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .GROUP 19 Periodic Electrical Inspection 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.

Cables & Wiring l Make sure wire connections are secure. l Check wiring for damage. Replace as required.3 N-m) / m Clamp 5ii?IMPORTANT lamps must be Terminal Barrels lositioned so al must face opposite -APE MARKERS each other. 5iiiiir (11.lamp guides. SM-587 19-8-7 Dee94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . able (or) (Pump Motors) / . .re aligned witk lr hidden under 3e clamps 01 . l Check harness clamp/guides for secu- rity of mounting. Cable (Steer Control Negative) Buss Bar Wire 13C & 13D (Main Harness) e 138 (Main Harness) 1 \ \ -TC-P Cable. you may experience shorts and component damage. ressure If they are not installed as illustrated here. in. Be certain the clamps and harness are installed as shown. l Be certain power cables are tight and installed properly as illustrated here. in. TC-NEG. Wire Harness L Torque to: 100 lb.Periodic Electrical lnpsection GROUP 19 Assemble Front - Torque to: 100 lb. A! CAUTION Wire harness. clamps (guides) and terminal connections must be installed exactly as shown.

Dee 94 19-8-8 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . l Be certain the steering control and control card are securely mounted. I l Be certain all terminal connections are tight and properly installed on the solenoid control card.ougged in and theat the wiring Main Harness is in good condition.GROUP 19 Periodic Electrical Inspection 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 l Check steering control connection PL-4 to be cy Q sure it is securely .

sockets and wiring for damage. l Inspect wire PL-DP for security of mounting and damage. l Check Key Switch for security of mounting. Repair or replace damaged wires.GROUP 19 Periodic Electrical Checks NOTE Connect PL-DP to Display Unit prior to assembling to bracket. l Inspect wires 12 & 12B and 10A & 10 for security of mounting and damage. l Check the display unit for security of mounting and damage. Inspect Plug & Socket Wires for damage. l Check plugs. Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . cuts (exposed wire). Replace damaged components with new.

screws and C-rings).Replace any that are damaged. Cable Guides and Marking Tapes: IMPORTANT Cables must be positioned with all tape markers aligned with or hidden under clamps or guides.). Inspect wiring for damage (cuts. l Check the handle mounting bracket for security of mounting. Refer to following mounting.). Make sure the harness Marking Tape page for detailed drawings. is in alignment with or covered by the clamp. Report condition on the PM check sheet and damage. Check to be give to the designated authority. etc. replace as required. Multi-Function Control Handle l Inspect wire and harness clamps for security of damage and proper installation. . Plug (or Socket) Housing l Inspect handle switches for damage (Reach. l Inspect all connectors (plugs and sockets) for Dee 94 19-8-l 0 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . The bracket must be adjusted so the handle is vertical and in line with the hydrau- lic control valves. l Check security of all mounting fasteners (bolts. Repair or This assures the harness is correctly positioned. Replace any that are miss- ing or damaged. l Inspect the multi-function control handle for . sure thefasteners on the switch and heel sides of the handle are secure. Seal should be pressed flush with housing. Make certain the mounting bolts are tight. The handle has two halves.Periodic Electrical Checks GROUP 19 z 6 hrkrng -Clamp Tape or Guide Clamps. ALIX. / . Tilt.

condensation. l Check seals for damage that would make them unfitforfurther service(cuts. There is a pin retainer plate in the socket sub-assembly. L ----. etc. Check the plates for damage and security of mounting. see above.GROUP 19 Periodic Electrical Checks IMPORTANT Typical Panel Firmly push plug into socket until xeptacle & PI latch “clicks” locking the two com- Assembly ponents together. The plug is equipped with a seal and pins and their sockets.).I ’ ing. retainer plate. Make certain Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . 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. Ass$mbly Rubber Seal ----- r IMPORTANT 1 I End Seals must be 1 1 firmlysaatedwithin 1 I theassembly hous. There is a seal at each end (wire end) l The retainer plates snap into place to secure the of the connector.

Cables mIlnt he rmltd ac chnwn Dee 94 19-8-l 2 SM-587 Copyrighted Material Intended for CLARK dealers only 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 TC-NEG.yut to: 100 lb. Torque. Cable l Ifanyconnectionsare TC-NEG. Cables must ue to: 100 lb. in.3 N-m) . Cable found to be loose. be Steer Control Negative sure to torque them to Wire 13C & 13D (Main Harness) e 138 (Main Harness) nections on the pump motorandcontactorpanel for damage and security of mounting. Guides and Markin! IMPORTANT Cables must be positioned so all tape markers are aligned with or hidden under clamps or guides. -4 _ (11. in.

rorque Cable Mounting Nuts to: 100 Ib. (11.3 Nom) Cable (or) Wire Harness IMPORTANT Clamps must be positioned so all TAPE MARKERS are aligned with or hidden under the clamps or clamp guides. (16.GROUP 19 Periodic Electrical Checks l Inspect power cable connections on the drive motor and the contactor panel for damage and security of mounting.. Tighten connections to the torque specified./ /” Torque Motor Cable Fasteners Cables must be routed as shown.9 N-m) 19-B-l 3 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .in. ‘Q. Replace damaged parts.in. to: 150 Ib.

_ Pa”e.) motor for damage and connections to the torque specified. (11. Tighten the power steering (aux. -% TC-NEG.NEG. Typical Illustration Cables must be installed as shown . Rttrs Rar I .Periodic Electrical Checks GROUP 19 . in. 7ack-to-Back SC-POS.<I bsemble Front-to-Front /‘sJ. Cable b (Pump Motor “A”) c TC-NEG.3 Nom) Control Panel 0 r. F _ L hire 13C & 13D (Main Harness) LTorque to: 100 lb.. Inspect power cables on the control panel and security of mounting. Cable (BAT.) _ TC-NEG. Replace damage parts. Dee 94 19-8-14 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .

Eable (Pump Motor “A”) Cables. (Bat. If they are not.NEG. TC-NEG. Connections must beinstalled as shown.) 1r Cables must be routed as shown. 13C & 13D (Main Harness) CP-FU tF% Wire 138 (Main Harness) LTorque A to: 100 lb. in.) shorts and component damage. Torque fasteners to speci- fications listed. TC-NEG.3 Nom) t Inspect connections for damage and security of mounting. Cable (BAT. SM-587 19-8-l 5 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Replace dam- aged parts. Torque all connections to 100 lb.in\TC-NEG (11. Cable (Steer Control Neg.3 N*m)unless otherwise specified. (11. Neg.GROUP19 Periodic Electrical Checks Assemble Front-to-Front Assemble A CAUTION -% TC-NEG. you may experience electrical hw. Wiring and Terminal .

// f Do not smoke or allow open flame near the battery. If acidcontactsyoureyesorskin. Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Explosive gas is always A& I present around batteries. flush immediately with water and get medical assistance. Refer to Group 12 for Tvoical Illustration installation and safety instructions. l Install battery retainers. Protective Cover Cardboard or Plywood) A WARNING The battery contains corrosive acid which can cause injury.Periodic Electrical Checks GROUP 19 l Install truck battery. I Battery Retainer - l Connect battery to truck receptacle.

El!!YRK ~.$ria\Handling GROUP 19 Section 10 Oscillator Card Remove & Replace / J SM-587 19-10-l Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .

l Remove console cover. l Disconnect truck battery.GROUP 19 Oscillator Card Truck Preparation l Turn key switch OFF. A A Removeall Jewelry before working on truck. l Discharge capacitors. Always wear Safety Glasses Dee 94 19-l o-2 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .

/I A Switches CAUTION may be II damaged if the Switch UP (Lift) & Down (Lower) Cam is not removed. see above. l Remove Nuts (A) from control Fastener- handle bracket. Tilt and Auxiliary Switches Disconnect SO-7 from PL-7. This is to prevent component damage Switch Cam.Oscillator Card R&R GROUP 19 Oscillator Card Removal Disconnect Plugs Disconnect PL-8 from SO-8. SM-587 19-10-3 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Disconnect SO-9 from so-9 PL-9 Remove Switch Actuator l Remove Nut (A). Switches Be very careful when removing cam that you do not damage the switches. 1 when pivoting control out of the way. l Pull Switch Actuator (l3) from control and move downward on Bracket the plastic wire looms. see below. Disconnect SO-10 fron n PL-10.

l Remove card from truck. l Disconnect plugs from card. r Mounting Screew TBl . l Remove wiring from ‘II3 l-TB6. Mounting SC&w” ’ Dee 94 19-l o-4 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . remove upper and lower mounting bolts secur- ing card to panel. * Installation is the opposite of removal.GROUP 19 Oscillator Card R&R Remove Card Installation l Using a 8 rnxn socket and a 6-inch extension.TB6 .

. ...... .. 19-16-2 RH5 Voltage Checks .. .... ..... .... ... . . .. ... .. ... .... .... .... . .. when one or both lights illuminate with no “flicker” (a solid glow).... .\Handling GROUP 19 GROUP 19. ... .... There is a problem.....oe Checks) Voltage Data Sheet .. 19. .16-3 RH4 Volatge Checks . ......... ..... .. ..... . ............... ......... ........ Refer to the procedures on the Solenoid Control Card Top View SM-587 19-16-l Aug 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .. . Section 16 Solenoid Control Card Trouble Shooting (Vol ta. . 19-16-4 Indicator Lights (Leds) It is normal for the indicator lights (leds) to” flicker” when the different hydraulic switches are activated... .... .......... ..El!!flRIC Wl.. . .. .. .. ........ .. .. . .. .... .. however. ... ... ... . This does not indicate a problem............... ....... ........ . ...................... .... . . . ....

GROUP 19 Trouble Shooting -1OA Output 5011 Amp +lOA Zero Ohms : Common Battery Negative n Wire arness lo T. Solenoid Control Card indicator Lights (LEDS) \ J 19-16-02 SM-587 Aug 94 19-l 6-2 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .B.

This does not indicate a problem. to “flicker” when any part of the hydraulic system is put into use.) Checkforshorted switchorwire tocorosponding temlinal with avolt-ohm meter.continued next page - SM-587 19-16-3 Aug 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .Wire #48 Battery Positive . l RH4 Light “ON” (Key Switch “ON” and all Hydraulic Switches Open.seeoppositeillustration. seeopposite illustration. Open door on Solenoid Control Card and check to see if the indicator lights (leds) are illuminated.Wire #28 Battery Positive . however. Otherwise meter should register: . There is a problem. l Both Lights “ON” (RH4 & RH5) If both lights are illimunitated.Wire#65 ov Repair or replace as required. the solenoid is defective or there is a open in the TB8 .24 or 36 Volts If voltage is other than specified TB6 .24 or 36 Volts TB4 .24 or 36 Volts quired.24 or 36 Volts wiring.Wire#35 ov TB14.Wire #58 *Battery Positive . All Hydraulic Functions Disabled: Check Indicator Lights (RH4 & RHS) 1. the Solenoid Card is defective and should be replaced with a new one. Connect black (-) lead to ground and check each one of the following using red (+) meter lead [Meter should be set on the 5OV +DC Scale): Connect RED (+) to: Meter shoul read: TBlO. Repair or replace as re- TB5 .) Check for open solenoid or wires to corresponding terminals shown below: Connect RED (+) to: Meter shoul read: TB3 . there is a short in the switch and/or wire.Wire#5 ov l RH5 Light “ON” (Key Switch “ON” and all Hydraulic Switches Open. TB13.Trouble Shooting GROUP 19 NPR-345 Trouble Shooting Solenoid Control Card IMPORTANT ItisnormalfortheIndicatorLights~EDs). Wire#55 ov at any of these checks.0 Volts . when one or both lights illuminate with “no flicker”.24 or 36 Volts at any of these checks.Wire #38 Battery Positive .Wire #18 Battery Positive . TB12. *only when truck is equipped with side shift function. wire#m ov If there is any voltage present TBll.

10 Solenoid Control Card Indicator Lights (LEDS) Aug 94 19-l 6-4 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . 13 .- . 48 SO// Amp +lOA . 38 Zero Ohms .-. 28 -2o- SELECTOR nr nr . 65 B _?A Battery . 55 .. 58 ._- c .GROUP 22 Trouble Shooting . 18 -26- . 35 Negative -5- . 45 Common _ + n1 .

Wire#13 Battery NEG. (0 V) Battery Charged TB15 . (24 or 36 V) When Installing a New Solenoid Control Card Refer to the following page. 0 Volts means .Trouble Shooting GROUP 19 Lift Function ONLY Disabled (The remainder of the Hydraulic Functions should be operable.) (Key Switch “ON” and all Hydraulic Switches Open.Battery Charged indicating the Solenoid Card is receiving BDI Signal from the EV-T15 Oscillator Card.Battery is below 80% Discharge and must be taken out of service and “fully” charged or replaced if defective.Wire #lO Battery POS.) l RH5 Light “ON” TB7 . NPR-345 Solenoid Control Card Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . ) RH4 & RH5 Lights “OFF” Connect RED (+) to: Meter shoul read: TBl .Wire #26 10 to 12 Volts .

-. you will experience the following conditions: -The hydraulic system will fail to function .. l If you have a truck equipped with side shift function and the “Jumper Plug JP2” is in place. Aug94 19-16-6 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . See illustration below. the side shift circuit will be operable. . Jumper Plug JP2 . there will be no hydraulics at all. the following conditions will exist: -The monitoring function of the card for side shift solenoid circuit will not work. Remove JP2 when truck is equipped with Side Shift Function. -The RI35 Indicator Light (LED) will be “ON”..GROUP 22 Trouble Shooting NEW SOLENOID CONTROL CARD INSTALLATION When Installing a New Solenoid Control Card: IMPORTANT l Remove “Jumper Plug JP2” . -However. if the truck is equipped with 2nd Auxiliary function. be certain it is installed correctly as shown.. \ NPR-345 Solenoid Control Card against board. NOTICE l If you have a truck without side shift function and the “Jumper Plug JP2” is removed. IMPORTANT When replacing plug.

. . .... . .. .. . . . . . .. . . . . .. . .... . . .. .. . .. . . . . . .. . . . . .. .. .. . . .. . . . . . . .... .CLqRIC M$d$pk&Handling GROUP 20 Section 20 Axle... . . . . .. . . . . . .. . .. .. 20-l-2 Adjustment . . . .. ... . . . . . .. . .. . Articulartion Adjustment Contents Illustration . . .. .. . . . . .. . .. . . .. . . . . . .. .. . . . . . ... ... . . .. . . . . . . . .. 20-l-3 rC----. .. .. . . . . .. .. . . Mounting Block Articulating Axle Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . . .

GROUP 20 Axle Dee 94 20-l-2 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .

Open rear door. Place forks in forward tilt. l Clearancemay bechecked by using a 9/32”twist drill. SM-587 20-I-3 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . The drill should just fit between the bolt head and the top of the axle housing. refer to illustration on page 2. WI 6” If adjustment is required. Check clearance at Point “B” using a 5/16”twist drill. Check clearance between stop bolt and axle at Point “A”. 4. Remove floor plate. loosen adjustor set screw and rotate adjustor in direction necessary to obtain proper adjustment. 5. Retract and fully lower pantograph. 2. Tighten set screw to secure stop bolt in the adjusted position.Axle GROUP 20 Truck Preparation 1. Park truck on a flat level surface. \ Floor Plate / Check Adjustment of Axle Stop Bolts 1. 2. 3. 6. NOTE Batteryshouldbeinthetruckwhen checking or adjusting axle articulation. Turn key switch OFF.

.17 Special Tools ........................ ............................................................... .......... Helical Gear......................... 22-2-16 Mounting the Top of the Gear Unit ....................... 20-2-5 Dismounting the Helical Spur Gear and the Conical Pinion Shaft.....................~.......................................................................................20-2-g Setting the Circumferential Backlash ........................................ 22-2-14 Mounting the Housing Lid ........... 20-2-3 Removing the Top of the Gear Unit ........................................................... 22-2-10 Checking the Tooth Pattern .. 20-2-7 Measuring the Assembly Dimension of the Conical Pinion Shaft ................... ........................ 20-2-5 Dismounting the Outer Race ................... .......................CLqRRlVl........... 20-2-4 Dismantling the Housing Lid .......................... 22-2-18 Drive Motor Removal Copyrighted Material Intended for CLARK dealers only Do not sell or distribute ....................................................12 Mounting the Wheel Shaft ........... 22-2.............................................. 20-2-5 Dismounting the Inner Race ...........................................................6 Mounting the Gear Unit .......................................... 22-2-10 Setting the Conical Pinion Shaft........................................ 20-2-8 Preassembly of the Wheel Shaft .........General Remarks .................... ..........20-2.....................h\Handling GROUP 20 Section 2 Drive Unit Contents Lubrication ................................................. 20-24 Dismantling the Crown Gear and Wheel Shaft ...... and Bearing Cle a....22-2-12 Mounting the Conical Pinion Shaft ......................... 22-2.8 Preassembly of the Conical Pinion Shaft ........................ 20-2-g Preassembly of the Wheel Shaft Bearing in the Housing ......................20-2......................................

Typical Foot Pound Pivoted Torque Wrench Pointer Dee94 20-2-2 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .I__. 3fl I_ Drive Unit A WARNING Wear eye protection and protective clothing when drying with air pressure. Remove all Jewelry before working on truck. Reduce air pressure to 30 PSI (207 kPa). Use a Torque Wrench to tighten Terminal Connections.C=RnlIP _. Debris removed with air pressure can cause injury.

whichever comes f?rst. Fii unit to bottom of level plug opening with First 500 Oueratiw Hours the drive unit in the vertical position. \ Seal Drain Plug Level Plus lbp3 SM-587 20-2-3 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Before disassembling the drive unit. change oil after 2000 hours of operation or once a year. l Place transmission on a clean work surface. Change oil after fust 500 hours of operation or ( 6 ) months . INSTRUCTIONS FOR REPAIR Fverv 2000 Oueratiw Hour3 General After initial 500 hours. whichever comes first. Use AMOCO 1000 or equivalent. drain the trans- mission fluid.Drive Unit GROUP 20 LUBRICATION Refer to the Lubrication Chart in Group 01 of this manual.

GROUP 20 Drive Unit Dismantling the gear unit Removing the top of the gear unit (300) from the basic gear unit (100). Remove the screws (135).g. Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Dismantling the housing lid (134). and lift off. Remove the screws (402/404/406). 1. loosen the lid by tapping lightly.. with a plastic hammer) and lift it off. 1. Loosen the top of the gear unit by tapping lightly (e.

If a new wheel shaft or a new set of bevel gears is mounted.133) and bind them together with a wire or the like. new bearings must be fitted. To dismantle the inner race. Dismounting the outer race (122). Take the crown gear out of the gear unit. Insert a g-mm diameter punch into the threaded hole of the wheel shaft and drive to dismantle the wheel shaft. Pry out the sealing ring. Make sum not to damage the shims. 4. 2. dismount the outer race (122 outside) by lightly tapping with a copper punch or the like. NOTE Surface X of the wheel shaft is used for setting the wheel shaft bearing and must not be damaged. 2. Hold the wheel shaft tight and remove the screw (129). Remove washer (128) with shims (130. cut open the bearing cage and extract the inner race via the small bearing collar using the extractar.Drive Unit GROUP 20 Dismantling the crown gear (104) and wheel shaft (119) 1. 3. and place the outer race with the wheel shaft. shims (124-127). SM-587 20-2-5 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Bind the outer race and the shims together with a wire or the like and place them with the crown gear. 2. it is recommended to loosen the hex nut (118) on the conical pinion shaft at the same time (refer to “dismounting the helical spur gear on the next page). 1. The inner race should be dismantled only if the bearings am damaged and have to be replaced. Dismount the outer race (122 inside) by lightly tapping with a copper punch or the like. 1. Fasten special tool “A” (see page 18) with screws (135) to housing. If the conical pinion shaft (104) is dismantled as well. radial sealing ring (102). Dismantling the inner race. The wheel bolts (120) can be removed by pressing them out when the wheel shaft is dismantled 5.

Unscrew the hex nut. dismount the helical spur gear using the extractor. Again make sure nottodamagethe shims (107-l lO).. 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. Make sure not to damage the shims (114-l 17). Dismount the bottom outer race (105) by lightly tapping with a copper punch or the like. Dismount the top outer race (112) by lightly tapping with a copper punch or the like.g. Dee 94 20-2-6 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . using a copper punch). and drive out the conical pinion shaft (e. 3. 1.Bindtheouterraceandtheshims togetherandplacethemwiththeinner race or the conical pinion shaft and the spacer bushing. 4. 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.GROUP 20 Drive Unit Dismounting the helical spur gear (201) and the conical pinion shaft (104). 2. Remove the top inner race (112) and place it with the helical spur gear.

. Cleaned anti-friction bearings should be lubricated before being mounted. damage and cracks and replace them if necessary.g. Hone the sealing surfaces with an oil stone or a smooth-cut file. For sealing.Drive Unit GROUP 20 Mounting the gear unit General remarks Before mounting the gear unit. Wheel set components such as helical spur gears should be replaced in pairs. the following points should be noted: Clean all parts carefully and remove all traces of sealing compound. SM-587 20-2-7 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . use only elastic non-hardening sealing compound (e. Check all parts for wear. Loctite 574). helical gears must be replaced in pairs. It is recommended to always replace seals and radial seal rings whenever repairs are made.

Press the inner race (105) carefully with special tool “C”(see page 18) up to the limit stop.5 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. The housing dimension E is determined addcording to the following formula: E=L-F+22.GROUP 20 Drive Unit Mounting the basic gear unit (100) Measuring the assembly dimension of the conical pinion shaft (104) 1. Dee 94 20-2-8 SW587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Insert special tool “D” (see page 19) into the bearing borehole of the housing and measure dimension F.

Using special tool “H” (see page 20). 3.Drive Unit GROUP 20 PI-e-assemblyof the wheel shaff (119) 1. Apply Loctite 575 to the sealing ring (102) at its outside diameter and mount it using special tool “E” (see page 19). press inner race (122) onto the wheel shaft up to the stop. Applu Lock 242 to the Gamma ring (103) and press it onto the housing using special tool “E” (see page 19). inside SM-587 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . the open side of the ring must point to the inside of the gear unit. 2. Rush the Nilos ring (121) onto the wheel shaft up to its stop at the flange. 3. Pre-assembly of wheel shaft bearing in the housing (101) 1. 4. 2. Apply Loctite 242 to the knurled portion fo wheel bolt (120) and press into the holes providedon the flange of the wheel shaft. Grease the inner race of the taper roller bearing on the wheel shaft (cavities between rollers and cage and between cage and Nilos ring. Insert the outer race (122 outside) into the housing and insert the outer race (122 inside) with shims (124 127) for the preliminary setting. use Shell Alvania R3 or a grease of identical composition and specification). IIE" @.

5. its direction is indicated by the “Mounting guideline”.004 . Secure the hex nut (118) by staking. and (‘. 2. The circumferential backlash is corrected by adjusting with shims (124-127). . If a correction is necessary. Insert the crown gear (101) into the housing. Compare the pattern obtained with the “Mounting guideline” below. 3. 6. Admissible circumferentail backlash 0. 3. 1. 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.). ITY Tooth pattern on the ring gear Correct pattern adjustment by Defective patterns changing the mounting di. 2.1-O.006”). or backlash S. Mesh the coated tooth flanks several times with the conical pinion. with a wooden wedge. secure the conical pinion shaft against turning. Press the inner race (122) onto the crown gear using the special tool “H” (see page 20). 15 mm (0. For measuring the circumferential backlash at the crown gear. 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.. 1 & 2 Dee 94 20-2-l 0 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .0.A. The mount- ing dimensions may only Note fig. e.GROUP 20 Drive Unit Setting the circumferentail backlash on the crown gear (104) and checking the tooth pattern 1. Setting instructions Concave Flank 1 Convex Flank mensions in direction of arrow Pattern at tip marked mounting dimen- Pattern at root sions +_A a. 4. The pattern will show better if the conical pinion is slightly braked while in mesh.g.

15 SM-587 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .lOjO.Drive Unit GROUP 20 wooden wedge circumferential backlash O.

Allowable clearance: O-0. Insert the shims and the top outerrace.110) according to instructions on page 8 and insert the outer race (105) into the housing (101). Position the shims (107. Mark the measuring point on the helical spur gear with a grease pencil.Placethehelicalspurgear(201)ontotheconicalpinionshaftandscrewthehexnut(l18). Hold the helical spur gear tight using the special tool (see illustration) and torque the nut to 60 + /. apply a light pre-stress to the conical pinion shaft via the housing towards the stop. NOTE If the outer race is higher than the inner race (dimension as shown in detail “Z”). Read the bearing clearance off the dial gauge. Using the special tool “F’ (see page 19). turning it as described above. Fit the inner race by tapping onto the pinion shaft using special tool “G”(seepage19).02 2. S= Distance between surface of outer race and surface of inner race. 1.S . Checking the bearing clearance of the pinion shaft 1. Adjustment of bearing clearance. Press the conical pinion shaft downwards by hand.3. Adjust the dial gauge to zero at the measuring point. 3. After checking the tooth pattern the shaft nut is locked by staking.GROUP 20 Drive Unit Setting the conical pinion shaft (KM). 2. 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. dimension X is determined as follows: Shim thickness X = C .002”).7 ft-lb. Insert the previously mounted conical pinion shaft. while turning it serveral times through approximately 180”.0. 3. The thickness of the top shims (114. 4. 2.117) 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.).02 If the outer race is lower than the inner race. Dee 94 20-2-l 2 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .0. dimension X is determined as follows: Shim thickness X = C + S . helical gear (201) and setting the bearing clearance 1.5 Nom (44+/. Pull the conical pinion shaft upwards via the helical spur gear. and hold it steady at the measuring point.05 mm (O-0.

Z ’ Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute ..Drive Unit GROUP 20 detail .

there should be no measurable bearing clearance.10%. 5.ring method described above.4 ft-lb. turn the wheel shaft several times tin both directions to enable the bearing rollers to align themselves. Nevertheless. 3. and setting the bearing clearance.) +/. Measure dimension “Y” via the hole of special tool “J” (see page 20).) = approximately 5000 N bearing pm-stress 2. 4. Unscrew special tool “J” (see page 20) and remove. NOTE A direct check of the bearing pre-stress as not set is hardly possible. 6. Tightening torque MA = 110 Nom (81 ft-lb. Insert shims in accordance with dimension “X”. Dee 94 20-2-l 4 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .GROUP 20 Drive Unit Mounting the wheel shaft (119). 7.washer thickness of auxiliary unit. Shim thiclcness “X” = Y . When checking according to the measu. 1. Apply Loctite 242 to screw (129) and pull together the previously mounted wheel shaft and crown gear via the washer (128). Use special tool “J” (see page 20) to pull together the mounted wheel shaft and crown via washer (128): Torque to 10 Nom (7. When doing so. it should still be possible to rotate the wheel shaft easily by hand. crown gear (104).

Drive Unit GROUP 20 SM-587 20-2-l 5 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .

g. A closed plastic cover is sufficient to package the unit for storage. Dee 94 20-2-l 6 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Conservation can be carried out.) NOTE If the basic gear unit is stored as an assembly group.. e. by filling the unit with oil and draining it afterwards.GROUP 20 Drive Unit Mounting the housing lid (134) 1. e.g. it should be suitably protected against corrosion and be packaged accordingly.. Coat the housing lid with loctite 574 and fit into position. Torque to 9.5 Nom (7 ft-lb. Apply Loctite 242 to screws (135) and fasten. for standby purposes.

). 5. 2. Screw in bolts (402 and 404).l/8”). SM-587 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .). Tighten bolts (402/406) with ti tightening torque of 23 N*m (17 ft-lb. Insert dowel pins (401) into the basic gear unit in such a way that they project from the sealing surface by about 3 mm . 4. Tighten bolts (404) with tightening torque of 46 N*m (34 f&lb. 3.Drive Unit GROUP 20 Mounting the top of the gear unit (300) Fitting the top of the gear unit to the basic gear unit (100) 1. Coat the sealing surface of the top of the gear unit with Loctite 574 and place it onto the basic gear unit.

2 42 20.2 250/300 3oj.O.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. 95 170 17s {dent-Nr.z 4820.5 Jdcnt-Nr.5 79.I 'F-F3 31.2 00 67. 618 710 618 711 618 712 Special Tool ” C” HFK400/500 00 0d HFK 28.2 f HFK 26'0.2 F so.2 1692 0.5 79.2 G 21 k3.+s.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 -2 L min. 618 713 618 7lL 618 715 Dee 94 20-2-I 8 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .2 40.2200 23+O.2 35.5’0.SQ.

5 51.841 618. HFK 200 HFK250/300 HFK400/500 23-0.1 618.5 63.718 Id _I& W Y * rated dimension -< II -2 Actual dimension marked on bushing Special Tool “E” pdent-Nr. Drive Unit GROUP 20 Special Tool “D” fl--L-?~ HFK 200 HFK 250/300 HFK 400/500 0D 46.2 26+0.5'0.840 618.842 SM-587 20-2-l 9 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .717 77s 618. 0d mm.723 1 618.2 --.” Special Tool “G” .724 ] Special Tool “F” manufactured from M 12 x L DIN 933 1779-1 Teil 1 Teil 2 .5 L’ Ident-Nr.722 1 618.2 30.5 618. 55 618.716 67. 618. L 35 35 35 Ident-Yr.

2’O.: 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 .GROUP 20 Drive Unit Special Tool “H” ~1 l NennmaQ Special Tool “I” f7.

270 SM-587 20-2-21 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .7+o. 450 685 450 688 28 Ir max.7+0.l Ident-Nr. Drive Unit GROUP 20 Special Tool “K” HFK 300 HFK 400 1 0d 136 140 A 13.l 14.

GROUP 20 Drive Unit DRIVE UNIT -I-- 303 407 408 304 402 Upper Half Dee 94 20-2-22 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .

Drive Unit GROUP 20 SM-587 20-2-23 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .

. ................22-l-3 Illustrtion....El!‘YRK IVl~leri-i~Handling GROUP 22 Section 22 Traction Wheel & Tire Contents Preparation ............................................................................... exploded view ...................................................................................................... ..... 22-l-2 Pressing Tire .22-l-3 Tracti SM-587 22-l-l Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .................................

139 Ib.188 Nom) Wheel & Tire A Drive Unit Dee 94 22-l -2 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . (168 .ft.GROUP 22 Tires Fastener Tightening Sequence Tir Wheel Torque Fasteners to: 124 .

Place forks in forward tilt.:. Replacing Traction Wheel Tire 1. Elevate and block rear of truck.. 5. .:::::::.Tires GROUP 22 Truck Preparation 1...:{:.. ::::::::::::::: .. .: .. ::::::::::::::: illustration on page 2.. 2..:. Retract and fully lower pantograph. . :F::::::::::. ::::::::. Remove wheel fasteners 7.:::::: ::::::::::+:. tightened using diagonal sequence shown in ::::::::::::::: ::::::::::::::: ::::::::::::::: . v.:+: ‘:~$$:~:~: press ~ ‘:jjjjjjjjj ~ Old Tire Table SM-587 22-l-3 Dee94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .:+. Remove wheel assembly.188 N*m).:.A.$$$g ::::::::::::::: ‘. . ~~~. ::::::::::::::: .... 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. . 4.:.:s:. 139 lb..:+:..‘.‘. (168 .~q :g#.:. hardwood (oak) blocks.:.: ::::::::3>3 :::.. Park truck on a flat level surface. . 3. -_ _ of truck using ..:.: ::::::::::::::: :K::.y.:.ft. see oppo- site illustration. Turn key switch OFF and disconnect truck battery.:$. ...::::. 2.: . Install wheel fasteners and torque them to 124 . 6. Fasteners must be ::::::::::::::: ::::::::::::::: ::::::::::::::: .:.‘.~~~.:.

............ 22-2-2 Pressing Tire ............... CLSRKlflfx&$Handling GROUP 22 Section 2 Caster Wheel & Tire Contents Preparation .................................................................................... 22-2-3 Illustrtion............................................................................................................................ 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 ............................. exploded view ......

Nut 1 Chamfer’ - Wheel & Tire Assembly Dee 94 22-2-2 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . GROUP 22 Tires Refertoadjustmentprocedures and torque specifications outlined on Page 4 in this section.

SM-587 22-2-3 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Replacing Caster Wheel Tire _ of truck using 1. they should be replaced. Park truck on a flat level surface. Retract and fully lower pantograph. Place forks in forward tilt. En. Turn key switch OFF and disconnect truck battery.Tires GROUP 22 Truck Preparation 1. The thin lipped section of the caster wheel must be protected during handling and pressing. If the bearings are fit for further service. NOTE Reused bearings should bewashed in a non-flammable cleaning solution and dried. Remove caster wheel assembly. 3. 8. 6. Press D. Remove hub cap from caster wheel and loosen nut. 5. 7. Inspect bearings for further serviceability. Refer to Group 25 for overhaul procedures. 4. Elevate and block rear of truck.irection sure that the tire is seated evenly on the wheel # 4 before starting to press. then install wheel assembly and adjust bearings as outlined on the following page. 2. A sleeve to fit wheeel as shown with a depth larger than the wheel should be used when pressing on a new tire. see opposite illustration. Block the brake pedal in the down position to release the caster brake. 3. 2. 4. New or cleaned bearings must be carefully packed with wheel beating grease prior to reassembly. If the bearings areunfit for further service.

GROUP 22 Tires Check Caster Wheel Bearings Refer to Group 01 for proper lubrication. l Tighten nut (do not loosen nut) to the first available locking tab of the lock washer. Adjustment l Spin wheel when torquing nut to specifications. l Using a torque wrench and the special tool shown below. torque the bearing nut to 300 lb. Special (Socket Type) Adapter Applications: Used to torque 24H Nuts. yet not have more than 0. Bend lockwasher “tab” into nut slot to secure adjust- ment.006” end play after adjustment. Refer to opposite illustration. (33. May be purchased from most engine or auto parts stores. Chamfer To Face Inward This is to insure proper seating of the wheel bearings. The wheel should spin freely. Install hub cap.9 N*m) while spinning the wheel. l Loosen nut and then retorque to 25 lb. in. Dee 94 22-2-4 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . IMPORTANT Be sure the “chamfer ” side of nut is installed toward wheel bearing.in.82 Nom) while spinning the wheel. (2.

........... Brake Bleeding Procedure is covered in Section 3 and Brake Pedal Check and Adjustment Procedure is covered in Section 4 of this manual.... ... GROUP 23 Section 1 Brake..........................................................................................................1 Brake Bleeding Procedures (Refer to) ..................... 23-3... 23-4............1 Brake Pedal Check and Adjustment (Refer to) ..23-l-5 Final Brake Adjustment Specifications ............................... Motor Contents Motor Brake Service...............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..... ......................23...... ... The caster brake service procedures are covered in Section 2 of this manual................23-l-2 Brake Adjustment.... Drive Motor SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute ................................. Both brakes are spring applied and hydraulically released by a brake pedal and two master cylinders. ....... ........................................1-8 Caster Brake (Refer to) ....... 23-2........

NOTE only be necessary to do the It will if following two steps thecomplete brake assembly is to be removed l Disconnect wiring from brake pressure switch.inch on pump elbow. l Remove brake drum nut from motor shaft. 23-1-2 SM-587 Dee94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Loosen clamp (A) and pull hose (B) downward approximately 1 . l Move wiring where it will not be damaged upon removal of the brake drum. NOTE On 24 Volt models it is necessary to perform the following two steps to allow brake drum removal. Tighten clamp (A). Brakes GROUP 23 Motor Brake Service Brake Pressure A! CAUTION Park truck on a level surface and chock wheels.

l Now lift brake drum from motor shaft and brake assembly. Depress brake pedal and place a block on the pedal to retain it in the down position. L Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . l Bring drum to a vertical position and remove it as shown here.Brakes GROUP 23 . Doing so will release brake shoe pressure against the brake drum.

ft. Clark Part No.25 Nom 1 w v to bolt threads. bore and threads before assembling drum Clark Part No. 18Oi300 20 . key andnut. Clark Part No. drum. l Release pedal and remove blocking. Cla l Locate assembly onto drive motor as shown P&t No. check brake cylinder mounting bolts for proper torque. 1802307 tb motor below. NOTE Prior toinstally brake drum. threads and install bolts finger tight. in.221 Ibf. bore and threads.) Drive Motor Dee 94 23-1-4 Copyrighted Material SM-587 Intended for CLARK dealers only Do not sell or distribute . in. 170 .190 Nom quence (A thru D) shown below. (177 . (125140 Ibf. Now install the l Replace hydraulic hose and retighten. Tighten Torque nut to: bolts to soecifications using the diagonal se. then complete the following steps.GROUP 23 Brakes If brake assembly is to be serviced in the truck: l Replace old shoes and spring with new ones as required times.) Torque bolts to: 20-25 Nom (177-221 Ibf. 1802300 to the mounting bolt nut. 1802307 to l Reconnect pressure switch wiring motor shaft. IMPORTANT Ao~lv Anti-Seize. Torque to specification shown above. Apply general Purpose Threadlocker. shaft. IMPORTANT Install bolts using General Purpose Torque bolts to: Threadlocker. l Apply Anti-Seize. ’ If the brake assembly had to be removed from the truck for service.) l Replace old shoes and springs with new ones as required.

Now loosen nut (4) releasing spring pres- piston and rod end. Step 1 l Loosen nuts (2 & 3). While holding light pressure on pedal. 3 & 4). be fleeto move in either direction. Step 2 l Rotate actuating rod counterclockwise while l Now depress brake pedal several times to move holding nuts (1. see below. Tighten The brakearm must beallowed bleeder. see below. Rotate them inward several l Pull boot from cylinder exposing the cylinder turns. sure. Do not release brake pedal. loosen bleeder to allow pedal to be depressed to IMPORTANT the floor. Typical Illustration SM-587 23-1-5 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . 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. Brake are must down.Brakes GROUP 23 Brake Adjustment l Loosen and back-off jam nut (1) freeing brake arm.2. to “float” until adjustment is made. Do not force pedal gap between rod end and piston).

. Measure amount of rod protruding beyond the back of the plate as shown below. You can do this visually or by feel. . Typical Illustration Step 4 l Next.. install the boot. tighten nut (1) against arm .GROUP 23 Brakes Step 3 . while holding nuts (2 thru 4) screw rod clockwiseuntilitjust touches thecylinderpiston. screw rod inward l/4 of an inch while holding nut (4).. l Release brake pedal. finger tight. l Next. This willmove thepistoninward l/4 of an inch. l Using two wrenches. tighten nut (2) against arm . securely tighten both nuts 0 While holding arm in neutral (brake released). finger tight. Secure Adjustment Tvnienl llhxtratinn 23-1-6 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Now. . l Now. with&t moving brake are &t-of neutral.

Make certain jam nut is tightened securely without disturbing the spring preload adjustment.Brakes GROUP 23 Step 5 l Fkeload brake spring. until spring length is 44. Tighten nut (4) against the spring washer. tighten jam nut (3) while holding nut (4) to secure adjustment. Typical Illustration SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Typical Illustration Step 6 l Using two wrenches. as shown.5 mm (l-3/4”). Measurement should be taken from the inside of spring washer to inside of spring washer as shown below.

GROUP 23 Brakes Brake Pressure Spring Final Adjustment Specification Cooling Plate must in place at all times I to provide required Drive Motor Typical Illustration Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .

. . ... .. . .... . .. .. Caster Assembly SM-587 23-2-l Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . The motor brake service procedures are covered in Section 1 of this manual.. .. ........ . .. .... ... . .. .. .. . .. .... . . .. . . .. ......... . . ..... ........ . .. . .. ... ... . .. . . . .. .. .. .... . . .. .. ... . . ... 23-2-5 Brake Backing Plate Remove & Replace ... . . . . .... .. .. .. ... .. . . . ... .. .... .. 23-2-2 Service Procedure . . .\Handling GROUP 23 Section 2 Caster Brake Contents Truck Preparation . . .... ..... . ... . ... .. ... ... . .. . . . 23-4. . ...... .. ... . . .. .. . .. .... 23-2-8 Bleeding Brake System (Refer to) . .... . . 23-2-5 Brake Arm and Brake Shoe Installation . . .. . .. 23-3-l Brake Pedal Check and Adjustments (Refer to) . ... ... . . . .. .... . . . . .. . ... . .. . .... . .. .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. . .. . . ..... . . ... . .. .. . . ... . . ... ... ... ..... 23-2-2 Slave Cylinder Remove & Replace . ... . . . .... . . . . ..... .... . .. ... . . . Both brakes are spring applied and hydraulically released by a brake pedal and two master cylinders.. . ... . ... . . Brake Bleeding Procedure is covered in Section 3 and Brake Pedal Check and Adjustment Procedure is covered in Section 4 of this manual. .... .. .. . .. . .... ... ... ...... .... .El!!RKM$&ri.. . . ..... . .. ..I.. . . .. .. .. . .. .. .. ... . .. 23-2-6 Caster Wheel Brake Linkage Installation ... .... . ..... .... .. 23-2-7 Caster Brake Adjustment .. . . . . . .. . .. . .... .... . ......... ....... . ..... ..

Brakes GROUP 23 Caster Brake Service Truck Preparation l To service the caster brake. the truck should be elevated so the caster wheel just clears the floor. Remove nut and spring. Brake Spring Release spring application pressure and remove spring. l Elevate rear of truck farenough to allow rotation of the caster assembly. Typical Illustration Block Truck 2-inches off floor. l Place oak blocks beneath frame (as shown) on each side of truck. Caster Assembly ypical Illustration Dee 94 23-2-2 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Typical Illustration Remove Access Cover l Remove two bolts and cover from caster assem- bly. This allows rotation of the caster providing access to each side of the assembly. Loosen and back off jam nut (1). Slowly rotate nut (2) away from the spring until thecasterwheelis free torotate.

move arm 1-spline away from weldment. install new brake linings. 3. the brake arm will move inward toward the caster “weldment”. Remove clip lock (2). Remove caster wheel exposing the brake assem- bly. Adjusting for Lining Wear When to Replace Brake Linings As brake Iiningswear. The brake assembly does not have to be removed to replace the brake shoes. Brake Brake Arm Expose Brake Assembly 4. Remove retainer pins and clips (1) securing the spring and slave cylinderrod to the brake arm. loosen brake arm clamp- ing bolt (3) and remove brake arm. When the brake arm reaches the 3/16” measurement a fifth time. IMPORTANT: This adjustment may be made a maximum of four (4) times. SM-587 23-2-3 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . When the armiswithin3/16ofaninchfi-omthisweldment.Brakes GROUP 23 Disconnect Rods & Remove Brake Arm 2.

f$$s I Retainer Ring c 6. SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Clean the shaft and bore in backing plate. Spring @ ~’ -y.GROUP 23 Brakes 5. Remove old brake shoes. NOTE Go to Step 7 if the Slave Cylinder or Brake Backing Plate does not require service. Remove shoe actuating shaft.

1802300 on bolt threads.Donot torque bolts at this time. Replace cylinder with a new one. SM-587 23-2-5 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . in. Loosen and remove cylinder mounting bolts. Remove slave cylinder. Tightenmountingboltsfingertight.ClarkPart No.Brakes GROUP 23 SLAVE CYLINDER If the cylinder needs to be replaced: Disconnect brake line fitting at cylinder. Remove cylinder push rod fkom cylinder. Tighten the bolts to a torque of 240-300 lbs. Install the six mounting bolts using General PurposeLockthreader. Bolts must be tightened in the sequence shown here. Connect brake line fitting. 1 Tightening Sequence BRAKE BACKING PLATE If the brake assembly was removed: Install the backing plate (less brake shoes) align- ing bolt holes in plate with those in the caster housing.

GROUP 23 Brakes 7. move arm 1-spline away from weldment as shown. With brake arm held parallel to weldment. Install cam shaft through bore. l Secure arm to shaft with clamping lock bolt. 9. Install brake shoes. Typical Illustration Dee 94 23-2-6 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Brake Shoe & Lining &+* Clip Lock Typical Illustration 10. Move Arm 1-Spline as shown l Install clip lock over arm and onto cam shaft. 8. Sparingly grease the cam shaft and bore with Moly grease.

Install bearing locking washers and nut lock over shaft. Typical Illustration 12. . Install wheel being careful not to damage seal. . Install caster wheel .Brakes GROUP 23 11. Replace shaft seal with a new one. Install chamfer toward wheel. . Repack wheel bearings with lubricant recom- mended in GROUP 01. Tighten nut lock to the first available locking tab. lock in place using tabs on lo&washer. . Typical Illustration SM-587 23-2-7 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Install spring and cylinder rods to brake arm and secure with retaining pins and clips.

GROUP 23 13. l Using wrench. without moving cylinder and rod out of alignment.300 lb. The tighten bolts finger tight. Align push rod and slave cylinder. Adjust brake spring length. l Rod and cylinder must be parallel with one another. l After obtaining correct spring adjustment.2 mm) can be measured between inside of one washer to the inside of opposite washer. torque bolts to 240 . use a second wrench and tighten jam nut (2) against nut (1) without disturbing spring adjustment. thrn nut (1) against washer until 2-l/4” (57. in. Typical Illustration 14. Loosen mounting bolts and locate cyl- inder so it is absolutely parallel with the push rod. Typical Illustration Dee 94 23-2-8 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . l Now.

Brakes GROUP 23 15. Typical SM-587 23-2-9 Copyrighted Material Dee 94 Intended for CLARK dealers only Do not sell or distribute . Install cover and secure with the two bolts previously removed NOTE Check brake pedal up-height for correct adjustment.Refer to section 4.

.. Bleeder Screw Drive Motor NOTE &!..Cl!!lRK Material Handling Company GROUP 23 Section 3 Brake Bleeding Procedure Contents Bleeding the Brake .... .. / brake. It is not necessary to remove 3 i................ -.. ... 23-3-2 Brake System Bleeder Screw .. .. c: -- SM-587 23-3-l Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute ........ the cover to bleed the caster \ / \ :> -...................?a :3 -3....... ..............

submerged in brake fluid during bleeding operation or air will be drawn into the brake Pressure Bleeder Method system during the bleeding operation. the glass jar.GROUP 23 Brakes Pump Brake Pedal Keep Reservoir * Master Cylinder(s) filled wi ith fluid. open the bleeder valve allowing air reservoir until it is nearly full. Once the system has been bleeder hose to the valve. to motor brake bleeder valve. Bleeder Valves SlavXylinder (Caster Brake) Bleeding Brake System Manual Method (as illustrated) l Repeat above (checking reservoir fluid level Fill the brake reservoir full of brake fluid. l Wipe bleeder valve(s) with a clean cloth. If they do not. Section 4. Shut off pressure bleeder. then the pedal up height brake fluid. Open bleeder valve. Empty reservoir to l/4 full. Attach pressure bleeder l Depress andrelease brake pedal several times. Repeat at caster brake bleeder valve. valve. Be sure end of hose remains should be adjusted. bled. hold pedal in the down bleeder. l Using a brake line hose (or a clear plastic hose). place one end over the bleeder valve of IMPORTANT the cylinder to be bled. Dee 94 23-3-2 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . glass jar filled part way with is depressed. Let fluid flow into position. Be l Go to the next cylinder and bleed in the same sure debris is removed prior to attaching a manner described. check the brake reservoir to be sure it is full. Refer to Group 23. Keep full frequently) until air bubbles cease to appear in during bleeding operation. Close bleeder. Turn on pressure On the last stroke. Place opposite end of Check to be sure the brakes release when the pedal hose into a clean. Shut off bleeder to escape into the jar of fluid.

. . .. ... . . .. . . . . . ...Cl!“lRK $at&rfi\Handling GROUP 23 Section 4 Brake Pedal Adjustment Contents Brake Pedal Check and Adjustments .. 23-4-2 * Master Cylinder(s) SM-587 23-4-l Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .. .. .. .. . .. . . .. ..... . ...... . . .

l Tighten jam nut after making adjustment. If not. further brake pedal height adjustment may be necessary. Check by lifting pedal full up and individually check piston for even tension. Rotate piston rod(s) until correct adjustment is accomplished. Correct adjustment as required. If one is / Master Cylinder loose. be certain to secure adjustment with jam nut(s). MEASURING -Pedal Up-Height PEDAL UP-HEIGHT 112. Adjusting Pedal Up-Height l Using two wrenches.0 mm (4-l/2”) Floor Plate * Master Cylinder(s) Dee 94 23-4-2 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . adjustment is not even.5 mm (4-7/l 6”) to 114. See opposite illustration. then an adjustment should be made at the brake master cylinder(s). ADJUSTING NOTE Checkthat both brakesrelease with PEDAL UP-HEIGHT pedal down. Again. IMPORTANT Be absolutely certain that both cylinders are ad- justed evenly. If measurement is not as specified.GROUP 23 Caster Brake 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. hold piston rod(s) and loosen jam nut(s).

/Handling GROUP 26 Section 1 Hydraulic Pressure Checks Lift. Steering. 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 SM-587 26-l -1 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .WIRU lVi. Auxiliary.$Dri.

Hold control in the 1. Open truck door. NOTE 7. see above. Tilt. System relief setting may be checked by actu- The therelief valve for these circuits is located in the ating the Multi-Function Control to place the auxiliary pump. gauge and then release control. Test Port 2 l Refer to Group 30 for Lift Circuit Relief Valve check and adjustment procedures.GROUP 26 Hydraulic Pressure Checks Test Port 1 l Auxiliary.. Connect Adaptor (see above) to pressure gauge. tilt. Steering and Side Shift (if so equipped) pressure test port. 6. Refer to illustration on Page 3. pantograph forks in full reach. Reach. Check Relief Valve Setting for the Auxiliary. Remove cap from test port #l. read the pressure gauge. Reach &Tilt. (Clark Part No. immediately read the pressure 3. Steering and 5. Notice: The hydraulic relief valve setting may Dee 94 26-l-2 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Remove console cover. 110 to 130”F. ates over relief. Do not operate system over relief any longer than it takes to 4. IMPORTANT: Check system pressure with the hydraulic fluid at operating temperature . Side Shift (if so equipped) Circuits. or side shift (if so equipped) position. fully actuated position. When the system oper- 2. Turn key switch ON. 1800106) HYDRAULIC PRESSURE CHECKS be checked with a Mica Quudrigage or with a conventional pressure gauge having a scale of 0 to 3OOOpsi. Attach adaptor to test port #l..

install and securely tighten cap to secure adjustment. Rotate adjustor CLOCKWISE to increase pressure and COUNTERCLOCKWISE to decrease pressure. 2. Install console cover and close door. However. elief Valve Sub-Assembly Spring(s) I Relief Valve Configura- tion may vary with pumps. 1. follow the procedures listed here. Remove cap covering the adjustor. NOTE Relief valve(s) are factory preset and shouldnotrequire adjustment.Hydraulic Pressure Checks GROUP 26 Relief Valve Adjustment If adjustment is required. Adjust the relief valve to operate between 1550 and 1650 psi. Once adjustment has been attained. 3. If adjustment is not required go to Step 3. Auxiliary Pump SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . if adjustment is required. do not exceed specified setting.

gauge and then release control. Remove console cover. The hydraulicreliefvalvesetting may be checked If adjustment is correct. Dee 94 26-l-4 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Remove cap from test port #2. Port 2 Lift Circuit pressure test port. see above. Turn key switch ON. Check Lift Control Circuit Relief Valve 7.GROUP 26 Hydraulic Pressure Checks Test Port 1 l Refer to Group 26 for Auxiliary. refer to S tep 6 next page. immediately read the pressure control valve. read the pressure gauge. OFF. upright to full maximum lift. 3. Turn key switch 2. Refer to illustration on Page 3. HYDRAULIC PRESSURE CHECKS 5. procedures next page. Open door. Do not operate system over relief any longer than it takes to 1. IMPORTANT: Check system pressure with th hydraulic fluid at operating temperature: 110 to 130” F. refer to the adjustment 4. When the system oper- The relief valve is located at the top/rear of the lift ates over relief. Connect adaptor (see above) to pressure gauge. Attach adaptor to test port #2. with a Mica Quadrigage or with a conventional pressure gauge haveing a scale of 0 to 3000 psi. Hold control in the NOTE fully actuated position. 6. If adjustment is required. Move the Multi-Function Control to elevate Setting. Reach & Til Steering and Side Shift (if so equipped) pressur check and adjustment procedure.

However. 5. using two wrenches. Loosen lock nut securing the adjustor (see below). hold adjustor and tighten lock nut to secure adjustment. Once adjustment has been attained. Adjust the relief valve to operate between 2650 and 2750 psi. Now. turn key switch OFF.Hydraulic Pressure Checks GROUP 26 Relief Valve Adjustment 1. 4. 2. Install console cover and close door. NOTE Relief valve(s) are factory preset and should not require adjustment. Adjustor ‘-1 SM-587 26-l-5 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . 6. if adjustment is required. do not exceed specified setting. Rotate adjustor CLOCKWISE to increase pressure and COUNTERCLOCKWISE to decrease pressure.

Clean and Refill NPR-345 Open rear door to expose sump tank SM-587 29-i-l Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Material Handling CORK Company GROUP 29 Section 1 Hydraulic Sump Tank Filter and Strainer Drain.

A WARNING When usina air pressure to clean off truck: Wear eye protection and protective clothing when drying with air pressure. Always Wear Safety Glasses Dee 94 29-l -2 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Removeall Jewelry before working on truck. Good ventilation is normally adequate. Reduce air pressure to 30 PSI (207 kPa). clean exterior of plumbing and solenoid valve to prevent dirt and foreign matter from entering hydraulic system. Before dis- connecting the hydraulic components.GROUP 29 Hydraulic System A WARNING Hydraulic fluid is toxic to skin. eyes. A CAUTION Cleanliness is of extreme importance. Debris removed with air pressure can cause injury. and respiratory tract.

Be sure: . Upright is fully lowered and pantograph re- tracted. Set the parking brake. A CAUTION Protect drive motor and brake assembly from any oil spill. Sump capacity is approximately 8 gallons. Power key switch is OFF. Place end of hose into a 10 gallon container and allow the sump tank to drain. Forks are in full forward tilt and the side shifter (if so equipped) is shifted fully to the right.Hydraulic System GROUP 29 HYDRAULIC SYSTEM SERVICE Drain Hydraulic Sump Tank IMPORTANT All cylinders should be fully retracted. 2. Pull hose free of fitting using the cloth to retard fluid leakage. (Key should be re- moved from switch. Place chocks to the front and rear surfaces of the tires to provide restraint from inadvertent ve- hicle movement. Truck is on alevel surface. . see opposite illustration. Place a shop cloth behind hose and fitting. 10 Gallon Capacity SM-587 29-l -3 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . 3. . Loosen and pull hose clamp downward on hose. .) 1.

. . Place clean plasticparts bagsover hose ends to prevent dirt from entering hoses and tubes. Secure bag with hose clamp. Place a clean plastic parts bag over end of hose. Dee 94 29-1-4 SM587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . . Place end of hose into container and allow fluid to drain. GROUP 29 Hydraulic System 4. Loosen clamp (6) and pull hose from pump fitting. Tie hose to filter mounting bracket so it is out of the way. 5. . Loosen clamp (3) and pull hose free of sump outlet allowing remainder of fluid to drain from sump tank. . Set tube with hoses andfittings to one side. Place a container beneath hose and tube (18~ 2). Pull hose free of tube (5). Loosen hose clamp (4).

7. Flush sump tank with two or three quarts of hydraulic fluid. hydraulic tube and lines. Secure hoses with clamps. Wash both tank strainers in a Stoddard type cleaning solvent and allow to air dry. Remove pan and dispose of used fluid in ap- proved manner. 10. 11. . Remove strainer (7) from sump outlet and allow remainder of fluid to completely drain from sump tank. Install strainers.Hydraulic System GROUP 29 6. . 8. 9. Remove fill breather cap and strainer from sump filler tube. Inspect breather cap for further serviceability. SM587 29-l-5 Copyrighted Material Dee 94 Intended for CLARK dealers only Do not sell or distribute .

Clean gasket surface on the filter base. Check Ground Discard old cartridge and gasket. Dee 94 29-l -6 SM587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Wire to be sure it 13. Hand tighten until gasket is seated. Locate gasket on cartridge as shown. 14.GROUP 29 Hydraulic System Using a filter wrench or a strap wrench. see white arrows. . loosen and remove the spin-on type filter cartridge. . Then Tighten l/2 to 3/4 additional turn. 15. Fill hydraulic sump tank with hydraulic fluid recommended in Group 01. 16. . Install cartridge to filter base. Apply a light film of fluid to the new gasket. Check fluid level as outlined on the following page.

l Fluid level should be at the full mark on the sump tank. Operate the hydraulic controls through their cycle sev- eral times forcing air from the lines into the sump tank. add fluid until it is. If it is not.Hydraulic System GROUP 29 Check Sump Tank Fluid Level IMPORTANT All cylinders should be fully reacted. side shifter is shifted fully to the right. Multi-Function Control Handle Refer to Group 01 for recommended Hydraulic Fluid(s). l Forks are in full forward tilt. SM587 29-l-7 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Use Hydraulic Fluid recommended in Group 0 1. l Purge air from the hydraulic system. l If so equipped. Be sure: l Upright is fully lowered. l Check sump fluid level again. Add fluid as necessary to bring fluid level to the full mark on the sump tank.

El!BRIC Material Handling company GROUP 29 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 .

imiter I valves : I- Mateftal Handling Co.17. 20. NPR 150. mli2Y!~ b---a I ------- I Lift inder i!l : : L Flay ?!. 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 Front Buikhead L”Gzo’ Plate of Truck ReachIIin Selector Valve Reach Cylinders I I r-i------i’Lz----F”_l____.

........................................................29-4-3 Reassembly ...29-4-3 Parts Inspection ...................................................................29-4-5 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute ................. GROUP 29 Section 4 Hydraulic Pump Overhaul Contents Disassembly ........................................................................... ...... ........... ....................

GROUP 29 Hydaulic Pump Outlet Do Not Force Seal I below-.surface -_-_ --.--__ Bronze Face Torward Gears --(6) High Pressure Side Pressure Loading Seal (15) Wear Plate (8) Dow Pin (7) Wasf7er (2) -Bolt (1) -Seal (5) Dee94 29-4-2 Copyrighted Material SM-587 Intended for CLARK dealers only Do not sell or distribute .

Somewhat heavier wear pattern is normal on the since cover and internal parts will drop sud. Clean outside of pump in a S toddard type clean- Dowel pins (7) may remain either with the body ing solvent and dry thoroughly. remove seal and lift out NOTE thrust plate before proceeding. Invert pump body with shaft seal up.shaftendup. On models with splined drive shaft. 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. 3. Inspect wear plate (8) and thrust plate (6). On models with keyed drive shaft. there should be no heavy scoring in this area. remove any burrs from shaft end or cover. At no timeshould screwdrivers be inserted further into pump body more than the depth of Pump Disassembly the relieved areas. SM-587 29-4-3 Dee94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . 4. because this will result thrust plate (6) will also have a in shaft seal leakage. Using a may or may not remain with rear file or stone. drive gear (12). How- denly when dowels are disengaged. 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. Also note that the long Parts Inspection journal of the driven gear (13) is toward the front of the pump. Cover seal (5) and thrust plate (6) remove drive key (11) from drive shaft. During disassembly. Overhaul pump only in a clean. Lift out driven gear (13). proceed to NOTE Step 3. Holding shaft end down. remove rear cover (3). Remove rearcover (34) always corresponds shaft seal (10) by prying it out with a large to the inlet side of the pump.onmountingflanges place if scoring or uneven wear is observed. andpressing on drive shaft end in arbor press. body (14). the opposite page. 2. or tap drive shaft with a plastic mallet. The large port in the 6. and wear plate (8). using clean tools and equipment. the body. Use one NOTE hand tosupport rear cover from underneath. 1. thrust plate (6) and wear plate (8). Re- portingpump. Separate rear cover (3) Ii-om body (14) by sup- 2. take special note of the wear patterns on the 5. inlet side can be further identified by the gear contact pattern in the . Should they remain with key way. dust-free location. pattern than can be established for reassembly. ever. Dirt or grit will damage the highly machined surfaces and will result A CAUTION in leakage or premature failure of the pump. 1. lowpressure (inlet) side of the plates (6 & 8). The screwdriver.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. Wash all parts and dry thoroughly with a clean lint free cloth.A CAUTION body (gear) bore. The bore. or with the rear cover.

(:3C) a II Bronze Face Tot-ward Gears --(6) High Pressure Side Pressure Loading Seal (15) Wear Plate (8) Dow Pjn (7) -Bolt (1) Seal (5) SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Gear Face below surface .GROUP 29 Hydaulic Pump Do Not Force Seal .

Remove pressure loading seal (15) and seal (9) 2. 4. 10 engine oil and install thrust plate (6) in its tact wear on low pressure side (inlet) exceeds original position.D. *Sleeve wall thickness should be approximately 0. of the 5. bronze face toward the gears. burned. 7. Check that drive shaft turns with adjustable l Pack the area between the double lip of the seal wrench without evidence of mechanical bind.127 mm) beyond surface of PO@. rShaft Seal -ing . Inspect body for wear and scoring.-J--j\ -J \ /&_JGearlShaft -+ . Lubricate the bushings in body (14) and wear surface at any point.. 1.Hydraulic Pump GROUP 29 3. If the 6. 0. Inspect bushings in body and cover.) 11. legs of “W” seal pointing toward the suction mum of 0. Torque bolts to: 34 .C_ Installation *Sleeve -_Ekl. Ensure outside of “w” circled view in exploded parts illustration on seal is exposed to the discharge pressure. Replace if faces shaft. The seals may be two-piece or plate (8) in bottom of bore. If gear con. In either case. Lubricate bushings in rear cover (3) with SAE Pump Reassembly 10 engine oil. below. suitable de-burring tool. with Lubriplate or equivalent grease. Cleanliness is of extreme importance. Position pump with shaft end down.38 lb. See bottom of bore surface. (Sleeve I. plate (8) with SAE 10 engine oil. The seal should extend a mini. Apply Lubriplate or equivalent to outer surface cover or body if bushings are heavily scored or of drive shaft in installation sleeve.D. .52 mm (l/l 6”) Figure 1 Figure 2 Figure 3 SM-587 29-4-5 Dee94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . scribe marks on cover and body and install cover. Place body (14) on flat plate with shaft seal bore up.) or journals are scored or worn. (Or opposite page. Inspect gear journals and faces. . Install cap screws (1) and washers (2) finger bore until it is to approximate depth shown tight. be slightly smaller the outside diameter of the install drive key (11).ess I-Mounting Face Bear .005” (0..ft. Prevent dirt 8.25 mm (0. Press seal into 9. should be slightly larger than the O. Lubricate rear gear faces and journals with S AE 6. Invert body so that gear boresare up. Replace 4. Install new shaft seal (10).V. discard old seal pressure loading seals (9 & 15) are positioned or seals. (The outside diameter of the sleeve should 10. All replacement seals are two-piece properly in seal grooves and installed against design and should be installed into groove. On models equipped with keyed drive shaft.010”). Apply a small amount of grease to rear cover body is usable lightly remove/wipe burr with seal (5) and install seal into groove.005” (0. Do not push seals below wear plate 3. Match or foreign matter from entering hydraulic system.. shaft seal. Install wear from wear plate.127 mm) depth. making sure that one-piece design. replace body. 5. wearplate.

. .. . ..... . . . . .. . . . .. .. . . . . .. . .l-5 Removal of Hydraulic Lines . .. .. . 30-l-2 Control Linkage . . ...... . . .. .. . . . . . . ..30... ... . .. . . .. .. . . . .. . . .. .. . . . . ... .. . . . ... .. . . . . Reach & Tilt Control Valves .. ... . . .. . . . . . . . . . . ... .... .. ... .. .. . . . . ... . . . .. ... . . 30-l-13 & 14 7 Lift I I Aux I Aux Solenoid Valve Solenoid Valve Typical Illustration SM587 30-l-l Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . . . .. ... .. . . 30-l... .. ...~pri-i~Handling GROUP 30 Section 1 Hydraulic Control Valves and Solenoid Control Valves Remove & Replace Contents Truck Preparation .. . ... . .. . . .. .. . .... . .. . . 30-l-8 Flow Regulator. .. . . .. . .. . ...... . .. .. . . . . . . .. . ... . . ... .... . . .. . . . . .l-6 Lift. . . . . . . . .. . . . . . . . . .. .. . .. . .. . ... .. ... . . . . . . . .. . .. . . . . . .. . . . . .. .. ... . . . . .. .10 Reassembly Suggestions . . .. .......CUIRK~. . . . . . . . . .. . ... . . .. ... .. . . .... .... . . ... .. . . . . . . . ... . . .l-9 Auxiliary and Lowering Solenoid Valves ... . ... . . . . . . . .. .... . . .. . . . . Auxiliary.. ..... . . ... . . . . .. .. .... .. .. .. .. . . . . .. . . . .. . ... ....30.. . . . . . .30. 30-l-13 Hydraulic Tube Installation . .... . . . .. . . ..... . .. . .. . .. .

‘. Debris removed Typical Illustration with air pressure can cause injury v Hydraulic fluid is toxic to skin.F’ . and respiratory tract.. Carefully lift cover a little forward and upward until the cover is free of the control. \. l Tilt forks forward until fork tips touch the floor.:. r l Park truck on a flat level surface. Slip boot off cover lip and tuck bottom of boot into cover hole. Copyrighted Material Intended for CLARK dealers only Do not sell or distribute ...>.. Good ventilation is normally Q:: : adequate. .. &connect truck battery. l Remove key. Move truck to service area. .GROUP 30 Hydraulic Valve 1.. . .. Turn key switch off.. ..- Always wear F?+.+Y .. L .Y Safety Glasses -.c’ 2. Reduce air pressure to 30 PSI (207 kPa). j .. Remove fasteners securing cover to truck.. Remove Front Console Cover Typical Illustration ...:. . l Extend pantograph. . l Fully lower pantograph. I /i ‘. .. eyes.\ A WARNING : :. Remove all Jewelry before working on truck. i”h.j When usina air pressure to clean off truck: Wear eye protection and protective clothing @ when drying with air pressure. l- 3.

) without using specified resistor could cause serious injury to yourself and Typical Illustration bystanders. Remove bolt securing left overhead guard leg to the overhead guard. Open Access Door . l Discharge capacitors using a 100 ohm. . Remove door latch bolt.Hydraulic Valve GROUP 30 . 10 watt resistor connected between the Positive and Negative power terminals on the solid state control panel. SM587 30-l -3 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Hold the resistorinplacefor two ( 2 ) seconds before removing. Remove console cover from truck. NOTE TheFrontHipPadmayberemoved for easier access to components. Typical Illustration 5. Open door. A WARNING Discharging the capacitors \ unplugged. 4. A CAUTION Using a shorting device without a “~esisfor/oad”could cause damage to the control. Discharge the CaDacitorS Discharge Capacitors l Be sure the battery is unplugged. . Refer to opposite illustration.

Twical illustration Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Beforedisconnecting hydrauliccomponents. valves and compartment to prevent dirt and foreign matter from entering hydraulic system. clean exterior of plumbing.GROUP 30 Hydraulic Valve /d CAUTION Cleanliness isof extremeimportance. Lowering Solenoid Valve Lift Control Valve Aux Reach & Tilt Valve ux Solenoid Val Viewed from Right Rear Comer of truck. Immediately cap fittings as lines are removed to prevent fluid leakage and contamination.

l Push pins free of valve spools and control linkage.j$. see above.::I. Carefully pull switch cam away from bracket and switches. Truck Mounting Bracket /.:j:: ‘. “::$:. Be very careful when removing cam that you do not damage the switches. r Mounting Pin &&Control Linkage Control Linkage 0 Remove retainer from each lever mounting pin. 0 Remove Switch Cam.Hydraulic Valve GROUP 30 Step 1 A CAUTION Switches may be damaged if the Switch Cam is not removed.. SM587 30-l-5 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . ‘. Loosen and remove fastener. i Step IA ‘. .

. Disconnect Tube #2 from Aux Valve and Bulkhead Fitting.Bulkhead Fittings .GROUP 30 Hydraulic Valve Lowering Solenoid Valve. Sollenoid Valve. Retu Disconnect Return Line from lift valve. Disconnect Return Line from Aux. Disconnect Tube #l from Aux Valve and Bulkhead Fitting. Disconnect Lift Line from valve and tee fitting. Dee 94 30-l -6 SM587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .

S. Control and Aux. Solenoid Valve. Disconnect Tube #2 from the Aux Solenoid Valve and the Lift Valve. SM587 30-l-7 Dee94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .Hydraulic Valve GROUP 30 Dismnect Tube #I from the Lowering Solenoid Valve and Flow Regulator. Aux Soienoid Valve Disconnect Tube #1 and #2 from P.

\I a\ve ‘\JT Tag and disconnect Tube #I and #2 from control valves. Step IO Remove Lift Control Valve Remove Auxiliary Control Valve. \ . Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .GROUP 30 Hydraulic Valve Step 8 Tag each tube 2 upon removal.

Hydraulic Valve GROUP 30 Step 11 \ ) * Flow Regulator I.Jc’ L r--------7 Remove Flow Regulator from valve. Typical Illustration Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .

--- If removed. be sure to install Harness Clamp/Guide as shown here or harness will not fit resulting in possible shorts and component failure. 0 Disconnect Electical Connectors Typical Illustration Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .GROUP 30 Hydraulic Valve Step 12 .

Typical illustration SM587 30-l -11 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Lift aux solenoid valve from bolts. Lift retainer plate from bolts.Hydraulic Valve GROUP 30 Step 13 Nuts 1 Lowering Solenoid Aux Solenoid Valve e nting Bolts <\ Remove nuts from mounting bolts.

GROUP 30 Hydraulic Valve Step 14 Loosen nut and back off several turns. Slide bolt and valve free of bracket. 30-2-l Auxiliary Reach & Tilt Control Valve 30-3-l Lift Control Valve 30-4-l Lowering Solenoid Valve 30-5-l Auxiliary Solenoid Valve Note: The following valves are located on the Pantograph and include remove and replace procedures. V&e S8nrfce ProcedUreS are covered in the following sections. 30-6-l Reach & Tilt Solenoid Valve 30-7-l Side Shifter Solenoid Valve Typical Illustration Dee 94 30-l -12 Copyrighted Material SM587 Intended for CLARK dealers only Do not sell or distribute . Refer to the appropriate section.

Tube or Hose Fitting Connector SM-587 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .. tighten the valve mounting bolts only O-ring Face Seal Fittings finger . or 5. until it stops turning whilemoving fitting (or nut) lightly side to side to prevent cocking. Initially.Hydraulic Valve GROUP 30 REASSEMBLY SUGGESTIONS Hydraulic Tube Installation 1. Align the tube. Now. tighten finger 4. ing pins and retainers. tighten valve mounting bolts. Insert control linkage into slot of each valve seal is lubricated. l Usiw finger tins only. Do not tighten them at this time. 2. Realign the multi-function control handle as (or align the fitting to the port) and check to see instructed in Group 13. lightly snug fitting (or nut) with a wrench until it bottoms out on the seat or port.. slots.. seated and spool. properly retainedin fitting groove. Check to be sure the O-ring face 2. or hose nut to the mating fitting 3. tight . tight. . that the threads seat properly . Valve Assemblies IMPORTANT 1. temporarily hold linkage in place within the in the connection will leak. If the seal is missing or the slotted end of each valve spool. Remove l/4-inch rod and install linkage mount- thread damage. l Insert l/4-inch rod through the holes provided in see below. This is to not fitted properly in its groove. . Lubricate all O-rings slightly with hydraulic Mounting the Lift and Tilt Control fluid.

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. Using a pen or marker. 30-l -14 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . STEP 2 Tighten One (1) Flat from finger tight (bottomed out) position using I I second wrench.GROUP 30 Hydraulic Valve 3. see above. Holdconnector withone -! O-Ring Face Sea/s wrench and tighten the cap with a second wrench. Initial osition - IMPORTANT Hold connector with one wrench while tighten- ing the nut with a second wrench. l Rotatenutjustoneflatas shown.

.... 30-2-4 Lowering Solenoid Valve Lift Control Valve Viewed from Right Rear Comer of truck.........\Handling GROUP 30 Section 2 Auxiliary................................ Inspection and Reassembly ......................CLqRK M$d$............................. .......... 30-2-3 Cleaning..................... Reach & Tilt Control Valve Contents Valve Cut-A-Way with Specifications ..... _ Typical illustration SM587 30-2-l Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute ...................30-2-2 Disassembly ...................................

(11.25 Lb.9 N-m) Tvoical Illustration AUX VALVE .TOP VIEW l Flow Rate : 3 Gal / min. (27.1 .SIDE VIEW Plug Torque to: 8 . Ft.) r -Bushing \ / LSpacer Ls2asher !.8 .6 N-m) 7 Breather (Must be open at all times.33. Cap Torque to’.4 Lhnin) Typical Illustration Dee94 30-2-2 SM587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . 20 . (10.Body I_ O-Ring .13. Ft.GROUP 30 Hydraulic Valve AUX VALVE .10 Lb.

Typical Illustration SM587 30-2-3 Copyrighted Material Dee94 Intended for CLARK dealers only Do not sell or distribute . Remove wiper seal from valve body. Discard 1. not over tighten.33. and remove the spool cap. care- fully remove spool O-rings from valve body Brass Tool bore.9 Nom) Disassembly 4.1 . (10. To do so will make the valve unfit for further service. (27. Do not scratch. Placevalve assembly in avise with softjaws.8 . A CAUTION Be extremely careful when removing spool and O-rings from valve body. Discard the O-rings.25 Lb. Remove port plug and O-ring.Hydraulic Valve GROUP 30 Port PlUCJ Torque to: 8 . NOTE Do not remove spring retainer ring unless the spring is broken and needs to be replaced 3. 5. Remove spool from valve body as shown. do the seal. ring. nick or m ar the spool or the body bore. Ft.10 Lb. Ft.13. Discard the O- 2.6 Nam) Typical Illustration Cap Torque to: 20 . Using a brass tool similar to that shown.

ft. l Inspect valve spool and bore for burrs and scoring.finger tight.lOlb. If scoring is not deep enough to cause objectionable leakage.8 . Port Plug l Install a new O-ring on the port plug and screw the plug into the appropriate port .13.8 . cracks or other damage caused by foreign material in the hy- draulic system. Be care- ful when polishing that you do not remove the chrome plating. nicks or scratches make the part unsuitable for further service and the valve should be replaced. Debris removed with air pressure can cause injury. Port Plug- Valve Reassembly 8 . The spool and body are a matched set and cannot bereplaced as indivudal parts. l Discard all old seals and the spool wiper ring. Reduceair pressure to 30 PSI (207 kPa). O-Ring l Lubricate all parts with clean hydraulic fluid to (10. Any surface having deep cuts. the surfaces can be stoned or polished with a crocus cloth. paint or debris.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.ft.6Nem) Dee94 30-2-4 SM587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .13.6 N*m) facilitate reassembly andprovide initial lubrica- tion. Inspect the cap breather to be sure it is not obstructed with dirt.10 lb. Look for loose chrome plating. 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. l Torquetheplug to: 8. Use a light to inspect the body bore. (10.

Typical Illustration l Using brass tool as shown. l Insert clevis end of spool into the back end of valve body bore. Typical Illustration SM587 30-2-5 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . slightly smaller than the O. l Install spool cap and torque to 20 . Typical illustration l Continue to move spool until the spring bushing is seated in the valve bore. See opposite illustration.Using a sleeve with an O.D.ft. carefully seat the O- ring completely into groove. l Install O-ring into cap end ov valve. slowly rotate spool (as required) pushing Carefully seat O-ring. Let loose of O-ring. l Now. Push spool inward until it is even with the back side of the seal “groove” located at the front of the valve body bore. tap the seal inward until seal is flush with the outside of the body.D. l Pinch lubricated O-ring (as shown) so it can be inserted into the groove. spool until it is through O-ring. Body l Install wiper.Hydraulic Valve GROUP30 Valve Spool Spool flush with back side of “groove”.25 lb. of the wiper seal.

13. Cap Torque to: 20 . (27. (27. Place washer over end of spool. Ft.ft.1.GROUP 30 Hydraulic Valve Pklg Torque to: 8 . Ft. Now.6 . Install spring over spacer.9 Nem) Typical Illustration Spool Spring Assembly If the spool spring assembly was disassembled for parts replacement.) -Bushing / LSpacer ~s~asher . Install bushing over spool and into body.25 Lb. (10. Install cap and torque to: 20 . install the spacer with the spring onto the valve spool and secure components in position with the retainer ring.6 Nom) open at all times.9 Nom).1 .25 lb. Typical Illustration L Dee94 30-2-6 SM587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .10 Lb.33.33. lubricate the parts with clean hydraulic fluid.

Operate the hydraulic controls through their cycle several times forcing air from the lines into the sump tank.885385 ‘\ the sump tank. If it is not. l Now. Add fluid as necessary to bring fluid level to the full mark on \ Clark Part No. Hydraulic Fluid 7-ypical Illustration “\ L Copyrighted Material Dee 94 Intended for CLARK dealers only Do not sell or distribute . Use Hydraulic Fluid per Clark Specification MS68.Hydraulic Valve GROUP 30 Check Sump Tank Level l Fluid level should be at the full mark on the sump tank. purge air from the hydraulic system. add fluid until it is. Multi-Function Control Handle l Check sump fluid level again.

.......................................................... ..................... 30-3-6 Lift Control Valve ..... 30-3-7 & 8 Valve Disassembly ........................30-3-10 Lowering Solenoid Valve Lift Control Valve Aux Reach & Tilt Valve Viewed from Right Rear Comer of truck............. ....................30-3-2 & 3 Pilot Operated Relief Valve Assembly with Schematic ........................................ GROUP 30 Section 3 Lift Control Valve Contents Specifications ................................................ SM587 30-3-l Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute ................. ............................................................... 30-3-g Valve Reassembly .......................................30-3-5 Cut-A-Way View of Valve ......................................

Disconnect truck battery. Cover \ Dee94 30-3-2 SM587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . l Park truck on a flat level surface. Remove Front Console Cover . Move truck to service area. . 3. and respiratory tract. l Extend pantograph.GROUP 30 Hydraulic Valve 1. Remove key. . Remove fasteners securing cover to truck. Good ventilation is normally adequate. Debris removed with air pressure can cause injury Hydraulic fluid is toxic to skin. Remove console cover from truck. . l Tilt (if so equipped) forks forward until fork tips touch the floor. Turn key switch off. Carefully lift cover a little forward and upward until the cover is free of the control. Remove all Jewelry before working on truck. l Fully lower pantograph. Reduce air pressure to 30 PSI (207 kPa). Front Console . Slip boot off cover lip and tuck bottom of boot into cover hole. eyes. . @ Always wear Safety Glasses 2. A WARNING When usina air oressure to clean off truck: Wear eye protection and protective clothing when drying with air pressure.

.Hydraulic Valve /@ GROUP 30 Q e 4. Hold the resistor in place for2 seconds before removing. ide Cove . Be sure the battery is unplugged. Dischawe the CaDacitorq Discharge Capacitors . Lift cover off truck. 5. A WARNING Discharging the capacitors without using specified resistor could cause serious injury to yourself and bystanders. A CAUTION Using a shorting device without a “~esisforload”couid cause damage to the control. Discharge capacitors using a 100 ohm. Remove Side Cover . 10 watt resistor connected between the Positive and Negative power terminals on the SCR control. SM587 30-3-3 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Remove fasteners seuring side cover to truck.

ft. (11 .47 N*m) 11 Relief Valve Adjustor 2650 ..2 l/min) NOTE f? : Liquid Lock Threads1 Spool and Body are a matched set and cannot 4 s. (3 .GROUP 30 Hydraulic Valve Torque to: 8 .10 Ib.14 N*m) After Setting Relief TorqueDrive Screw to: 20 - .. (41.190 bar) @ 8.ft.3 Ib.5 GPM (32..ft.35 lb.. Torque to: 2 .2750 PSI (183 .4 N*m) bepurchasedseparately. T Dee 94 30-3-4 SM587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .

Hydraulic Valve GROUP30 SM587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .

GROUP 30 Hydraulic Valve Load Check Poppet 1 r-Washer Spacer I O-Ring O-Ring 1 Return Spring Liquid Lock Threads ue to: 2 .ft. (3 .4 N-m) Dee94 30-3-6 SM587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .3 Ib.

Lubricate new O-ring withclean hydraulic fluid. Discard O-ring. l Remove hex plug. If found. SM587 30-3-7 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . 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 Remove O-ring from hex plug.Hydraulic Valve GROUP30 Spring T I LIFT CONTROL VALVE Load Check Valve Reassembly Disassembly Lubricate the poppet and spring with clean hydraulic fluid.47 N*m). Take care not to cut Inspection or over-stretch the O-ring. Install O-ring onto hex plug. Next insert spring into poppet hole. l Inspect poppet for scratches or nicks. Install poppet into cavity center. (41 . Torque hex plug to 30 . If poppet is to be used again.35 lb. l Remove spring and poppet. replace poppet with a new one.ft. care must be taken not to damage it.

rw. -.ft. .4 N-m) 30-3-8 SM587 Dee94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Torque to: 2 . . (3 .-- (Washer) m h’yw’u w-w. Hydraulic Valve GROUP 30 O-Ring I 7 O-Ring To remove (or install) Screw “A”.3 Ib. you must keep valve spool from rntntinn ‘3 2 rod as shown. .w_ .. . .

screwdriver. dirt and foreign matter from entering hydraulic system. 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. Do not scratch. Reduce air pressure to 30 PSI (207 kPa). clean exterior removed from the spool and valve body. Examine the spool. spring and washer. Discard all seals. Debris removed with air pressure can cause injury. Look for loose chrome plating.Hydraulic Valve GROUP 30 Cleaning and Inspection Valve Disassembly Wash all parts in a Stoddard type cleaning Ceanliness is of extreme importance. A WARNING AIR PRESSURE Wear eye protection and protective clothing when cleaning or drying with air pressure. To doso. Inspect the surface of the spool and body bore End Cap Removal for cuts. Nicks on the spool can than the hole in the end of the valve spool. spool seals and springs. SM587 30-3-g Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . 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. Any surface small a diameter rod will cause damage to the having cuts or scratches makes the part unsuit- spool cross hole bore. valves and compartment to prevent parts. draulic system. moved to prevent fluid leakage and contamina. Air dry of plumbing. only slightly smaller bore in the valve body. NOTE This may require heavier than normal forces since the screw has been installed using loctite. Reassemble only with new seals and springs. A CAUTION Be extremely careful when removing spool and O- rings from the valve body. Too be removed with a crocus cloth. Before dis. l Using a brass tool similar to that shown. tion. Immediately cap fittings as lines are re. solvent.will make the valve unfit for further service. Spool and Seal Removal l Remove spool from valve body. nick or mar thespool or the body bore. remove screw (A). Be certain all foreign matter has been connecting hydraulic components. l Remove spacer.D. Discard these seals. Use a light to inspect the spool l Insert a rod with an O. able for further service and the valve should be replaced. scratches. care- fully remove O-rings from valve body bore. nick etc.

Dee 94 30-3-l 0 SM587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . previously described and push the spool back through the valve and the newly installed O. Be extremelycarefulthatyoudo not damage (cut or nick) the O-ring during installation. Install mounting screws 2. 6. could hamper proper operation. Sparingly such time as the valve is installed onto the apply Loctite to the screw threads. Align the “mounting holes” of the end cap with those in the valve body. . Continue this process until the end of the or equivalent) to the spring and spacer. 4. 3. pinch (as shown) a new lubricated O-ring so it can be partially inserted into the groove.ft. completely push the O-ring into the groove. of Screw “A”. Install port plugs into valve openings until Loctite and assembling the components. use the procedure spring should return to its original position. is flush with the inside edge of the grove located 6. Hold rod and spool from turning and using a flat at the cap end of the valve. Torque Screws to: IMPORTANT 2 .4 Nom) Threads of Screw “A and those in the valve spool should be free of dirt and grease before applying 9. (3 . 1. After the O-ring is installed. 2. Continue to push the spool inward until the front (clevis) end of spool is flush with the inward side of the front O-ring groove as shown here. on push the spool inward until the end of the spool page 8 & 9) into the hole of the spool. Lubricate valve spool and a new O-ring with clean hydraulic fluid. Continue to 5. finger tight. Insert the spacer into the spring. securely tighten Screw “A’. into the base end of the spool finger tight. . Now.3 lb. Next. Follow the same procedure described in Steps 3 & 4. Place one drop of Loctite onto the threaded end tions. Push down on Screw “A”. Using a brass tool. bladed screwdriver. 4. The spring should compress and upon releasing the screw. Apply a mediumcoating of lubricant (Lubriplate ring. ing it on through the front O-ring. Lubricate and install a new O-ring into this Check Spring Operation groove. Position rod (described in “Disassembly”. slowly rotate the spool while gently mov. Sparingly apply Loctite to the threads of both End Cap Assembly (Refer to Illustrationon Page 8) end cap mounting screws. Install Screw “A” through the spacer(andspring) 5. Install washer onto the end of the valve spool.Be extremelycarejidthatyoudo not damage the body bore. Too much Loctite truck. Now tighten screws to specifica- 3. spool is flush with the casting at cap end of body. the 7. Carefully insert spool into the bore at the cap end of the valve body. 7.GROUP 30 Hydraulic Valve Valve Reassembly Flush with Back Side of Groove Spool and Seals 1. To do so will make the assembly unfitfor service. 8.

... ..... . . .. . . .. 30-4-2 Hydraulic Schematic .. ... .. . ... . . .. . . .. .. . ..... .. . . . . .. .. . ....... .. ... ....... . . .. ...Cl!!!!RK Ma~pri-i~Handling GROUP 30 Section 4 Lowering Solenoid Valve Contents Specifications. . ...... . . ... . ... . ... . . . . . .30-4-5 Lift Control Valve Aux Reach & Tilt Valve Viewed from Right Rear Comer of truck..... . . . . . . . .. . . . ..... .. .. .. . 30-4-5 Installation Notations (refer to Section 1 for Removal Instructions) .... ... ...... . .... . .... .. . .. . . . .. . . .... .. . . . . . ... .. .. 30-4-3 Disassembly . . ..... . Typical Illustration SM587 30-4-l Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . ... . . ...... .... ... . . .. . .. .. ..... .... .. . .. . .. .. ... . .... . .. . . ... .. .. . . . ...... . . . . . . Wamings and Caution . . . . .. ... .. . 30-4-4 Reassembly ... . .. ... .

Debris removed with air pressure can cause injury. Removeall Jewelry before working on truck. clean exterior of plumbing and solenoid valve to prevent dirt and foreign matterfromentering hydraulic system. and respiratory tract. eyes. Reduce air pressure to 30 PSI (207 kPa). Good ventilation is normally adequate. Always Wear Safety Glasses Dee 94 30-4-2 SM587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . A CAUTION Cleanliness is of extreme importance. A WARNING When using air pressure to clean off truck: Wear eye protection and protective clothing when drying with air pressure.GROUP 30 Solenoid Valve A WARNING Hydraulic fluid is toxic to skin. Before dis- connecting the hydraulic components.

normally closed.8 Nom) max. push button in. lettering side out as shown here.__ $ 0 1 Rated Flow: 114 L/MIN (30 G.M.P. Toraue: 5 Ib. ing Valve. When energized the poppet lifts to open the 2 to 1 flow path.ft. twist counterclockwise 180” and release.4 II 1’ I ‘I ---- L__.Solenoid Valve GROUP 30 LOWERING SOLENOID VALVE Description A solenoid-operated.) Minimum Pull-in Voltage: 85% of nominal @ 20685 kPa (3000 PSI). In this mode. IMPORTANT poppet-type. Typical Illustration SM587 30-4-3 Dee94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . To return to normal opera- tion. Coil must be installed with the designed to function as a load-holding or block. In this position the valve will remain open. twist clockwise 180’ and release. allowing flow from 1 to 2. 2-way. Torque: 35 Ib.ft. see below. while blocking flow from 2 to 1. \/ Operation When de-energized. the solenoid valve acts as a check valve. flow is also allowed from 1 to 2. Override will be detented in this position. screw-in hydraulic cartridgevalve.) Rated Pressure: 24132 kPa (3500 PH. (6. --- 1 I I II 1 io II li II 2 -J -+ p-1 ----.

GROUP 30 Solenoid Valve Manual Override ACAUTION Retainer Control Thevalvestemisveryfragile.ft. Beverycareful Nut Torque: 5 Ib.. clean exterior of plumbing and solenoid valve to prevent dirt and foreign matter from entering hydraulic system. l Remove solenoid valve from valve body. l Wash all parts but the coils in a Stoddard type l Inspect wire leads and plugs for further service- cleaning solvent. Do not take apart. Replace defective parts. dent or bend the stem. l Remove fittings from valve body. A CAUTION Cleanliness is of extreme importance. l Wipe all parts dry with a clean lint-free cloth. 1 (I) O-Ring Back-Up Ring (3) L__//-(21 O-Ring ACAUTION Valve is not serviceable. when handling the valve that you do not L (6.4 NVTI)9. ability. Dee94 30-4-4 Copyrighted Material SM587 Intended for CLARK dealers only Do not sell or distribute . Before dis- connecting the hydraulic components. ----- (47. Over torquing the coil nut or Over torquing the valve at installation will cause damage to the valve. Wire Leads DISASSEMBLY l Remove nut and coil from solenoid valve stem. Allow components to airdry beforereassembly. Cleaning & Inspecting Solenoid l Replace al seals with new ones.8 Nom) max. BodyT- Va’ve Lead Wires-. Torque: 35 Ib.ft.

Install coil onto valve stem. ft. 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. Install solenoid valve into body bore. Locate valve over bolt and install retainer Install coil retainer nut and torque to 5 ft lb (6-8 nut finger tight. REASSEMBLY INSTALLATION Lubricate all parts in clean hydraulic fluid prior to installation. SM587 30-4-5 Dee94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Again.4 N*m). clean and lubricate on opposite page. Replace defective parts. not nick or cut the O-rings or leakage will occur. Refer to Section 1. (6. Nom) Install hydraulic fittings install finger tight.Solenoid Valve GROUP 30 A CAUTION Typical Illustration Be certain coil is positioned as shown below so wire leads may be connected without causing damage to the wiring. Torque to 36 ft lb (47. Remove caps just prior to installation. hydraulic connections and their seals verycarefulthatyoudonotnickorcuttheO-ring for damage. Install large O-ring (1) into it’s groove being IMPORTANT Inspect hoses. Be certain solenoid valve is tightened securely to the body. Prior to attaching hose ends and connections to the Install O-ring (2) and backup ring (3) as shown fittings on the solenoid valve. Reassemble only with new seals. truck. If you over- tighten the nut damage to the valve stem will result. making if unfit for service as it will leak. Be certain to tighten coil retainer nut to 5lb. be very careful you do them with new hydraulic fluid. rWires IOL & IOM 18 HARNESS CLAMP/GUIDE must be installed as shown or the harness will not fit resulting in possible shorts and component failure.8 Nom) maximum.

Refer to instruc- tions in Section 1. Dee 94 30-4-6 SM587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . l Tighten coil retainer nut. Now go back and securely tighten each hy- draulic connection. l Tighten valve body mounting nuts securely. l Replenish hydraulic system. IMPORTANT Allelectricalplugsandtheirreceptaclesarematched labeled for easy connection.GROUP 30 Solenoid Valve When Connecting Hydraulic Plumbing: l Be certain valve fittings and hose ends are in proper alignment and then install each one finger tight until all connections have been made. 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 Connect coil plugs to their receptacles in the wire harness.

. .... .. . ... ... . . ... . . ..... . .... ... ... .. . . 30-5-2 Hydraulic Schematic . ... ........ . ....... .... . . ... . . . . . .. . ... ....... .. ... ....CORKMaterial Company Handling GROUP 30 Section 5 Auxiliary Solenoid Valve (Reach and Tilt Control) Contents Specifications... .. ..... .. . 30-5-5 Lowering Solenoid Valve Lift Control Valve ux........ ... .. ... ... ....... 30-5-5 Installation Notations (refer to Section 1 for Removal Instructions) . .... .. Reach & Tilt Control Valve 11Auxiliary Solenoid Valve 11 Viewed from Right Rear Comer of truck. . ... .... ...... ... ............ . .... .... ...... Typical Illustration SM587 30-5-l Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .. ... .. . .. . 30-5-3 Disassembly ...... ... ...... .. . ...... . . .. .. .. ..... . . ...... . . .. .. ... . Warnings and Caution . . .. . . . ...... ..... .. ..... ... ....... ... .. ..... 30-5-4 Reassembly . ..

Reduce air pressure to 30 PSI (207 kPa). Good ventilation is normally adequate. A WARNING When usina air Dressure to clean off truck: Wear eye protection and protective clothing when drying with air pressure.GROUP 30 Solenoid Valve A WARNING Hydraulic fluid is toxic to skin. Before dis- connecting the hydraulic components. A CAUTION Cap all ports to prevent dirt and foreign debris from entering assembly. eyes. Debris removed with air pressure can cause injury. clean exterior of plumbing and solenoid valve to prevent dirt and foreign matter from entering hydraulic system. and respiratory tract. Always Wear Remove all Jewelry before working on Safety truck. A CAUTION Cleanliness is of extreme importance. Glasses Dee 94 30-5-2 SM587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .

You will experience shorts and component failure if the orque: 35 lb.I.) Rated Pressure: 20685 kPa (3000 P.8 N*m) Max. careful when making Be 1 connections. _-I -- -- Hydraulic Schematic Rated Flow: 114 L/MIN (30 G. -ypical Illustration Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .P.ft. plugs and Torque: Slb. (harness routing) I plugs.Solenoid Valve GROUP 30 AUXILIARY SOLENOID VALVE 0 IQ IMPORTANT All wiring. (6. (47.and receptacles are not correctly installed.) Minimum Pull-in Voltage: 85% of nominal @ 20685 kPa (3000 p-s-i.). receptacles are labeled for - easy identification.M.4 N*m) Max wiring.ft.S.

res 10K & IOL * Remove nut and coil from solenoid valve. L 1rypical Illustration Dee 94 30-5-4 SM587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . l Remove fittings from valve body.GROUP 30 Solenoid Valve O-Ring(s) /- Typical Cartridge Kit -ypical Illustration Disassembly l Unplug Coil S3 from wire harness. Replace defective parts . Inspect wire leads and plugs for further service- ability. Cleaning & Inspection Wash all parts except coils in a Stoddard type cleaning solvent. I Body @I Inspect wire leads and plugs for further l.----- servicability. Wipe coils with a clean cloth. If damaged. replace the coil.Use Service l Parts Kit(s). Replace all seals with new ones. Wipe all parts dry with a clean lint-free cloth. Allow components to airdry before reassembly. l Remove solenoid valve from valve body.

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. Take particular care not to damage the coil stem.Before disconnecting the hydraulic components. to the harness leads without causing damage to wiring. 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. on the solenoid valve. INSTALLATION l Connect coil plugs to their receptacles in the IMPORTANT wire harness. Refer to Section. lic connection. Be certain l Tighten valve body mounting nuts securely. mounting. l Installcoilretainernut and tighten to5 lb. Clean and lubricate them with new l Check wire harness clamps for security of hydraulic fluid. Now go back and securely tighten each hydrau- l Next. made. Replace defective receptacles are matched labeled parts. l Install solenoid valve into body bore. making if unfit for service as it will leak. hydraulic IMPORTANT connections and their seals All electrical plugs and their for damage. (6. Check to be sure each plug and receptacle Prior to attaching hose ends match before attempting to make and connections to the fittings connections. l Align valve body “slots” with mounting bolts on l Install large O-ring into it’s groove being very truck. clean exterior of Wires 10K & 1 plumbing and solenoid valve to prevent dirt and fqreign matter from entering hydraulic system. installation. l Lubricate all parts in clean hydraulic fluid prior When Mounting Solenoid Valve: to installation. Again.8 A CAUTION N*m).. install coil over solenoid valve. Be certain the harness is in good Remove caps just prior to condition and that it is routed properly. Inspect hoses. 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. for easy connection. SM587 30-5-5 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . solenoid valve is torqued correctly to the body.Solenoid Valve GROUP 30 REASSEMBLY A CAUTION Wires 1OL & 10M Cleanliness is of extreme importance.ft.Locatevalveoverboltsandinstallretainer careful that you do not nick or cut the O-ring nuts finger tight. Use only new seals.

. Add fluid as necessary to bring fluid level to the full mark on the sump tank.-_I I22 MS68 Clark Part No. l Now. Use Hydraulic Fluid per Clark Specification MS68. add fluid until it is. purge air from the hydraulic system. Multi-Function Control Handle Use . l Check sump fluid level again. Operate the hydraulic controls through their cycle several times forcing air from the lines into the sump tank.GROUP 30 Solenoid Valve Wires 1 OK & 1 OL resulting in possible shorts and com- Check Sump Tank Level r l Fluid level should be at the full mark on the sump tank. If it is not.885385 \ Typical lllustratior jpical Illustration “1 Hydraulic Fluid Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . .

...................... ... 30-6-2 Discharge Capacitors .. 30-6-6 Specifications and Hydraulic Schematic ................ 30-6-3 Hydraulic Plumbing Diagram ..................................... ............ Material Handling C19RK Company GROUP 30 Section 6 Reach & Tilt Selector Valve Contents Truck Preparation .... ... 30-6-9 Removal.. ....................................... ....... ... .......... ............... Disassembly & Reassembly ...... ....... ........ 30-6-9 SM-587 30-6-l Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .......... .... ........ . 30-6-6 Location and Mounting Illustration ............. ................................................................................ . .....I... ...............................I..

Remove console cover from truck. Front Console Cover \ Dee 94 30-6-2 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . 2. Refer to opposite illustration. l Disconnect truck battery. . Remove Front Console Cover . l Remove key. . . Move truck to service area. . . Turn key switch off. 3. Carefully lift cover a little forward and upward until the cover is free of the control. Fully lower pantograph. Remove fasteners securing cover to truck. Extend pantograph. Tilt (if so equipped) forks forward until fork tips touch the floor.GROUP 30 Selector Valve 1. Slip boot off cover lip and tuck bottom of boot into cover hole. . Park truck on a flat level surface.

Discharge capacitors using a 100 ohm. Remove door latch bolt. A WARNING Discharging the capacitors without using specified resistor could cause serious injury to yourself and bystanders. Be sure the battery is unplugged. NOTE TheFrontHipPadmayberemoved for easier access to components. .Selector Valve GROUP 30 4. Remove bolt securing left overhead guard leg to the overhead guard. Open door. . A CAUTION Using a shorting device without a “resisforload”could cause damage to the control. 10 watt resistor connected between the Positive and Negative power terminals on the solid state control panel. Dischawe the Car>acitoq Discharge Capacitors . Holdthe resistorinplacefor two (2 ) seconds before removing. . Open Access Door . 5. SM-587 30-6-3 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .

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. A CAUTION Cleanliness is of extreme importance. Always Wear Safety Glasses Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Reduce air pressure to 30 PSI (207 kPa). Good ventilation is normally adequate. - Removeall Jewelry before working on truck. eyes. Debris removed with air pressure can cause injury. Before dis- connecting the hydraulic components. and respiratory tract.GROUP 30 Selector Valve A WARNING Hydraulic fluid is toxic to skin.

BE CERTAIN IT IS BLOCKED AS SHOWN. SM-587 30-6-5 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . This is to prevent “retraction” of the pantograph when disconnected from the upright. BEFORE WORKING ON PANTOGRAPH.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).

Pantograph #5 SAE o-RingPOTRetract. Pantograph ~4 SAE o-Ringport Back Tilt (S. Tilt (S. Pantograph #5 SAE o-Ringport Retract. Pantograph #5 SAE o-Ringport Reach.S.Right) #4 SAE o-RingPODReach.GROUP 30 Selector Valve #5 SAE o-Ringport For.LA) #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 .S.

Selector Valve GROUP 30 Over torquing the coil nut or the valve at 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 .

wiring out of the way. “Crack” the valve bodies unless there was fittings to release pressure leakage between the two. A WARNING NOTE Hydraulic lines may have It will not be necessary to separate trapped pressure. 4. Remove both mounting fasteners from panto- graph frame “B” and valve “A”. Cap both hose ends. 2. then remove four l/4-20 screws and separate the bodies. Beware. Use caution when disconnecting fittings. Wipe coils with clean cloth. Tag tubes and disconnect fittings #ll & #12 from bottom side of valve “A”. Be sure to use 3. Move a brass tool when removing seals. connectors #2 from coil S5. Tag hoses and disconnect h ydraulic connections #5 and #8 from valve “A”. Discard the six O-ring seals located A WARNING between the bodies. valve was leaking between the bodies. Cleaning l WashallpartsexceptthecoilsinaStoddardtype cleaning solvent. Place com- ponents on a clean work bench.7. A WARNING DISASSEMBLY Be sure pantograph is blocked l Remove coils and solenoid valves S5 & S6 from as illustrated on page 5. . l Replace all seals with new ones. If the before disconnecting. A CAUTION Residual pressure will be pressent when disconnecting lines. valve body. Loosen guard mounting bolts and remove guard. Remove fasteners #4 from clamps #3. Removevalve from the pantograph. 5. 6. 1. l Wipe all parts dry with a clean lint-free cloth. Dee 94 30-6-8 SM587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . the pantograph may settle.GROUP 30 Selector Valve REACH 81TILT SELECTOR VALVE 7. When trapped pressure is relieved. Remove hoses 6. Cap all hose ends. Unplug connectors #l from coil S6 and unplug Allow components to airdry before reassembly. REMOVAL l Remove both counterbalance valves fromvalve body. 9 & 10 from each reach cylinder.

Selector Valve GROUP 30 Solenoid Valves es Cleanliness is of extreme importance. clean exterior of plumbing and solenoid valve to prevent dirt and foreign matter from entering hydraulic system SM587 30-6-9 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Before disconnecting hydraulic components.

*6. Install the solenoid valves into their respective bores in the valve body.9 N*m)maximum. Torque: 5 Ib. Dee94 30-6-l 0 SM587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . This will allow thecoil to Torque: 25. Again.ft. Install coil retainer nut and torque to 251b. the truck. ft. Install O-ring and backup ring as shown above. Be certain the solenoid valve is torqued correctly to the body. install the coil over the solenoid valve. Install large O-ring into it’s groove being very careful not to nick or cut the O-ring making it unfit for service or it will leak. Ib. be very careful not to nick or cut the O- rings or leakage will occur.8 N-m) Max. be correctly positioned at time of installation to (33.9 N-m) Max. (33. Next.ft.GROUP 30 Selector Valve Typical Cartridge Kit rypical Illustration REASSEMBLY Receptacle Leads Lubricate all parts in clean hydraulic fluid prior to installation.

(47. to prevent dirt and foreign matter fr entering hydraulic system. If thevalve has been tampered with 9c 1eanexteriorof plumbing and solenoidvalve itmustbereplaced with anew one. rings or leakage will occur. Remove hose caps just prior to l Install the counter balance valves into their installation. be very careful not to nick or cut the O. respective bores in the valve body. solenoid valve. Wipe hose ends and connections l Install O-rings and backup ringsas shown above. careful not to nick or cut the O-ring making if unfit for service or it will leak.Back-Up Kings Typical lllustratio REASSEMBLY INSTALLATION l Lubricate all parts in clean hydraulic fluid prior IMPORTANT to reassembly. Use only new seals1 Inspect hoses. .4 Nom) to valve body. Before (NON-ADJUSTABLE) dis-connecting the hydraulic components. hydraulic connec- tions and their seals for damage.ft. clean prior to installing them to the Again. l Install large O-ring into it’s groove being very Replace defective parts. SM587 30-6-l 1 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .Selector Valve GROUP 30 A CAUTION Cleanlinessisof extremeimportance. Torque them to 35 lb.

GROUP 30 Selector Valve Valve Mounting Fastener i Nui A Solenoid Valve B Pantograph Frame C Reach Arms D Carriage Frame Typical lllustratior Dee 94 30-6-q 2 SM587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .

Install connections #5 and #8. tightenfasteners until after the hydraulic hoses are installed.9 & 10 to the reach cylinders finger tight. 5. hose tag and install #12 connec- tion finger tight. Remove cap. securely tighten each hydraulic connec- tion to the valve body and the reach cylinders. Now.Selector Valve GROUP 30 Mounting Selector Valve 1. Install mounting fasteners finger tight. Next. hose tag and then install connec. Remove cap. Connect coil plugs to their receptacles. 4. The system must be purged of air before putting truck back into service or damage to the hydraulic system Connecting Hydraulic Plumbing may result. Do not truck into service. Position valve to the pantograph frame aligning holes in frame with those in the valve. Replenish hydraulicfluid in the sump tank before putting the 2. Refer to page 5 for correct routing. 7. tion #l 1 to valve finger tight. 6. 3. 9. Refer to A CAUTION opposite illustration. be sure the valve guard is located properly and securely tighten both solenoidvalvemount- ing bolts.7. SM587 30-6-I 3 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Install and tighten clamp bolts #M.8. 4. tighten nuts and bolts. Then install con- nections #6. Check to be sureeachplugandreceptaclematch before attempting to make connections. Install wire clamps #3 with bolts #4. IMPORTANT All electrical plugs and their receptacles are matched labeled for easy connection. Installing clamps. 8. IMPORTANT Be sure the hoses are routed correctly before attempting to connect them to the valve. connect wire plugs.

............................................... ..............................................................30-7-5 & 6 Disassembly and Reassembly ........... ......................................................................................................................................... ............................... 30-7-8 Hose Routing .........30-7-2 Removal .......................................X&7-7 Installation . .......................... 30-7-g SM587 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute ................. Material Handling EllFlRH Company GROUP 30 Section 7 Side Shifter Solenoid Control Valve (Optional Equipment) Contents Truck Make Ready ....................................... 30-7-4 Specifications and Hydraulic Schematic....................

l Park truck on a flat level surface. l Tilt (if so equipped) forks forward until fork tips touch the floor. Turn key switch off.GROUP 30 Solenoid Valve 1. l Fully lower pantograph. * Remove key.. l Disconnect truck battery. Dee 94 30-7-2 SM587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Move truck to service area. Typical Illustration 2. l Extend pantograph.

Solenoid Valve GROUP 30 Typical Illustration SM587 30-7-3 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .

C2 and C4 from the side shift selector valve. draulic schematic. C6. clean exterior of plumbing and solenoid valve to prevent dirt and foreign matterfromentering hydraulic system. Pages 6 & 8 provide diagrams and hy. A WARNING Hydraulic fluid is toxic to skin. l Unplug connectors from S7 coil. Place a rag beneath the fitting to be removed. AWARNING When usina air Dressure A CAUTION to clean off truck: Hydraulic lines may be under pressure. Reduce air pressure to 30 PSI (207 kPa). “Crack” Wear eye protection and fittings slowly. adequate. l Cap each hose when disconnected. l Disconnect hydraulic connections Vl. protective clothing when drying with air pressure. Before dis- connecting the hydraulic components. eyes. Debris removed with air pressure can cause injury. l Tag each hose as to its location. l Inspect hoses and connections for further serviceability. Refer to page 7 for valve service instruc- tions. V2. Cleanliness is of extreme importance.GROUP 30 Solenoid Valve Removal Refer to Illustration on opposite page. and respiratory tract. Glasses bench. NOTE There will be some fluid Always Wear leakage upon disconnectin g each fitting. Dee 94 30-7-4 SM587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . l Remove mounting fasteners securing the selector valve to the pantograph. A CAUTION l Replace defective parts. l Unplug connectors from S8 coil. Good ventilation is normally l Replace all O-rings with new ones. C5. Remove all Jewelry before working on Safety l Remove valve and place on a clean work truck.

. ~--~--_-_-_---_rxrr~~~ Top view [ Solenoid j I I _-_-_-I j r Valve t c2 #5 SAE O-Ring Port c4 #4 S AE O-Ring Port C5 #I4SAJZO-Ring Port C6 C6 ##4SAE O-Ring Port . . Vl Vl ?&I SAE O-Ring Port f v2 ##4SAE O-Ring Port NOTE Refer to Hydraulic Schematic on the next page.Solenoid Valve GROUP 30 Solenoid Valve S8 . Fmnu Back SM587 30-7-5 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute ..

_I_ ...... 4 Hydra- ............... c2 0** c4 .. Hydraulic Circuit tv2 C6 J ______-___r-_l---I...GROUP 30 Solenoid Valve Hydraulic Schematic 0* Vl _-. ........... Schematic Side Shift Cylinder 0* Return to VI/C2/SS Circuit u** Return to V2/C4/S6 Circuit rypical Illustration 30-7-6 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute ....._-_.... ..... ....... ..._ ......

30-7-7 Copyrighted Material Dee94 Intended for CLARK dealers only Do not sell or distribute . valves and body in clean hy- draulic fluid. Inspect wire r...14 N*m). ..10 lb. Reassembly l Lubricate seals.Solenoid Valve GROUP 30 Typical Cartridge Kit jlpical Illustration Disassembly l Remove nut and coil from each solenoid valve. ------ Cleaning & Inspection (11 .< . . . .. ft.... Body--l l Install cartridge valve into valve body and torque -ypical Illustration to 8 . leads for damage.... (11 . ---.. ..‘.. Discard old seals. -l l Install seals and backup rings as shown above... Wash hydraulic components in a 22 Coil Stoddard type cleaning solvent and wipe dry with a j clean shop rag... ft. Replace defective parts Use Service Parts Kits. . l.IO lb. ...Retainer Nut Becarefil that you do not nick or cut seals upon r installation.. . . . .14 Nom) r f-l1 Wipe coil(s) clean using aclean shop rag. 11. Torque nuts Receptacle Leads 8 . l Remove both solenoid valves from valve body.

Plugs and Side Receptacles arelabeledfor easy identification. Remove hose caps just prior to installing connection to valve. You must install cables and wiring exactlly as shown or you will experience shorts and component failure. Tighten all mounting fasteners. . Side Shift Selector Valve II Mounting Bracket Dee 94 30-7-8 SM587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . (see below) Install Hoses l Wipe hose ends and connections clean.GROUP 30 Solenoid Valve Installation I Mount Selector Valve l Line up mounting holes in selector valve with those in mounting bracket. . Connect Coils Plug connectors to S8 and S7 coils. Mounting Fasteners IMPORTANT All Wiring. Be certain all connections are tight. See illustra- tion at left. Install fasteners fin- ger tight. Install guard.

Solenoid Valve GROUP30 Important Route Hosing As Show Side Shift Cylinder Grease XT’/ $$#!p&& Reach & Tilt Solenoid Valve Greast Fitting I Grease Fitting Typical Illustration SM587 30-7-g Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute .

......... ............................................................................................................... 32-2-4 Cleaning & Inspection ........................................................................................................................32-2-2 Preparation Cleaning and Inspection suggestions .................................................................... 32-2-5 & 6 Sump Tank Fluid Level ................................ Material Handling Cl!!IRIC Company GROUP 32 Section 2 Tilt Cylinder Overhaul Contents Safety .......................... 32-2-7 Models Equipped with 1 Side Shift SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute ..... 32-2-5 Reassembly .......................................................... 32-2-3 Disassembly .....

eyes. clean exterior of plumbing and solenoid valve to prevent dirt and foreign matter from entering hydraulic system. Before disconnecting hydrauliccomponents. Reduce air pressure to30 PSI (207 kPa). Debris removed with air pressure can cause injury. Remove all Jewelry before Always wear Safety Glasses working on truck. A CAUTION Cleanlinessisof extreme importance. A WARNING Hydraulic fluid is toxic to skin. and respiratory tract.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. Good ventilation is normally adequate. Typical Illustration Dee 94 32-2-2 Copyrighted Material SM-587 Intended for CLARK dealers only Do not sell or distribute .

l Threaded area of piston rod should be examined for damage. l A soft fiber brush should be used to remove debris and foreign objects from grooves and threaded areas. l A Stoddardtype cleaning solvent should be used to wash the cylinder. Soft Fiber Brush Nut Rod En d Cylinder Piston Rod 1 - NOTE PressBushings flush with rod end. etc. l Any part unfit for further service should be replaced with a new Pm* SM-587 32-2-3 Copyrighted Material Dee94 Intended for CLARK dealers only Do not sell or distribute . l All foreign objects should be removed from between threads on the piston rod. in the nut and rod end. stripping or marring after removal of rod end and jam nut.Tilt Cylinder GROUP 32 Preparation Cleaning & Inspection 1 Suggestions l The exterior surface of a cylinder should be thoroughly washed before disassembly. The bushing in rod end should be inspected for further serviceability.

Remove O-ring from piston rod and discard. Remove wiper ring. Again.) are free of cylinder housing. remove grease and grime from the cylinder tube. Be careful that you do not nick or scratch inner sutiace if gland 1. 4. Remove nut from piston rod while holding 8. sealing ring (Glyde Ring@) and 10. into cylinder housing clear of the shear ring. provided just below threaded area of piston rod. wiper and backup rings. Discard the shear scratch piston surfaces. Placecylinder in avise equipped with softjaws. Piston Rod & Piston 4. Remove washer. 2. Use a brush to 1. 6. Pull outward on piston rod until rod and gland energizer. Remove gland. gently tap gland assembly onto the piston rod nut. be carejXyou do not ’ energizer from piston. split type retainer ring.distort barrel 3. or scratch the piston rod. 2. Using a bronze drift. 9. Insert a 12 to 15 inch holding rod into the hole 5. Using screwdriver. 6. ring. DiscardO-ring. Remove seal from inner groove. 3. Remove outer O-ring and backup ring from the 2. carefully lift end of shear retainer rod.GROUP 32 Tilt Cylinder Split Retainer Ring Disassembly (Refer to illustration above. Discard seals. remove the 4. Wash exterior of the tilt cylinder in a Stoddard type Gland Assembly cleaning solvent before disassembly. With a pair of pliers. ring from it’s groove. Remove O-ring. see arrow (4) above. Use care not to nick or nickor scratch the piston rod. Remove rod end and jam nut. Pull piston free of piston rod. Dee 94 32-2-4 SM-587 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . gland assembly. anchor and rod ends. Do not over-tighten . Now install a l-l/S” socket 7. Push piston rod all the way into cylinder. Using a narrow blade screwdriver. 1. assembly. carefully pull shear ring 5 Remove sealing ring (Glyde Ring@) and the from cylinder tube. Remove white backup ring. Becareful you do not nick 3. Always install new seals.

wiper ring and gland as- 4.. New bushings should be pressed flush with outer surface of the anchor and rod ends. Now. smooth and free of damage. Slide a new O- ringoverthebagandintothegrooveinthepiston 2. Remove bag and install piston onto rod. Install a new wiper ring into the gland. Lubricate new seals. 7. 4.312 N*M). Be car@2 not to remove the chrome plating when polishing surface. 1. Both the rod and anchor ends have two bushings each end. A crocus cloth may be used to clean up light scratches. Install the inner seal. on opposite page. 3. (273 . 11. torque nut to: 201 to 2301b. Install nut onto rod finger tight against the 4. 8. Reassembly 9. Discard old seals.ft. they may be pressed out and new bush- ingspressedin. Inspect cylinder mounting bushings for dam- age. etc.Tilt Cylinder GROUP 32 Cleaning & Inspection 1. SM-587 32-2-5 Dee 94 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . Inspect threaded parts for damage. Using a torque wrench and the l-l/S” socket. wiper and shear ring. fully slide piston over the O-ring and up against rod shoulder. Startpistonintocylindertube whilegentlypush- parts with clean hydraulic fluid. Becareful that you do not cut or nick the sealing lip upon 5. inward. 5. Refer toillustration tube. Lubricate and install the square energizer ring h